K300+ops XMLRevA C37 122914

JCI Crusher Operation &
Service Manual
+
Kodiak 300
Milo Software Version: C.3.7
XML Revision A
86470 Franklin Blvd, Eugene, OR 97405 • 800-314-4656 • 541-736-1400 • Fax 541-988-9401
24/7 Parts Number 888-474-0115
Table of Contents
Introduction................................................................................................... 1
Operation and Service Manual ..................................................................................... 1
Address For Notices ................................................................................................. 1
Kodiak+ Series Crusher Overview ................................................................................ 2
Kodiak+ Series Crusher Theory of Operation ........................................................... 5
Crusher Upper Assembly ..................................................................................... 6
Crushing Parameters ................................................................................................ 7
Material ................................................................................................................. 7
Mechanical ........................................................................................................... 7
Application ............................................................................................................ 8
Safety............................................................................................................. 9
Safety Overview ............................................................................................................ 9
Hazard and Advisory Statements ............................................................................. 9
Hazard Warning Symbol ...................................................................................... 9
Hazard Statements ............................................................................................... 10
Advisory Statements ............................................................................................ 10
Arc Flash Safety ....................................................................................................... 10
Lockout/Tagout ......................................................................................................... 11
Who Must Use Lockout/Tagout? .......................................................................... 11
What is Lockout/Tagout? ...................................................................................... 11
When Must Lockout/Tagout Occur? ..................................................................... 11
When Can Lockout/Tagout Devices be Removed? ............................................. 11
Lockout/Tagout Rules .......................................................................................... 12
Additional Lockout/Tagout Requirements ............................................................ 12
Lockout/Tagout Devices ....................................................................................... 13
Lockout/Tagout Procedure ................................................................................... 14
Miscellaneous Safety Tips ........................................................................................ 14
Know Your Machinery .......................................................................................... 14
Be Prepared for Emergencies .............................................................................. 14
Wear Personal Protective Equipment (PPE) ........................................................ 15
Observe Personal Safety Precautions ................................................................. 15
Help Prevent Accidents ........................................................................................ 16
Avoid Alcohol and Other Drugs ............................................................................ 16
Be Aware of Your Surroundings ........................................................................... 16
Practice Good Housekeeping ............................................................................... 17
Inspect And Maintain Machinery .......................................................................... 17
Safety Decals ........................................................................................................... 18
Crusher Safety Decal Locations ........................................................................... 26
Hydraulic Power Unit Safety Decal Locations ...................................................... 28
Lube Panel Safety Decal Locations ..................................................................... 29
Crusher Installation...................................................................................... 31
Machinery Installation Safety ........................................................................................ 31
Foundations .............................................................................................................. 31
Table of Contents
Guarding ...................................................................................................................31
Customer Modifications ............................................................................................31
Electrical Connections ..............................................................................................32
Hoisting and Handling Safety ........................................................................................33
General Precautions .................................................................................................33
Wire Rope .................................................................................................................33
Connecting Or Clamping Wire Ropes .......................................................................33
Chains .......................................................................................................................33
Fiber Or Synthetic Slings ..........................................................................................34
Crusher Lifting Guidelines .............................................................................................35
Crusher Lift Points ....................................................................................................35
Lifting Procedure for Crusher to be Installed ........................................................37
Lifting Procedure for Crusher Already Installed ....................................................38
Crusher Pre-Installation Considerations ........................................................................40
Kodiak+ Crusher Assembly and Drive Motors ..........................................................40
Support Structures ....................................................................................................41
Stationary Plants ...................................................................................................41
Portable Plants .....................................................................................................41
Clearance .............................................................................................................42
Drive Motors and Belts .........................................................................................42
Master PLC/HMI Panel ..................................................................................................43
Motor Control Center (Provided by User) ......................................................................44
Feed and Product Conveyors and Auxiliary Equipment ................................................44
Lubrication System ........................................................................................................45
Lubrication System Oil Flow ......................................................................................47
Lubrication System Connections ..............................................................................48
Lubrication System Installation Considerations ........................................................51
Lubrication System Installation Procedure ................................................................52
Crusher Hydraulic Safety Precautions ..........................................................................53
Hydraulic Power Unit (HPU) ..........................................................................................55
Crusher Hydraulic Manifold Assembly ..........................................................................57
Bowl Clamp ...................................................................................................................59
Bowl Clamp Circuit ........................................................................................................61
Bowl Rotation Motor ......................................................................................................62
Bowl Rotation Circuit .....................................................................................................63
Tramp Iron Relief (TIR) System ....................................................................................64
TIR Pressure Controls ...................................................................................................66
Tramp Iron Relief (TIR) Circuit ......................................................................................68
Clear Circuit ...................................................................................................................69
Crusher System Relief Pressure ...................................................................................70
TIR Relief Valve Pressure .............................................................................................70
HPU Connections ..........................................................................................................71
Hopper Level Sensor .....................................................................................................74
Hopper Level Sensor Configuration ..........................................................................76
Hopper Sensor Calibration Procedure ......................................................................78
Stack Light (Optional) ....................................................................................................80
Hydraulic Cone Brake (Optional) ...................................................................................81
Electrical Connections ...................................................................................................81
Table of Contents
Connections at the HPU ........................................................................................... 82
Electrical Connections at the JCI Kodiak+ Crusher .................................................. 83
Power Supply Connections ........................................................................................... 84
Power Cable for Crusher Drive Motor(s) .................................................................. 84
Power Cable for the Lube Pump Motor .................................................................... 84
Power Cable for the Lube Oil Cooler Fan Motor ...................................................... 84
Protecting the 24VDC Power Supply ........................................................................ 84
Local and/or Non-USA Electrical Voltage Considerations ........................................ 84
Power Transmission ................................................................................................. 85
Sheave Alignment and Belt Tension .................................................................... 85
Motor Topics ................................................................................................................. 85
Motor Controls .......................................................................................................... 85
Crusher Drive Motor Current Transducer(s) ............................................................. 86
Motor Feedback Connections ................................................................................... 87
Feed Conveyor “Enable” Output ............................................................................... 87
Integrating Into an External Control System ................................................................. 88
Transporting the Crusher .............................................................................................. 90
Kodiak Crusher Control Configuration .......................................................................... 91
Crusher Pre-Startup Inspection .................................................................................... 92
Crusher Inspection ................................................................................................... 93
Under Crusher Inspection ......................................................................................... 94
Lube Assembly Inspection ........................................................................................ 94
Hydraulic Power Unit Inspection ............................................................................... 95
Hopper and Crushing Chamber Inspection .............................................................. 96
System Testing ............................................................................................................. 96
Lubrication System Tests and Initial Startup ............................................................ 96
Hydraulic System Testing ......................................................................................... 97
HPU Initial Startup .................................................................................................... 98
Crusher Warranty, Record Keeping, and Startup Checklists ........................................ 99
Start Up Sheets and Inspection Checklists .............................................................. 99
Keeping Records ...................................................................................................... 99
Operation....................................................................................................... 101
Crusher Safety .............................................................................................................. 101
The Kodiak Crusher Control System (MILO) ................................................................ 103
Abbreviations/Definitions .......................................................................................... 104
HMI Navigation ............................................................................................................. 105
Main Operating Screen ............................................................................................. 106
Menu Languages ...................................................................................................... 107
Indicator Lights ......................................................................................................... 107
Monitoring Sensors ................................................................................................... 108
Emergency Stop (ESTOP) ....................................................................................... 109
HMI Troubleshooting ................................................................................................ 109
Bowl Rotation and CSS Adjustment ............................................................................. 110
The Crushing Zone ................................................................................................... 111
Closed Side Setting (CSS) ....................................................................................... 112
CSS Reset Procedures ............................................................................................ 112
Table of Contents
Bowl Position Counter Reset Procedure with the Crusher Turned Off .................113
Bowl Position Counter Reset Procedure with the Crusher Running .....................114
Bowl Position Counter Reset Procedure Using the Bowl Auto Zero Function ......116
Bowl Rotation Troubleshooting .................................................................................120
Crusher Pre-Start Checks and Procedures ...................................................................121
Crusher Pre-Start Troubleshooting ...........................................................................123
Crusher Startup Procedure ...........................................................................................124
Crusher Operational Troubleshooting .......................................................................126
Bowl Float ......................................................................................................................128
Bowl Float Detection System ....................................................................................129
How it Works .........................................................................................................129
Sensitivity ..............................................................................................................129
Optional Equipment ..............................................................................................129
Bowl Float Detection System Enable Procedure ..................................................130
WARNING/DANGER Threshold Adjustment Procedure While Not Crushing ......134
WARNING/DANGER Threshold Adjustment Procedure While Crushing .............136
Bowl Float Troubleshooting ......................................................................................137
Kidney Loop Filter (optional) .........................................................................................137
Kidney Loop Filtration Mode .....................................................................................138
Oil Circulation Mode ..................................................................................................138
Kidney Loop Filter Enable Procedure .......................................................................139
Lube Circulation ............................................................................................................140
Heaters Only .............................................................................................................140
Heaters and Lube Circ (3 Phase) .............................................................................140
Heaters and Lube Circ (1 Phase) .............................................................................140
Heaters and 4 Hour Kidney Loop Only .....................................................................141
Lube Circulation Procedure ......................................................................................141
Crusher Clear Function .................................................................................................143
Automatic Interlocked Crusher Shutdown .....................................................................144
Low Lube Oil Flow ....................................................................................................145
High Lube Oil Reservoir Temperature ......................................................................146
Low TIR Pressure .....................................................................................................146
Communication Fault ................................................................................................147
Automatic Shutdown Troubleshooting ......................................................................148
Warning Conditions and/or Reminders .........................................................................150
Lube Oil Filter Bypass ...............................................................................................150
Low Bowl Clamp Pressure ........................................................................................150
High Hydraulic Oil Temperature ................................................................................151
Maximum Bowl Position ............................................................................................151
Maintenance ................................................................................................. 153

Maintenance and Repair Safety ....................................................................................153
Electrical Systems .....................................................................................................153
Pressurized Systems ................................................................................................154
Welding On Machinery ..............................................................................................154
Clearing Jammed Material ........................................................................................155
Table of Contents
Hazardous Materials ................................................................................................. 156
Disposal Of Excess Fuels, Lubricants And Liquids .................................................. 156
Hoisting and Handling Safety ........................................................................................ 157
General Precautions ................................................................................................. 157
Wire Rope ................................................................................................................. 157
Connecting Or Clamping Wire Ropes ...................................................................... 157
Chains ...................................................................................................................... 158
Fiber Or Synthetic Slings .......................................................................................... 158
Offset Cone Lifting Eye Safety ...................................................................................... 159
Welding Considerations ................................................................................................ 160
Crusher Daily Inspection Checklist ............................................................................... 161
Crusher Maintenance Schedules .................................................................................. 162
After First 200 Hours of Operation ............................................................................ 162
Every 500 Hours of Operation .................................................................................. 162
Annually or 4,000 Hours ........................................................................................... 163
At Every Liner Change ............................................................................................. 163
Before Recommissioning the Crusher ...................................................................... 164
Maintenance Mode ....................................................................................................... 165
Depressurize Crusher Hydraulic System Procedure .................................................... 166
Oil Sample Procedure ................................................................................................... 167
Lube Oil Reservoir Fill Procedure ................................................................................. 170
Oil Filter Restriction Indicator ........................................................................................ 172
Lube Oil Filter Change Procedure ................................................................................ 173
Lube Oil Change Procedure ......................................................................................... 175
Lube and HPU Reservoir Air Breather Change Procedure ........................................... 177
Hydraulic Power Unit Oil Reservoir Fill Procedure ....................................................... 178
Hydraulic Oil Filter Change Procedure ......................................................................... 180
Hydraulic Oil Change Procedure .................................................................................. 181
Hydraulic Accumulator Removal Procedure ................................................................. 183
Hydraulic Accumulator Refill Procedure ................................................................... 184
Hydraulic Accumulator Installation Procedure .............................................................. 187
Bowl Rotation Gear Box Lubrication Procedure ........................................................... 188
Bowl Rotation Gear Box Oil Change Procedure ........................................................... 190
Hopper Assembly Removal Procedure ......................................................................... 191
Hopper Assembly Installation Procedure ...................................................................... 193
Upper Assembly Removal Procedure ........................................................................... 195
Upper Assembly Installation Procedure ........................................................................ 199
Crushing Zone Upper Limit ........................................................................................... 205
Bowl Removal Procedure ............................................................................................. 206
Bowl Installation Procedure .......................................................................................... 211
Manganese Liner Changes ........................................................................................... 214
Bowl Liner Change Procedure .................................................................................. 214
Mantle Liner Change Procedure ............................................................................... 227
Backing Material Procedure ................................................................................. 234
Reset Accumulated Liner Wear Procedure .............................................................. 237
Bowl Thread Lubrication Procedure .............................................................................. 238
Mantle Bolt Thread Maintenance .................................................................................. 241
Feed Conveyor Motor Test ........................................................................................... 243
Table of Contents
System Relief Valve Testing and Setting Procedure .....................................................244
Individual TIR Cylinder Relief Valve Testing and Setting Procedure ............................248
V-Belt Tension Procedure .............................................................................................253
V-Belt Change Procedure .............................................................................................255
Cog Belt Tension Procedure .........................................................................................258
Setting the Cog Belt Meter ........................................................................................260
Using the Cog Belt Meter ..........................................................................................262
Driven Sheave Change Procedure ................................................................................264
Crusher Service............................................................................................ 273

Maintenance and Repair Safety ....................................................................................273
Electrical Systems .....................................................................................................273
Pressurized Systems ................................................................................................274
Welding On Machinery ..............................................................................................274
Clearing Jammed Material ........................................................................................275
Hazardous Materials .................................................................................................276
Disposal Of Excess Fuels, Lubricants And Liquids ...................................................276
Welding Considerations ................................................................................................277
Hoisting and Handling Safety ........................................................................................277
Wire Rope .................................................................................................................278
Connecting Or Clamping Wire Ropes .......................................................................278
Chains .......................................................................................................................278
Fiber Or Synthetic Slings ..........................................................................................279
Bowl Support Thread Removal Procedure ....................................................................280
Bowl Support Thread Installation Procedure .................................................................282
Bowl Clamp Thread Removal Procedure ......................................................................289
Bowl Clamp Thread Installation Procedure ...................................................................292
Bowl Clamp Piston Seal Removal Procedure ...............................................................298
Bowl Clamp Piston Seal Installation Procedure ............................................................300
Cone Lifting Eye and Cone Lifting Eye Assembly .........................................................307
Cone Lifting Eye (one-piece) ....................................................................................307
Cone Lifting Eye Assembly (two-piece) ....................................................................308
Cone Lifting Eye Assembly Installation Procedure ...................................................309
Cone Removal Procedure .............................................................................................311
Cone Installation Procedure ..........................................................................................313
TIR Relief Cylinder Removal Procedure .......................................................................316
TIR Relief Cylinder Installation Procedure ....................................................................319
Replacing V-Seat Liners ................................................................................................322
Method 1: ..................................................................................................................322
Method 2: ..................................................................................................................323
Method 3: ..................................................................................................................323
Setup: ........................................................................................................................323
Preheat considerations: ............................................................................................323
V-Seat Liner Removal Procedure ..................................................................................324
V-Seat Liner Installation Procedure ...............................................................................326
Table of Contents
Pinion Assembly Removal Procedure ........................................................................... 327
Pinion Assembly Installation Procedure ........................................................................ 331
Backlash Setting Procedure .......................................................................................... 333
Setting Gap Between Thrustplate and Wedgeplate Procedure .................................... 339
Pin Clutch Removal Procedure ..................................................................................... 341
Pin Clutch Installation Procedure .................................................................................. 344
Drive Ring Seal Installation Procedure ......................................................................... 348
HPU Motor Removal Procedure ................................................................................... 350
HPU Motor Installation Procedure ................................................................................ 353
Hydraulic Pump Removal Procedure ............................................................................ 357
Hydraulic Pump Installation Procedure ......................................................................... 359
HPU Pump Coupler Removal Procedure ...................................................................... 360
HPU Pump Coupler Installation Procedure ................................................................... 364
Hydraulic Manifold Relief Valve Removal Procedure ................................................... 367
Hydraulic Manifold Relief Valve Installation Procedure ................................................ 369
Hydraulic Motor Removal Procedure ............................................................................ 370
Gear Box Removal Procedure ...................................................................................... 371
Hydraulic Motor and Gear Box Installation Procedure .................................................. 373
Hydraulic Pressure Transducer Removal Procedure .................................................... 384
Hydraulic Pressure Transducer Installation Procedure ................................................. 385
Low Lubrication Oil Level Shutoff Switch Removal Procedure ..................................... 387
Low Lubrication Oil Level Shutoff Switch Installation Procedure .................................. 388
Lube Cooler Bypass Valve Removal Procedure ........................................................... 390
Lube Cooler Bypass Valve Install Procedure ................................................................ 393
Lube Flow Encoder Removal Procedure ...................................................................... 395
Lube Flow Encoder Installation Procedure ................................................................... 398
Lubrication Motor Removal Procedure ......................................................................... 400
Lubrication Motor Installation Procedure ...................................................................... 403
Lube Pump Removal Procedure ................................................................................... 406
Lube Pump Installation Procedure ................................................................................ 408
Lube Oil Heater Removal Procedure ............................................................................ 411
Lube Oil Heater Installation Procedure ......................................................................... 413
Lube Temperature Transducer Removal Procedure .................................................... 415
Lube Temperature Transducer Installation Procedure ................................................. 417
Replacing Communication Module ............................................................................... 418
Kodiak Plus Crusher Control System (MILO) Software Update .................................... 421
Update Display Module (HMI) Procedure ................................................................. 421
Update the Master PLC Procedure .......................................................................... 423
Update the Slave PLC Procedure ............................................................................ 428
Post Kodiak Plus Crusher Control System Software Update ................................... 432
Reference Information ................................................................................. 433

Available Liner Configurations ...................................................................................... 433
K300+ Coarse Chamber ........................................................................................... 433
K300+ Medium Coarse Chamber ............................................................................. 434
K300+ Medium Chamber .......................................................................................... 435
K300+ Medium Chamber with Feed Slots ................................................................ 436
Table of Contents
K300+ Medium Fine Chamber ..................................................................................437
K300+ Fine Chamber ................................................................................................438
Crushing Application Guidelines ...................................................................................439
Pinion Speed .............................................................................................................443
Choke Feeding ..........................................................................................................444
Rock Characteristics .................................................................................................444
Abrasiveness ........................................................................................................444
Hardness ..............................................................................................................445
Fine Crushing ............................................................................................................446
K300+ Product Capacities ........................................................................................446
K300+ CSS Chart .....................................................................................................447
K300+ Pressures and Statistics ................................................................................448
Kodiak Plus Gradation Chart ....................................................................................449
System Control Variables .........................................................................................451
Codes for Integrating into an External System ..........................................................452
Product Specification Troubleshooting ..........................................................................454
Causes of Bowl Float ................................................................................................455
Reduction Ratio Too High .....................................................................................455
Crusher Not Choke Fed ........................................................................................455
Excessive Near Size Material ...............................................................................455
Too Much Clay, Mud, or High Moisture Content ...................................................455
TIR Pressure Too Low ..........................................................................................455
Air in the Relief System ........................................................................................456
Rock Material Backing Up into the Crushing Discharge Area ..............................456
Feed Related Problems ............................................................................................456
Crusher Lubrication Oil Specifications ..........................................................................458
Recommended Oil Type ...........................................................................................458
Synthetic Oil ..............................................................................................................458
Lube Oil Analysis ......................................................................................................459
ISO Rating ............................................................................................................461
Oil Filter Element Beta Ratings .............................................................................461
INTRODUCTION
OPERATION AND SERVICE MANUAL
Introduction
Operation and Service Manual
This manual provides the information for an experienced operator to successfully and safely operate your
equipment. Please review this manual carefully to ensure you receive the most benefit from your machine.
Make sure that all personnel are aware of, and use, proper safety precautions when working with and/or
around the plant and related equipment. For information on service, contact your dealer or the manufacturer
service department. Please refer to your parts book for further manufacturer contact information.
Address For Notices

Any and all inquiries and/or warranty claims should be submitted in writing to JCI at the following address:
Johnson Crushers International, Inc.
86470 Franklin Blvd.
Eugene, Oregon 97405
Office: 541-736-1400 / Fax: 541-988-9401
Toll Free: 800-314-4656
Service Department: (866) 875-4058
Parts Sales Department: (888) 474-0115
1
INTRODUCTION
KODIAK+ SERIES CRUSHER OVERVIEW
Kodiak+ Series Crusher Overview

The information detailed in this manual is directed to an experienced crusher operator and or service techni-
cian to successfully and safely operate and service the Kodiak+ series cone crusher. Read this manual care-
fully to ensure you get the most from your new crusher. Make sure that all personnel are aware of, and use,
proper safety precautions when working around the crusher and related equipment.
2
INTRODUCTION
The Kodiak+ series crusher is supported by an external hydraulic power unit (HPU) and lubrication unit, both
mounted on skids.
3
INTRODUCTION
1 Tramp Iron Relief (TIR) Cylinder
2 Hydraulic Bowl Clamp
3 Bowl Assembly
4 Hopper
5 Bowl Liner Retention System
6 Drive Ring
7 Hydraulic Bowl Rotation Motor
8 Bowl Support
9 Crusher Base Frame Assembly
10 Wedgeplate
11 Pin Clutch Assembly
12 Cone Assembly
13 Pinion Assembly
14 Driven Sheave
15 Mantle
16 Lubrication Unit
17 Hydraulic Power Unit (HPU)
18 Remote Control Panel
4
INTRODUCTION
Kodiak+ Series Crusher Theory of Operation

The Kodiak+ remote adjust crusher crushes rock by feeding it through the hopper and bowl opening into the
crushing chamber. As the cone gyrates inside the chamber, the crushing action is achieved when rock falls
into the open side and is crushed as the gap between the mantle and liner closes up.
The “closed side setting” (CSS) is the area in the chamber where the mantle and liner is the closest, and the
widest area between the mantle and liner is called the “open side.” The “stroke” is the difference between the
open and closed side distances, measured at the bottom of the parallel zone. The location of the CSS rotates
within the bowl as the cone gyrates. As the gap reopens, the crushed rock falls down lower in the chamber
or out of the chamber and onto the discharge conveyor.
1 Open Side
2 Bowl Liner
3 Mantle
4 Closed Side
The gyratory motion of the cone in a Kodiak+ crusher is created by the rotation of the wedgeplate around the
baseframe spindle. The cone is mounted on the upper half of the wedgeplate. The center axis of the upper
half of the wedgeplate is offset from the lower half and inclined at an angle. The wedgeplate is driven by a
right angle spiral bevel gear powered by the pinion shaft, which is housed in the baseframe. The wedgeplate
and cone assemblies are supported by large radial and thrust roller bearings. Although the cone gyrates
about the main center axis of the chamber, it does not spin about its own center axis in the wedgeplate. The
cone is allowed to rotate slowly about its center axis in a clockwise direction during crushing, but is prevented
from rotating in an counterclockwise direction by an anti-spin cone brake. Prevention of spinning improves
liner wear life and improves the balance of the machine when running empty.
NOTICE: Damage to the crusher bearings could result from bringing a spinning cone head to an abrupt halt. In
addition, manganese steel does not hold up well under sliding abrasion so its life would be greatly reduced.
5
INTRODUCTION
Crusher Upper Assembly
1 Bowl Rotation Assembly
2 Bowl Position Proximity Sensor
3 Driven Gear
4 Drive Ring
5 Upper Dust Seal Assembly
6 Bowl Clamp
7 Bowl
8 Liner Retention Components
9 Manganese Bowl Liner
10 Lower Dust Seal Assembly
11 Bowl Support
12 Bowl Clamp Hydraulic Oil Supply Hose
6
INTRODUCTION
The upper assembly includes the bowl and liner and is threaded into the bowl support. The upper assembly
is held into place by the bowl clamp, which is a hydraulically controlled lock nut. As hydraulic pressure is
increased, the bowl clamp piston removes all end play in the threads, which in turn secures the bowl
assembly. The threaded connection allows the bowl to be rotated up or down to adjust the closed side setting
(CSS) using the remotely operated control panel. The bowl is turned by a bowl rotator assembly mounted on
the bowl support. A proximity sensor detects the number of turns the drive ring makes. An electronic counter
displays the CSS on the control panel. Since the position indicator does not consider changes in the CSS due
to liner wear, the bowl position indicator should be reset often.
Crushing Parameters
The life of your crusher depends on adherence to these instructions.
Material
• Material with a compressive strength greater than 40,000 pounds per square inch should be reviewed
and approved in advance by JCI.
• No more than 10% of the total volume of feed material is sized less than the crusher closed side setting.
• The crusher feed material conforms to the recommended feed size on at least two sides.
• Moisture content of material is below 5%.
• Feed gradation remains uniform.
• Clay or wood material in crusher feed is limited to prevent the formation of compacted material or
“pancakes” being created.
Mechanical
• Crusher operates at factory recommended tramp iron relief pressures without bowl float.
• Crusher support structure is level and evenly supported across all four corners. In addition, the support
structure provides adequate strength to resist static and dynamic loads. (See the installation drawing.)
• Crusher is operated only when all electrical, lubrication and hydraulic systems are correctly adjusted
and functioning properly.
• Lubrication low flow warning system functions correctly.
• Lubrication oil filter functions properly and shows adequate filtering capacity on its indicator.
• Crusher drive belts are in good condition and tensioned to factory specifications.
• Crusher lubrication reservoir is full of lubricant that meets factory required specifications.
• Any welding on the crusher or support structure is grounded directly at the weld location.
• Crusher input shaft rotates in the correct direction.
• Manganese wear liners are replaced before coming loose or developing cracks.
• Crusher cone head is properly blocked prior to transport.
• Only authorized OEM parts or factory approved wear parts are used.
7
INTRODUCTION
Application
• Reduction ratio limited to 6 to 1 below 1" closed side setting and 8 to 1 above 1" closed side setting,
provided no bowl float occurs.
• Manganese chamber configuration conforms to the factory recommended application guidelines.
• Crusher is operated at the factory recommended RPM for the application.
• Crusher feed is consistent, providing an even flow of material, centered in the feed opening, and
covering the mantle nut at all times.
• Crusher input horsepower does not exceed factory specifications.
• Crusher discharge chamber is kept clear of material buildup.
• If the crusher cannot be totally isolated from metal in the feed material, a magnet should be used over
the crusher feed belt.
8
SAFETY
SAFETY OVERVIEW
Safety
Safety Overview
It is the responsibility of the quarry management team to develop a comprehensive safety awareness
program, and to ensure that all quarry workers and support personnel receive appropriate safety training as
approved by federal, state, and local regulations. Safety is basically common sense. There are standard
safety rules, but each situation has its own peculiarities, which can not always be covered by rules. Therefore,
quarry personnel must continually watch for possible safety hazards and be prepared to take prompt correc-
tive action when necessary. Failure to observe the precautions contained in this chapter can result in serious
personal injury and even loss of life. As with most industrial work environments, a careful operator is the best
insurance against an accident. The complete observance of one simple rule would prevent many unneces-
sary injuries and deaths each year.
The rule is:
“Never attempt to clean, lubricate, repair or adjust any machinery unless it is stopped and properly locked
out.”
Please note that this chapter is only intended as a brief review of basic quarry precautions and procedures.
The general guidelines included in the following paragraphs should not be considered in lieu of a quarry’s
official safety procedures, insurance company requirements, or applicable federal, state, and local regula-
tions.
Hazard and Advisory Statements
Hazard Warning Symbol

Hazard and advisory statements are emphasized throughout this manual.
The following safety alert symbol is used to bring attention to the specific advisory:
When you see the symbol, pay particular attention to the advisory that follows as your safety and that of others
is involved.
9
SAFETY
SAFETY OVERVIEW
Hazard Statements
The Caution, Warning and Danger statements are hazard statements used to alert workers of unsafe prac-
tices and potentially harmful or life-threatening situations. Each of these statements is preceded by the Safety
Alert Symbol.
• CAUTION indicates a potentially hazardous condition that, if not avoided, MAY result in minor personal
injury.
• WARNING indicates a potentially hazardous condition that, if not avoided, COULD result in serious
personal injury or death.
• DANGER indicates a potentially hazardous condition that, if not avoided, WILL result in severe personal
injury or death.
Advisory Statements
The Note statements are advisory statements that relate to equipment operation, maintenance and service
procedures. They are used to draw attention to proper procedures and practices.
• NOTICE is used to draw attention to a procedure that must be observed to prevent machine damage or
malfunction.
• NOTE is a basic informational statement or helpful suggestion.
Arc Flash Safety
10
SAFETY
SAFETY OVERVIEW
Lockout/Tagout
Who Must Use Lockout/Tagout?

Quarry owners, managers, and safety officers must be aware of OSHA’s “lockout/tagout” standard: CRF
Section 29 1910.147, The Control of Hazardous Energy. This standard is also recognized by MSHA. All
mechanics, maintenance personnel, operators, and electricians must fully understand and comply with this
standard to ensure the safety of all employees.
What is Lockout/Tagout?
Lockout/tagout is a means to ensure that personnel who install, operate, repair, maintain, service or otherwise
disable machines, equipment, or electrical energy systems are protected from harm due to unexpected ener-
gizing, or the release of stored energy by:
1) Lockout – Placing a disconnect switch, circuit breaker, valve, or other energy-isolating mechanism in
the off or safe position and securing it with a lock so the energy-isolating mechanism cannot be acti-
vated.
2) Tagout – A prominent written warning (tag or label) placed on the energy-isolating mechanism indicating
the name of the individual placing the mechanism out-of-service, and stating that the energy isolating
mechanism cannot be activated until the tagout device is removed.
When Must Lockout/Tagout Occur?

Lockout/tagout must occur whenever service or maintenance is performed, and injury could occur due to the
unexpected startup of equipment, or the release of stored energy. In general, lockout/tagout procedures must
be performed under the following circumstances:
• Before working on electrical, hydraulic or pneumatic circuits or devices.
• Before clearing jammed mechanisms, machinery or equipment.
• Before removing guards or other protective devices.
• Whenever a machine or its controls will be left unattended.
When Can Lockout/Tagout Devices be Removed?

Lockout/tagout devices can only be removed after the following conditions are met:
• All guards and protective devices are properly reinstalled.
• All tools and repair equipment are removed from the equipment and the immediate area.
• All mechanics and other personnel are clear of the equipment and its immediate area.
• All personnel have been warned that the equipment is about to be restarted (sound warning horn or acti-
vate warning lights).
After removing lockout/tagout devices, always use the normal startup procedure as described in the oper-
ator’s manual for the machinery.
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SAFETY
SAFETY OVERVIEW
Lockout/Tagout Rules
• Always lockout/tagout any machinery before performing any adjustment, inspection, lubrication, main-
tenance or repair procedures. Failure to observe this precaution may result in serious personal injury or
death.
• Your company’s lockout/tagout program may be somewhat different than described in this manual. If
so, be sure to completely follow your company’s official policies and procedures when lockout/tagout is
necessary. Consult your company’s safety officer if you have any questions.
• A lock must have only one user and one key. Anyone who installs a lock must keep the key in their
possession at all times. Except in an emergency situation, only the person that installs a lock is autho-
rized to remove it.
• To prevent accidental start-up, never give your lock or its key to another employee.
• Your key must open your lock only. Your key should not be capable of opening any other locks. Keys
for other locks should not be capable of opening your lock.
• Except in an emergency situation, never attempt to remove anyone else’s lock. Do not allow others to
remove your lock.
• When disconnecting power, be sure that the circuit breaker handle (or other isolating device) is in the
OFF position. Accidentally locking a control in the ON position could result in serious personal injury or
death.
• If two or more people are working on a machine, a multiple lockout device must be used to prevent acci-
dental start-up in the event that one person finishes working before another.
• Each lock must have a tag. If two or more people are working on a machine, each person must attach
a separate tag to their lock. Never attach a lock without a tag.
• Never use tags alone. A tag should always be accompanied by a lock which prevents the isolating
device from becoming energized.
Additional Lockout/Tagout Requirements

• Be sure that the power is COMPLETELY turned off. A motor may be stopped and locked out. However,
interlocks, starters, and other supplemental electrical components may still be energized. Use a volt-
meter and/or ammeter to verify that all electrical circuits are completely dead.
• Always be sure that all peripheral equipment, such as feed conveyors, grizzly feeders and discharge
conveyors, is also tagged and locked out. Serious personal injury or death can result if any of these
items starts unexpectedly while the crusher is being serviced.
• Although lockout/tagout procedures are most commonly associated with electrical systems, be aware
that hydraulic, pneumatic and mechanical systems must also be tagged and locked out before servicing.
This may involve the lockout/tagout of valves, levers and other non-electrical devices.
• For machinery powered by internal combustion engines (diesel, gas, etc.), always disconnect batteries
and shut-off fuel supply before servicing the machinery. Lockout/tagout engine controls to ensure that
engine is not accidentally started while the machinery is being serviced.
• Always be sure that all hydraulic or air pressure is completely relieved before working on hydraulic or
pneumatic systems. Dangerous pressures can be present, even when equipment is turned off and
locked out.
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SAFETY
SAFETY OVERVIEW
• After maintenance or repairs are completed, always warn all employees that the machinery is about to
be restarted. Be sure no one is on or near the equipment before a lock and tag is removed.
• As a precaution, always activate a warning horn or light before restarting the machinery. This will
provide additional warning for personnel to stay clear of machinery that is about to be started.
Lockout/Tagout Devices
1 Multiple User Lockout Device
2 Do Not Operate Tag
3 Padlock
A lock must be sufficiently durable, so it can withstand the environmental conditions (heat, cold, moisture,
etc.) around it. A lock must also be strong enough so that it cannot be easily removed or forced open. A tag
or label must be affixed to each lock to alert others that service work is in progress. Each tag or label must
have the following characteristics:
• Be sufficiently durable to withstand wear and abuse, even if used in dirty or damp environments.
• Be securely attached with a cable that is difficult to remove, cut or tear.
• Contain the name of the person that applied it.
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SAFETY
SAFETY OVERVIEW
• Contain a warning or other precautionary statement that briefly indicates why the machine is locked out
and what hazards could result if the equipment is started while service work is in progress.
When two or more people are working on a piece of equipment, a multiple lockout device must be used. This
allows each person to install their own lock, preventing accidental start-up.
Lockout/Tagout Procedure
OSHA has identified the following step-by-step lockout/ tagout procedure:
1. Prepare for shutdown – Before shutting down a piece of equipment, know the type and magnitude of
the energy that powers it, the hazards of that energy, and how to control it. Warn all employees that the
machinery is about to be shut down.
2. Shut down the equipment – After warning all employees, shut down the machine, equipment, or elec-
trical system by the normal stopping procedure.
3. Control stored energy – Any potentially hazardous stored energy (electrical, mechanical, hydraulic,
pneumatic, etc.) that remains must be released, dissipated, restrained, or otherwise rendered safe. If
stored energy re-accumulates, monitor it until the possibility of accumulation no longer exists.
4. Isolate the equipment – Disengage all isolating devices, both primary and secondary, so that the equip-
ment is isolated from all of its energy sources (electrical, mechanical, hydraulic, pneumatic, etc.).
5. Apply lockout/tagout devices – Attach lockout tagout devices (according to your company’s safety
program) in such a manner that the isolating device (circuit breaker, control, etc.) will be held in a safe
or off position. Attach tags to alert others that the machinery is being serviced.
6. Verify that equipment is isolated – After warning all employees to stay clear, engage the start button to
confirm the machine is inoperable. Return the control to the off position before proceeding with
servicing.
Miscellaneous Safety Tips
Know Your Machinery

• Read the manufacturer’s operation and maintenance manuals for all machinery and equipment that you
operate. Be sure that all hazard statements contained within the manuals are completely understood.
• Become familiar with the controls, functions and settings of each machine. Fully understand all phases
of each machine’s operation.
• Be sure that you completely understand and follow all startup and shutdown procedures as described
in the manufacturer’s manuals.
• Be familiar with the safety signs on your equipment, and the hazards against which they warn.
• Check the legibility of all safety signs every day. Order new signs from the machinery manufacturer if
they become illegible or worn.
Be Prepared for Emergencies

• Know the proper emergency shutdown procedures for the equipment you operate.
14
SAFETY
SAFETY OVERVIEW
• Know where fire extinguishers are kept and how to use them. Be sure that fire extinguishers are properly
rated, and that they remain fully charged and ready for use at all times.
• Know the procedure for contacting emergency medical personnel. Keep a list of emergency phone
numbers handy at all times.
• Know where first-aid kits, stretchers and other emergency supplies are kept. Be sure that first-aid
supplies are properly maintained and ready for use.
• Make sure that a clear path to emergency equipment and exits is always maintained. Do not allow
equipment, spilled materials or other obstructions to get in the way.
• Know how to report accidents. Always report all accidents immediately to the appropriate supervisor.
Wear Personal Protective Equipment (PPE)

• Wear safety glasses or goggles whenever outside of an approved operator’s enclosure. Failure to wear
appropriate eye protection can result in permanent eye injuries and loss of sight.
• Wear appropriate ear protection when working within 50 feet of any operating quarry machinery, and in
other areas where noise levels are high. Prolonged exposure to high noise levels can cause permanent
hearing loss.
• Wear steel-toe safety boots, heavy-duty gloves and a hard hat. This equipment is mandatory in most
areas of the quarry.
• Use respirators in dusty locations and when working with hazardous substances. Prolonged exposure
to rock dust or chemical fumes can cause permanent respiratory illness.
• Other personal protective equipment may be necessary for your specific job assignment, such as a full
face shield and safety harness. Wear or use these items when necessary and as required by applicable
federal state and local regulations.
Observe Personal Safety Precautions

• Never wear loose or ragged clothing when working on or around rotating power equipment. Avoid
wearing necklaces, rings or other jewelry. These items can become caught or tangled in the machinery,
resulting in severe personal injury or death.
• Keep hair short, if possible. Keep long hair securely tied up to prevent it from becoming caught in the
machinery.
• Be especially careful whenever using wet walkways, platforms, or ramps. The combination of rock dust
and wet metal can create an extremely slippery surface. Keep all walkways and other access structures
clean, dry and free of grease or oil.
• Use walkways and ladders when working near machinery, or observing its operation. Use a safety
harness when necessary. Keep handrails and machine contact surfaces clean.
• To avoid back injuries, always use proper lifting techniques to safely lift heavy objects. Lift with your legs
and keep your back straight. Keep the materials or object close to your body. Have a co-worker assist
you if the load cannot be lifted safely by one person.
• Before starting the machinery, check that no personnel are inside, on, under or beside the equipment.
Unless absolutely necessary, do not allow anyone to be on or near the equipment while it is operating.
• Never attempt to catch falling materials or objects.
15
SAFETY
SAFETY OVERVIEW
• Be aware of flammable liquids and other potential fire hazards. Do not smoke when refilling engines or
using cleaning solvents.
• Do not stand under equipment or components that are being hoisted or suspended. Never allow other
quarry personnel to do so.
• Before you assemble, operate, clean, lubricate, or adjust machinery, be sure to read and understand all
procedures contained in the machinery manufacturer’s manual.
• Be sure to operate quarry machinery in compliance with current OSHA and MSHA regulations, and all
applicable federal, state or local regulations.
Help Prevent Accidents

• Do not allow unauthorized personnel in or near the work area. Never allow unauthorized personnel to
operate, adjust, maintain or repair machinery.
• Allow only properly trained and experienced personnel to operate machinery. Be sure inexperienced
operators are carefully supervised at all times.
• Do not allow personnel to be near loading areas, or anywhere else that falling or ejected material could
hit them.
• Use extreme caution if the machinery must be operated for inspection or observation purposes. Stay a
safe distance from the machinery and wear appropriate personal protective devices.
• Before making repairs to the machinery, always clear all quarry material from the feed and discharge
devices (feeders, conveyors, chutes, etc.).
• In areas that present a danger of falling, use an appropriate fall protection device, such as a safety
harness and lifeline.
• Always report any unsafe conditions or defective equipment to the appropriate supervisor.
Avoid Alcohol and Other Drugs

• Do not operate or work near quarry machinery when under the influence of alcohol or other drugs.
These substances can result in reduced alertness and impaired judgment. Serious personal injury or
death could result.
• Some prescription and non-prescription medications can cause drowsiness or other adverse side
effects. Do not operate or work near quarry machinery when under the influence of such medications.
Be Aware of Your Surroundings

• The quarry environment contains many situations that are potentially hazardous. Use extreme caution
to avoid being struck by haul trucks, loaders and other quarry mobile equipment.
• Be aware of idle machinery that could start up without warning. Stay clear of such machinery and the
immediate area.
• Be aware of overhead obstructions, such as conveyors, support structures or power lines.
16
SAFETY
SAFETY OVERVIEW
Practice Good Housekeeping

• Do not store tools or equipment on walkways.
• Be sure that all walkways, platforms, stairs and ramps are kept free of spilled material and trash. A
buildup of material in these areas can cause slips and falls. Make repairs as required in areas where
spillage is present.
• Do not allow machinery to become buried under piles of spilled material. This will make the machinery
more difficult to inspect and may hide broken welds, loose fasteners and other serious problems that
could cause a safety hazard.
• Keep the areas around control panels and machinery free of spilled material. Free access must be
maintained at all times. In the event of an emergency, quick access to controls could prevent injury or
death.
• Clean up spilled fuel or oil immediately to eliminate slipping hazards. If necessary, use an oil absorbent.
• Always be sure that power is locked out and tagged before cleaning spilled material or oils. Never
clean-up these items while the machinery is operating.
Inspect And Maintain Machinery

• Always perform a safety inspection at the beginning of each shift. Refer to the machinery manufacturer’s
operation and maintenance manuals for detailed start-up inspection and maintenance procedures.
• Test all warning devices before starting the machinery to ensure that they are working properly. Never
disable or bypass any alarm systems or interlocks.
• Be sure that any defective components or systems are properly repaired by a qualified technician before
the machinery is started. Immediately report any serious problems to the appropriate supervisor.
• Before performing inspections or maintenance, always lock out power and tag controls to the machine
drive, and to all feed and discharge equipment. Warn all personnel that the equipment is being serviced.
Refer to the Lockout/Tagout section of this chapter for additional information.
• Maintenance inspection procedures are included throughout this manual. Although maintenance is not
typically a safety concern, machinery that is regularly maintained and in proper working condition will
minimize the occurrence of safety hazards and emergency situations.
17
SAFETY
SAFETY OVERVIEW
Safety Decals
Decal Meaning
WARNING: DO NOT EXCEED 55 MPH! — When towing the

equipment, do not exceed 55 MPH (96 KPH). Exceeding the
55 MPH speed limit could result in tire failure or a serious
accident.
WARNING: HAZARDOUS VOLTAGE — The electrical

mechanisms pose a risk of serious burns or shock. You must
make sure that all components are shut off and this equipment
is properly locked and tagged out before servicing the
electrical system.
WARNING: CRUSH HAZARD — The trailer can roll

unexpectedly when the brakes are released, posing a crush
hazard. Always chock the wheels before releasing the brakes.
Read the manual for proper operation of the trailer component.
WARNING: CRUSH HAZARD — This equipment drive poses

a crush hazard due to the belt drive. Lockout/tagout the power
source before removing the belt guard.
WARNING: LOUD NOISE HAZARD — This equipment’s

sound readings exceed 85dB and pose a noise hazard while
running. You must wear hearing protection when the machine
is operating.
WARNING: PINCH POINT — This equipment poses a pinch

hazard. You must keep feet and hands clear of the this
equipment while it is operating.
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SAFETY
SAFETY OVERVIEW
Decal Meaning
CAUTION: SLIP HAZARD — The walkways around this

equipment pose a slip hazard due to debris on the walkways.
Take care when working around this equipment and watch
your step.
WARNING: FALLING LOAD — This equipment is extremely

heavy and poses a crush hazard if it is lifted improperly. Use
the appropriately rated lifting device and rigging to raise. Lift
points are pointed out by this label.
WARNING: FALL HAZARD — This equipment is mounted on

a platform or trailer that is high off the ground. Falling from this
equipment could result in severe injury or death. Do not allow
anyone to climb on this equipment without proper safety
rigging and gear. Do not climb on this equipment while it is
operating.
WARNING: AVOID INJURY — This equipment poses a severe

injury risk if you do not read and understand the operation and
service manual before performing any service.
WARNING: FALLING MATERIAL HAZARD — Operation

causes debris to become airborne and poses a risk of injury.
You must wear approved head protection while the machine is
operating. Stay clear of operating machinery.
WARNING: AVOID INJURY — Performing service on this

equipment while it is running poses risk of severe injury. Do
not service while it is operating. You must follow the
procedures to lockout and tagout the power source before
servicing.
CAUTION: USE RESPIRATORY PROTECTION — Operation

causes dust and debris to become airborne and pose risk of
respiratory injury. You must wear approved respiratory
protection while it is operating.
19
SAFETY
SAFETY OVERVIEW
Decal Meaning
WARNING: AVOID INJURY — Operating this equipment with

the guards removed poses risk of severe injury. Do not
operate this equipment with any guards removed.
WARNING: WEAR EYE PROTECTION — This machine’s

operation causes debris to become airborne and poses a risk
of eye injury. You must wear approved eye protection while the
machine is operating.
WARNING: READ AND UNDERSTAND MANUAL BEFORE

OPERATING — This equipment poses severe injury risk if you
do not read and understand the operating instructions.
WARNING: PINCH POINT — This equipment poses a pinch

hazard. You must keep feet and hands clear of the this
equipment while it is operating.
WARNING: CRUSH HAZARD — This equipment’s tailgate is

extremely heavy and poses a crush hazard. Stay clear when
opening the tailgate to access.
CAUTION: HOT SURFACE — During normal operation this

equipment’s wheel case temperature can exceed 180° F (82°
C). Do not touch or service until the wheel cases have cooled.
20
SAFETY
SAFETY OVERVIEW
Decal Meaning
CAUTION: EQUIPMENT DAMAGE — Do not run the screen

with the shipping brackets installed. Severe equipment
damage could occur if you attempt to operate the screen with
the shipping brackets installed. Read the Operation Manual
before running the screen.
WARNING: HIGH PRESSURE FLUID HAZARD — This

equipment’s hydraulic system poses a high pressure fluid
hazard. You must wear protective equipment when working on
this system. Follow the steps to relieve hydraulic pressure and
lockout/tagout before servicing.
WARNING: FLAMMABLE MATERIAL HAZARD — Diesel fuel

and hydraulic oil pose a flammable material hazard. Do not
smoke near this equipment. Do not allow open flame near this
equipment.
WARNING: STAY CLEAR OF MOVING MACHINERY —

Moving machinery can cause sever injury or death. You must
stay clear of the machinery while it is running. Make sure that
you follow the lockout/tagout procedures before servicing.
WARNING: ROTATING SHAFT HAZARD — The conveyor

return idlers pose a rotating shaft pinch point hazard. Keep
away from the idlers when this equipment is operating. Follow
lockout/tagout procedures prior to servicing.
WARNING: ENTANGLEMENT HAZARD — Exposed

conveyor ends pose an entanglement hazard. Do not operate
the conveyor with the guards removed.
21
SAFETY
SAFETY OVERVIEW
Decal Meaning
WARNING: HAND PINCH POINT HAZARD — Conveyor

folding points pose a pinch hazard that could cause serious
injury or death. Keep your hands clear while folding
conveyors.
WARNING: CRUSHING FORCE FROM ABOVE —

Unsupported conveyors pose a crushing hazard. You must
support the conveyor with an appropriately rated stand before
servicing the conveyor.
DANGER: STAY CLEAR MACHINE STARTS/STOPS

AUTOMATICALLY— You and all bystanders must remain
clear of this equipment while it is in operation. Make sure that
everyone understands your intention to move the equipment
or start a conveyor. Failure to keep bystanders clear could
result in severe injury or death.
DANGER: FALLING DEBRIS HAZARD — During operation

debris can be thrown into the air posing a risk of serious injury
or death. You must wear a hard hat in the vicinity of this
equipment while in is operation.
CAUTION: CORROSIVE MATERIAL AVOID CONTACT WITH

EYES AND SKIN — Take care when servicing the battery as it
contains battery acid. Battery acid is extremely corrosive and
will cause serious injury to your eyes and skin. Always wear
protective glasses, gloves and clothes when working around
the battery.
WARNING: STORED ENERGY HAZARD — This equipment’s

hydraulic system uses an accumulator to store hydraulic
energy. This poses a risk of injury due to explosive
decompression of the accumulator. You must relieve all
hydraulic pressure before servicing. Wear protective gear and
follow the lockout/tagout procedures.
22
SAFETY
SAFETY OVERVIEW
Decal Meaning
WARNING: HIGH VOLTAGE HAZARD — This equipment’s

electrical system poses a risk of serious burn or electric shock.
You must take care when servicing the electrical system.
Follow all lockout/tagout procedures before servicing.
WARNING: HIGH VOLTAGE HAZARD SHUT DOWN

BEFORE SERVICE — The electrical components in the
control panel pose a risk of serious burns or shock. You must
make sure that all components are shut off and this equipment
is properly locked and tagged out before servicing the
electrical components.
WARNING: MOVING PARTS HAZARD — This equipment

poses a crushing hazard if a person were to fall into the
crushing chamber from above while the crusher is running. Do
not allow anyone on or near the crusher opening while it is
operating.
WARNING: FALLING LOAD HAZARD — This equipment is

extremely heavy. You must use a properly rated lifting device
and rigging when lifting. Do not allow anyone near or under
while it is lifted. Read the operator’s manual for information on
the lifting points and appropriate lift rigging.
WARNING: ELECTRIC POWER SOURCE PRESENT — The

electrical components in the control panel pose a risk of
serious burns or shock. You must make sure that all
components are shut off and this equipment is properly locked
and tagged out before servicing the electrical components.
DANGER: HAZARDOUS VOLTAGE. 480 VOLTS — The


23
SAFETY
SAFETY OVERVIEW
Decal Meaning

WARNING: CRUSHING HAZARD — Stay clear of the area

under the screen when it is lifted off its supports. The screen is
extremely heavy and could cause severe injury or death if it
were to fall.
WARNING: PINCH POINT — The area between the upper

and lower crusher assemblies pose a pinch hazard. Stay clear
when the crusher is operating or when the hydraulic power unit
is energized. Read the manual.
WARNING: READ OPERATION MANUAL — Improper use of

the lift devise poses a hazard. Read and understand the
operating instructions before using the lift device.
WARNING: NO ENTRY WHEN MACHINE IS RUNNING —

Moving machinery can cause serious injury or death. Stay
clear of the screen access platform while the plant is running.

24
SAFETY
SAFETY OVERVIEW
Decal Meaning
DANGER: HAZARDOUS VOLTAGE. Do not operate switch

under load. You must not move the switch to any position while
the plant is powered up. Severe injury or death could occur
due to high voltage electrical shock.
DANGER: HIGH PRESSURE HAZARD. Do not exceed 2300

psi (160 bar) while pressurizing the clamp cylinder. Do not
exceed 10000 psi (690 bar) while pressurizing the Jack
Cylinders. Severe injury or death will occur due to explosive
high pressure release.

psi (160 bar) while pressurizing the TIR cylinder. Severe injury
or death will occur due to explosive high pressure release.

psi (207 bar) while pressurizing the hydraulic system. Severe
injury or death will occur due to explosive high pressure
release.
25
SAFETY
SAFETY OVERVIEW
Crusher Safety Decal Locations
26
SAFETY
SAFETY OVERVIEW
27
SAFETY
SAFETY OVERVIEW
Hydraulic Power Unit Safety Decal Locations
28
SAFETY
SAFETY OVERVIEW
Lube Panel Safety Decal Locations
29
SAFETY
SAFETY OVERVIEW
30
CRUSHER INSTALLATION
MACHINERY INSTALLATION SAFETY
Crusher Installation
Machinery Installation Safety
Foundations
Proper foundations and support structures are essential to ensure the safe and efficient operation of quarry
equipment.
• Crushing and screening machinery needs a firm foundation on which to operate. This does not need to
be a poured pad, but it must not be unstable ground. When selecting the location, be sure that the entire
area is as level as possible.
• Follow all manufacturer’s installation drawings and specifications when constructing the base pads for
permanent plants.
• If any questions arise regarding foundation requirements or modifications necessary for JCI machinery,
please contact the JCI Service Department.
• Customer-designed support structures for JCI equipment must meet JCI’s engineering standards. All
plans must be submitted in advance to the JCI Engineering Department for approval.
Guarding
• Quarry management is responsible for the proper installation and placement of guards to prevent
personnel from coming in contact with rotating or moving parts.
• In addition to the guards supplied with the machinery, additional guards and related safety equipment
may be required to comply with OSHA, MSHA and any applicable local regulations. The proper fabrica-
tion, installation and placement of these items is quarry management’s responsibility.
• When fabricating guards, refer to MSHA’s Guide to Equipment Guarding at Metal and Nonmetal Mines.
Additional information can also be provided by the safety officer at your work site.
• Never remove guards until the machinery is stopped, power is locked out, and controls are tagged. Be
sure that guards are properly re-installed before reconnecting power.
Customer Modifications
• Do not modify quarry machinery in any way without prior approval from the manufacturer. Such modifi-
cations may include (but are not limited to) changing machine speed or direction of rotation, drilling addi-
tional holes and welding or bolting additional equipment to the machinery.
• All customer modifications to JCI machinery must be approved in writing by the JCI Engineering Depart-
ment.
31
MACHINERY INSTALLATION SAFETY
Electrical Connections
WARNING: When installing any electrical equipment, be sure to completely follow the
manufacturer’s instructions. Failure to observe this precaution could result in a
dangerous electrical shock hazard.
• Be sure that all electrical equipment is properly grounded.

• Lay out the power lines, especially those for portable plants, so that contact with standing water is mini-
mized.
• Do not place power lines in an area where they will be driven over by transport vehicles or other quarry
equipment. If it is absolutely necessary to extend a power line across a traffic area, protect the cable
with properly rated bridging.
• Be sure that all auxiliary control panels or power supply panels can be securely locked out. This type of
panel is mandatory.
• Maintain adequate overhead clearance from power lines or other obstructions, particularly when plan-
ning to use stacking conveyors for stockpiles.
• Be sure that electrical power supplies are located in an area that will be safe from accidental contact
during crushing operations.
• All JCI machinery is designed with electrical components of the proper size and voltage. Any modifica-
tions to these components or to the power supply must be approved in writing by the JCI Engineering
Department.
• Be sure that all connections are in accordance with the National Electric Code and any applicable state
or local codes.
32
HOISTING AND HANDLING SAFETY
Hoisting and Handling Safety

General Precautions
• Do not allow personnel to work or walk under loads supported by a crane or hoist.
• Use appropriate lifting devices to secure the load to the crane. See the following paragraphs of this
section for additional information.
• Use the correct lifting hooks to support the load.
• Use extreme caution when operating a crane near power lines or electrical equipment.
• Do not exceed the crane’s rated load capacity. Always subtract the weight of the hook block, slings,
chains, spreader bars and any additional equipment to determine the maximum load that can be safely
lifted.
Wire Rope
Wire rope requires careful use, handling and maintenance to ensure long life and safe operation. Always
observe the following precautions:
• Be sure to use the correct wire rope for the application.
• Be sure that the wire rope is inspected regularly following the manufacturer’s guidelines.
• Avoid sudden loading in cold weather. Never use frozen wire rope.
• Use suitable padding to protect wire rope from sharp corners or edges.
• Avoid dragging wire rope underneath loads or over obstacles.
• Never use wire rope that has been cut, badly kinked, frayed or crushed.
• Avoid reverse bends.
• Be sure that rope ends are properly sized.
• Use thimbles in eye fittings at all times.
Connecting Or Clamping Wire Ropes

When connecting or clamping wire ropes, use one of the following:
• Clamp and thimble connections combine both the clamp and thimble in one unit. Clamp and thimble
connections are capable of supporting 80% of the rated wire rope load.
• Cable clips are the most common way to secure a rope to a piece of equipment or to make an eye. The
cable clip or “Crosby Clip” is made of a U-bolt and saddle. If this type of clip is used to make an eye, the
use of a properly sized thimble is mandatory. If not, the cable may kink, forming a permanent weak spot.
Chains
Chains require careful use, handling and maintenance to ensure long life and safe operation.
• Ensure that the correct size chain is being used for the application.
33
• Ensure that the chain is inspected regularly following the manufacturer’s guidelines.
• Avoid sudden or shock loading (DO NOT jerk load upright).
• Use suitable padding to protect the chain from sharp corners or edges.
• Avoid dragging the chain under loads or over obstacles.
• Use the proper fittings at all times.
• Inspect links to determine the amount of wear. Refer to manufacturer’s specifications for wear tolerance
ranges.
• Be sure that all connections between chain sections are completed with properly sized hardware and
lifting hooks.
WARNING: Always follow proper rigging procedures as provided by the chain

manufacturer. The angle of rigging may decrease the rated lifting capacity.
Fiber Or Synthetic Slings

Slings require careful use, handling and maintenance to ensure long life and safe operation.
• Ensure that slings are rated or coded for the hitch or application.
• Ensure that slings are inspected regularly, following the manufacturer’s guidelines.
• Slings may be safely used in a temperature range of 20 to 180° F (-6 to 82°C) without decreasing load
limits. For temperatures beyond this range or for wet/frozen slings, follow manufacturer’s instructions
for load reductions.
• Do not use synthetic slings in temperatures exceeding 180°F (82°C).
34
CRUSHER LIFTING GUIDELINES
Crusher Lifting Guidelines

The following information will guide you through lifting the crusher properly and safely:
• NEVER attempt to lift the crusher using the hopper lifting eyes. These eyes are not designed to lift the
entire crusher. Serious damage could result!
• NEVER place slings around the drive sheave or the pinion shaft. These components should never be
used as lifting points.
• Handle the crusher with care. Ensure that it remains upright and evenly supported at all times. Rough
or careless handling can cause serious damage. Never allow the crusher to hit other objects or drop on
the ground. To prevent accidental damage to the underside of the crusher, always leave blocking in
place until the crusher is ready to be installed on its foundation.
The Kodiak+ crusher is extremely heavy, you must use a lifting device rated for the weight
of the crusher. Make sure that your lift rigging is also rated for the weight of the crusher.
Using lifting devices that are not adequate for the weight of the crusher could result in
serious injury or death.
NOTICE: Improper lifting procedures can result in permanent damage to the crusher and its components. Such
damage is not covered under warranty.
Crusher Lift Points

The following steps are provided so that you will be able to safely move your crusher to its operation
mounting. It is very important that you read and understand the safety considerations contained in the Safety
section of this manual. Crusher weights are on the installation drawing.
Do not allow anyone under the crusher as it is being hoisted, keep all bystanders away
from the area. Always use suitable rigging and hoisting equipment to stabilize and lift
heavy objects. Lifting heavy components with inadequate hoisting apparatus can
result in serious injury or death.
35
Do not use the lifting eyes on the hopper assembly to lift the crusher. The hopper lifting
eyes are not designed for the weight of the crusher. Serious injury or death could
occur if the hopper eyes were to fail during lifting.
The Kodiak+ crusher is equipped with three lifting eyes located on the upper assembly that are rated to lift
the weight of the entire crusher.
36
Lifting Procedure for Crusher to be Installed
1. Remove the hopper assembly from the crusher.

2. Remove any shipping blocks that may have been installed to prevent movement of the cone during ship-
ping.
3. IMPORTANT: Verify that the TIR is sealed and hydraulic oil prevented from leaving TIR cylinders during
lifting.
4. If the TIR/Clear hoses have been removed, verify that the fitting on the TIR cylinders have been capped.
NOTE: The Kodiak+ crusher typically ships from the factory with the TIR/Clear hoses connected to the TIR
cylinders and the hoses are capped at the other end with quick disconnects. The crusher can be lifted in this
condition. If lifting the crusher with hoses connected, verify that the hoses are capped to prevent loss of oil
from the TIR cylinders.
5. Disconnect the crusher from its shipping blocks or skid.
6. Verfiy that the mounting surface on the crusher support is cleaned off and ready to receive the crusher
prior to lifting.
7. Locate the 4x16ga shims that come with the crusher (located in the box of auxiliary parts) or be prepared
to fabricate shims if required.
8. Verify that the crane and rigging are suitable and rated for loads equal or greater than the complete
crusher weight. Crusher weights vary considerably due to variations in structural casting weights. It is
advisable to have considerable additional capacity in the crane and rigging. Providing 1000-2000lb of
extra capacity is recommended when the actual weight of the specific crusher is uncertain.
9. Visually inspect all rigging and the lifting eyes on the bowl for signs of mechanical damage.
10. IMPORTANT: Verify that TIR system has been capped so that oil cannot escape from TIR cylinders as
the crusher is lifted. When lifted, there may be some extension of the TIR cylinders. If the TIR has been
properly capped as described above, this will not damage the cylinders.
NOTICE: Failure to follow this step can result in a significant amount of oil discharging from the TIR plumbing.
11. Connect rigging to crusher using the lifting eyes provided in the bowl. DO NOT USE THE LIFTING
EYES ON THE HOPPER.
12. Connect tag lines to the crusher if necessary for stabilizing the crusher while it is suspended. The
crusher is ready to lift.
13. As the crane takes up the weight of the crusher, but prior to actually lifting the full weight, verify no oil is
leaking from the TIR assembly and that nothing is hung up on the crusher.
NOTICE: Do not approach the crusher when it is suspended, until it is directly over its final position and ready to
lower the last few inches.
NOTE: If the crusher is being placed on a steel support structure, follow steps 15-19. If it is being grouted to
a concrete structure, these steps can be omitted.
14. Set the crusher on its support structure with the mounting holes aligned. Do not bolt down yet, and do
not disconnect crane yet.
37
15. If the weight of the crusher is fully supported by the support structure, go under the crusher and visually
verify that it is in solid surface-to-surface contact with the support structure at each bolt hole location. If
there is a gap at any bolt hole location greater than .063” (1.6mm), prepare to use shim(s) at that loca-
tion(s) to fill the gap. If there are no gaps larger than .063” (1.6mm) then no shims are required.
16. If it was determined that the shims are required, lift and block the crusher to allow the required shims to
be installed.
17. Set the crusher down on the shims and reinspect.
18. Repeat if necessary until the crusher is sitting flat on the structure with no gaps greater than .063”
(1.6mm).
19. Install the mounting bolts and tighten to refusal.
RELATED LINKS:
Hopper Assembly Removal Procedure
Lifting Procedure for Crusher Already Installed
1. Remove the hopper assembly from the crusher.

2. Remove any shipping blocks that may have been installed to prevent movement of the cone during ship-
ping.
3. Disconnect all hoses from the crusher.
• TIR/Clear hoses (cap fittings on TIR cylinders when hoses are removed -- IMPORTANT)
• Bowl rotate hoses
• Bowl clamp hose
• Lube supply line (cap fitting on bottom of crusher when hose is removed)
• Hydraulic cone brake sensor hose (if installed)
• Lube oil return hose (cap off king nipple when hose is removed)
4. Remove all cables from crusher.
• CSS proximity cable
• Bowl float assembly cable
• Bin level sensor cable (if installed)
• Hydraulic cone brake pressure sensor cable (if installed)
5. Remove crusher mounting bolts.
6. Prepare a place to set the crusher once it has been lifted from its support.
7. Verify that the crane and rigging are suitable and rated for loads equal or greater than the complete
crusher weight. Crusher weights vary considerably due to variations in structural casting weights. It is
advisable to have considerable additional capacity in the crane and rigging. Providing 1000-2000lb of
extra capacity is recommended when the actual weight of the specific crusher is uncertain.
8. Visually inspect all rigging and the lifting eyes on the bowl for signs of mechanical damage.
38
9. IMPORTANT: Verify that TIR system has been capped so that oil cannot escape from TIR cylinders as
the crusher is lifted. When lifted, there may be some extension of the TIR cylinders. If the TIR has been
properly capped as described above, this will not damage the cylinders. Failure to follow this step can
result in a significant amount of oil discharging from the TIR plumbing.
10. Connect rigging to crusher using the lifting eyes provided in the bowl. DO NOT USE THE LIFTING
EYES ON THE HOPPER.
11. Connect tag lines to the crusher if necessary for stabilizing the crusher while it is suspended. The
crusher is ready to lift.
12. As the crane takes up the weight of the crusher, but prior to actually lifting the full weight, verify no oil is
leaking from the TIR assembly and that nothing is hung up on the crusher.
13. Do not approach the crusher when it is suspended, until it is directly over its final position and ready to
lower the last few inches.
14. Set the crusher down.
RELATED LINKS:
39
CRUSHER PRE-INSTALLATION CONSIDERATIONS
Crusher Pre-Installation Considerations

An installation drawing for your crusher should be available to your plant designer prior to the crusher delivery.
The installation drawing contains dimensional, weight, and loading information that is specific to your crusher.
NOTICE: You should have the installation drawing before you read this section and before you develop your plan to
install the crusher.
The installation drawing can be found in the manual set for your crusher, in a pocket inside the hydraulic
power unit electrical panel, or on the KPI-JCI website. Contact your dealer or JCI directly if you cannot locate
the drawings and schematics.
Kodiak+ Crusher Assembly and Drive Motors
1 Remote Control Panel
2 Kodiak+ Crusher Assembly
3 Lubrication Package
4 Oil Cooler
5 Hydraulic Power Unit (HPU)
• Drive Motor (Provided by User)

• Motor Control Center (Provided by User)
40
Support Structures
The support structure and foundation must transmit impact loads from the crusher to the ground. Design of
the foundation and structure must account for dead loads and crusher impact live loading. The crusher has
cyclic loading at four mounting bolts, at a frequency equal to the wedgeplate rotational speed of 320-360
RPM. The installation drawing contains loading information for your crusher.
Stationary Plants
The foundation must be designed with load bearing ability to support the combination weight of the crusher,
its impact live load, support structure, and material being processed. The foundation must be flat and level.
If the crusher is mounted directly to a concrete foundation, use epoxy grout between the frame and the foun-
dation to ensure proper bearing. If the crusher is mounted to steel beams, use steel shims to adjust for any
irregularities in the mounting surface. Shims are included in the box of auxiliary parts that come with each
crusher.
Portable Plants
Mounting the Kodiak+ crusher on a portable trailer plant requires special design considerations. Refer to the
installation drawing for your particular Kodiak+ crusher for loading design guidelines. The main objective is
to direct crusher impact loads through the trailer frame to the ground. To minimize flexing, the trailer frame
should be cribbed directly under the crusher support structure connections to the trailer beams. Mount the
crusher plant on a solid foundation of level compacted aggregate base. The illustration below is a typical
mounting structure for portable plants.
1 1” Thick Triangular Plate
2 Corner Brace Tubes 4 X 8 X 1/2”
3 Main Support Tubes 8 X 8 X 1/2”
The crusher mounting surface must be flat and level all around. Leveling of a portable crusher is accom-
plished by blocking the trailer frame with cribbing, or jacking trailer frame support legs.
41
Clearance
• Allow enough clearance to perform daily lube oil service, visual inspection, and maintenance of the
tramp iron cylinders. JCI recommends 30" (76.2cm) of minimum clearance all around the crusher, from
the base to the feed hopper.
• Under crusher discharge hoppers and conveyors should be designed to allow sufficient room to allow
servicing of the cone brake at the bottom of the crusher in the center of the baseframe spider. JCI
recommends a minimum of 24" of vertical distance from the crusher mounting surface to the discharge
belt at the center of the crusher. Access to crusher mounting bolts should also be taken into consider-
ation.
• In the event tramp iron enters the feed material and finds its way into the crushing chamber, the upper
assembly will rise to allow the uncrushable material to pass through the chamber. Vertical clearance will
also be required for the clear feature, which will raise the upper assembly to allow a feed rock jam to
pass through the crushing chamber. See the installation drawing for vertical clearance required for your
particular crusher. When positioning the feed conveyor, allow vertical clearance equal to or greater than
that recommended on your installation drawing.
• When performing a manganese change or crusher tear-down, the upper section of the crusher must be
removed. See the installation drawing for your particular crusher for required clearance. In addition,
there should be no permanent structures in place that would interfere with lifting cables being used to
remove the upper section from the crusher.
Drive Motors and Belts

The drive motor sheave size is determined by the application and should be considered along with the
chamber configuration before designing the installation. For assistance in selecting an operating speed
appropriate for a particular application contact JCI. Typical pinion speed varies from 750 to 1000 RPM (900
RPM is the default speed in the absence of any specific application consideration).
42
MASTER PLC/HMI PANEL
Master PLC/HMI Panel
1 HMI
2 24VDC, Ground, ESTOP, and Modbus Communication Connection
The Master PLC/HMI remote control panel is the standard control interface. It is designed for indoor or
outdoor use and comes as basic equipment with each control assembly.
External control systems, such as plant-wide computer control networks, may issue commands for START,
STOP, UP, DOWN, CLEAR to the Master PLC/HMI enclosure via connections provided (see electrical sche-
matic). Auxiliary ESTOP controls may also be provided. However, actual operational control of the crusher
and its lubrication and hydraulic systems are handled entirely by the Kodiak Crusher Control (MILO).
The HMI panel is connected to the HPU by a cable that contains 24VDC to power the PLC and modbus cable
to connect the main MASTER PLC (located in the HMI panel) to the SLAVE PLC (located in the HPU electrical
enclosure). The standard length for the cable to the hydraulic unit is 50’ (15.24M). The location of the remote
control panel should be considered early in the design process so that the proper cable length can be chosen.
Even though the electrical enclosure and HMI are designed for a variety of environmental conditions, some
consideration must be made to protect against flying rocks and debris that can be encountered around rock
crushing plants.
43
MOTOR CONTROL CENTER (PROVIDED BY USER)
Motor Control Center (Provided by User)

The motor control center includes any switch gear and enclosures required to run the Kodiak+ crusher. This
may be a standalone unit specifically for the Kodiak+ crusher or may be part of a larger electrical control
center for the entire operation. Motor power wiring can vary due to customer preference, country, state or
local codes and power source. JCI strongly recommends that all switch gear be removed from portable plant
trailer frames during crusher operation. The vibrations associated with crushing can lead to malfunctions and
reduced life of the electrical components. If switch gear is mounted to the trailer frame for transport, it should
be mounted in a way to permit removal and placement on the ground during crusher operation.
There are a number of items associated with power delivery and switching that are provided by the customer.
Prior to designing or installing switch gear for use with a JCI Kodiak+ crusher, it is important to read and
understand the motor control circuits shown in the electrical schematic.
Although most of the items listed below are ordinarily supplied by the customer, they may also be supplied
by JCI as optional equipment. The electrical components required by the Kodiak+ crusher include:
• Main power disconnect for all of the motors listed below as well as control power. All the motors supplied
with the Kodiak+ crusher come wired for 480V 60Hz. Other voltage options are available.
• Control power supply 120VAC 50Hz or 60Hz x 60amp minimum. The power supply, circuit breaker, and
the cable to connect the power supply to the HPU. There are circuit breakers located in the hydraulic
power unit for specific functions within the installation.
• Crusher drive motor(s). Refer to the installation drawing for the horsepower requirement for your partic-
ular Kodiak+ crusher. The crusher motor must be designed for the overhung loads produced by the
V-belt drive. The Kodiak+ crusher can be driven with single or dual drive motor arrangements. The drive
motors, belts, drive sheaves, guards and related equipment are supplied by the customer. The driven
sheave at the crusher pinion shaft is supplied by JCI (refer to installation drawing). V-Belt drive compo-
nents are available on request.
• Starter(s) for crusher drive motor(s). JCI recommends the use of electronic soft start or auto-transformer
to start the crusher drive motor(s) Typical ramp time for the soft start is 15 seconds, which is the time
required to accelerate the crusher to full speed. When the motor reaches full speed a bypass contactor
should engage, which will relieve the soft start and reduce the heat produced by the soft start. The drive
motors must be wired to produce a clockwise rotation of the crusher pinion shaft. (Refer to installation
drawing). In the case of dual drive motor applications, the control wiring should be designed to bring the
second motor on line after the crusher has reached full speed.
• Starters and cabling for motors supplied by JCI:
– 1 hp motor (oil cooler fan)
– 3 hp motor (lube pump located in the lubrication package)
– 15 hp motor (hydraulic pump located in the hydraulic power unit)
Feed and Product Conveyors and Auxiliary Equipment

JCI recommends that equipment feeding the crusher be interlocked with the crusher drive motors. The
Kodiak+ controls are designed to automatically sense conditions that could damage the crusher and to shut
the drive motors down in those situations. If the feed conveyor and auxiliary equipment are interlocked it is
possible to avoid overflowing the crusher. The product conveyor should not be interlocked, and should be
wired to keep running until shut down by the operator, which will allow the crusher to be cleared in the event
of an overload or if the chamber gets plugged.
44
LUBRICATION SYSTEM
Lubrication System
Lube oil is circulated through the crusher from a remote lubrication assembly with an oil reservoir. The
Kodiak+ crusher lubrication system is designed to provide your crusher with a continuous supply of filtered
and cooled oil.
45
LUBRICATION SYSTEM
1 Lubrication Unit Reservoir Filler
2 Lubrication Oil Filter
3 Flow Rate Transducer
4 Lube Unit Reservoir Breather
5 Lube Panel Junction Box
6 Lube Cooler Bypass Valve
7 Lube Pump
8 Motor
9 Lube Oil Heaters
10 Reservoir Level Sight Glass
11 Lube Oil Test Port
12 Lube Oil Cooler
46
LUBRICATION SYSTEM
Lubrication System Oil Flow
The lube pump pulls oil from the reservoir and then pumps it through the oil filter and flow sensor. The oil is
sent back to the crusher where it is pumped up the baseframe spindle to the bearings. The oil drains down
through the bearings to the pinion tunnel, lubricating the gears and pinion bearings along the way. Oil flows
by gravity back to the reservoir.
It is recommended that when the crusher is new and you are becoming familiar with the machine you observe
the oil level in the sight glass when the machine first starts up. The oil level will drop dramatically after the
lube pump starts. The level will continue to drop until return flow from the crusher reaches steady state. This
is normal and the effect is more pronounced when the oil is cold. The amount of the oil level drop is influenced
by a number of reasons and will vary from crusher to crusher. Then it will slowly start to come back up in the
sight glass as the oil warms up. Generally, if the oil is reasonably warm and the reservoir was full at startup,
the oil level will remain visible in the sight glass. As long as oil is visible in the sight glass, there is at least 14
gal [53L] remaining. As the oil warms up, the level in the sight glass will begin to come back up, but will never
reach full when the crusher is running. For instance, a K300+ operating at 120°F (49°C) will show approxi-
mately 19 gal (72L). The actual level will vary by both model and temperature. Operators and/or personnel
working around the crusher should become familiar with what is normal for their particular crusher.
Check the lube oil pump motor rotation carefully. There is an arrow on the pump. Make sure the motor rota-
tion matches this arrow. Verify that oil is flowing when the pump is running. An easy way to check is by
observing the visual bypass indicator on the filter. Observe the bypass indicator when the pump first starts
and verify that the indicator moves from left to right. Depending on oil temperature, it may return to its original
position after the flow stabilizes but should always move left to right when the pump first starts.
47
LUBRICATION SYSTEM
Lubrication System Connections

Oil is pumped from the lube oil reservoir to the crusher via a supply line. Oil returns to the reservoir via a return
hose and/or pipe.
1 Return Line, minimum angle = 5°, maximum angle = 45°
2 Line to Cooler
3 Line from Cooler
4 Supply Line to Crusher
5 12’ (3.65M) of 2 1/2” (63.5mm) hose is provided with crusher. 2 1/2” pipe is acceptable (do not extend)
6 Oil drain line ports, only one (1) is required
The lube assembly is connected to the oil cooler via two (2) hoses provided with the crusher.
48
LUBRICATION SYSTEM
1 Lubrication Panel
2 Line to cooler
3 Line from cooler
4 Line to the crusher
5 Cooler
49
LUBRICATION SYSTEM
There is a bypass valve is installed in the lube oil circuit to direct the flow of oil to the cooler whenever the oil
temperature exceeds 120° F (full bypass at 140° F). The cooler is bypassed when the oil temperature is below
120° F.The bypass valve is mounted on the lube package enclosure and has three (3) ports marked “inlet”,
“cooler” & “tank”. The “inlet” port is connected at the factory to the hose coming from the flow sensor. The
“cooler” port has one hose going to the oil cooler. The “tank” port has two hoses, one comes from the cooler
and the other goes to the lube supply port on the bottom of the baseframe. This hose delivers cooled oil to
the crusher.
1 Filtered Oil
2 Overheated Oil
3 To Cooler
4 Normal Temperature Oil
5 To Crusher
6 From Cooler
50
LUBRICATION SYSTEM
Lubrication System Installation Considerations

You installation plan should take the following into consideration:
• The lube assembly must be mounted in a manner that permits gravity return oil flow from the crusher to
the reservoir (see also installation drawing for mounting guidelines).
• Be sure to route the return hose so that it flows continuously down hill. Avoid any humps in the return
line as this will cause the return flow to back up, resulting in oil leaks at the crusher. Avoid long flat runs
as well as vertical sections. Route the return line so that its angle of descent is greater than 5° and less
than 45° throughout its length. Visualizing the return line as though it were a gutter rather than a hose
when designing the return hose routing should result in trouble free return flow.
• The lube supply line is routed under the crusher, so provide clearance in the support structure suitable
for a #12ORS hose end.
• The location of the fill pipe must facilitate easy access. It is permissible to extend the fill pipe if required
for more convenient access. Bear in mind that a longer fill pipe will make it easier to accidentally overfill
the reservoir.
• Position HPU and lube assembly so that the 24' [7315 mm] wiring harness will reach from the lube
assembly junction box to the HPU electrical enclosure.
• Do not install the breather in a location where rock and dirt can pile up around it. If this is unavoidable,
the breather can be remotely located and connected to the tank with a hose. If this is necessary, keep
the hose run to the breather as short as possible. See the installation drawing for physical dimensions,
fluid port locations, etc.
• Provide easy access for checking the oil level in the sight glass mounted to the side of the lube panel.
• The cables connecting the oil cooler fan motor (1 hp) to the motor control center are supplied by the end
user. Additionally, 3ph power for the 1 hp motor is required.
• The oil cooler can be located anywhere convenient with good air flow and some protection from falling
rocks and debris.
• The oil cooler provided is generally adequate for keeping the lube oil temperature acceptable. Larger
oil coolers are available for particularly hot or extreme high elevation applications. Longer lead times
apply; consult the factory.
51
LUBRICATION SYSTEM
Lubrication System Installation Procedure
1. Connect the 3/4” (19mm) supply line hose to the crusher under the pinion tunnel.
2. Trim the 2-1/2” (63.5 mm) rubber hose return line to fit, as the 12’ (3.6m) provided is generally longer
than required.
NOTICE: DO NOT EXTEND lube supply or return lines (see installation drawings).
3. Connect the return line to either of two (2) possible drain line ports on the front of the crusher, just under
the pinion shaft. If desired, the return line may also be connected to the underside of the pinion tunnel,
although generally this is less convenient.
4. Connect the oil cooler to the lube panel with the two (2) 13’ (4m) hoses that are supplied with the
crusher. Cooler hoses may be extended if necessary.
5. Connect the lube assembly transducers and the HPU PLC using the supplied harness. Verify that the
lube assembly and HPU are close enough together to permit the harness to reach. See the installation
drawing for particulars on lengths, etc.
1 HPU Electrical Enclosure
2 SO Cord
3 Harness (P/N 027426)
52
CRUSHER HYDRAULIC SAFETY PRECAUTIONS
6. Connect the supplied SO cord for providing 120VAC power to the lube assembly heaters.
7. Use the branch on the lube assembly harness to connect the hydraulic cone brake pressure transducer
(for crushers equipped with this option). The cable for making this connection is provided with the
crusher when this option is chosen. The length is such that it can be routed along with the lube supply
hose.
8. When all lubrication connections are complete, verify that the reservoir is full. Some loss of lubricant
during shipping and installation is not unusual.
Crusher Hydraulic Safety Precautions
CAUTION: The Kodiak+ crusher hydraulic system uses high pressure fluid. Exposure
to high pressure oil could cause severe injury or death. Always depressurize the
hydraulic system before conducting maintenance or service.
CAUTION: Some diagnostic and/or adjustment procedures described in this manual

require working on electrically and/or hydraulically energized equipment. Only
persons qualified by local safety and/or licensing regulations to work on electrically or
hydraulically energized equipment and who are familiar with the equipment should
perform any of the procedures described in this manual. Serious injury or death could
occur if an untrained person were to work on an energized system.
Keep in mind the following guidelines while servicing your hydraulic system:
• Allow time for hot hydraulic oil to cool before performing any maintenance or repairs. Hot oil can cause
burns.
• Before loosening fittings or removing components, always recheck that ALL pressure is relieved from
the system. Pressure gauges must read zero (0) psi (bar).
CAUTION: Never attempt to crack a hydraulic fitting while a hydraulic system is

pressurized. You could be injured or killed by a stream of high pressure oil.
53
CRUSHER HYDRAULIC SAFETY PRECAUTIONS
• Never have your face near or stand directly in front of a hydraulic line when cracking a fitting, even after
system pressure has been relieved. Always assume that the line has pressure.
• Use a piece of cardboard to check for hydraulic oil leaks, not your hand. Escaping fluid under pressure
can penetrate the skin, resulting in personal injury.
• Clean up any spilled hydraulic fluid. Hydraulic fluid is extremely slippery, and can be especially
dangerous if spilled on an elevated walkway or platform.
• Repair any leaks immediately. Always relieve system pressure and lockout/tagout power before tight-
ening fittings or making repairs.
• Never attempt to adjust pressure relief valves higher than the specified settings. Serious personal injury
and/or equipment damage could result. Do not operate the hydraulic system with worn, damaged, or
leaking components. Always replace any defective components immediately.
• Never place hands on hydraulic cylinder rods while equipment is in operation. Do not step on the
hydraulic relief cylinder hoses.
• Refer to manufacturer’s instructions when recharging hydraulic accumulators or checking accumulator
pressure. Allow only trained hydraulic system technicians to depressurize, recharge or repair hydraulic
accumulators.
54
HYDRAULIC POWER UNIT (HPU)
Hydraulic Power Unit (HPU)

The hydraulic power unit contains all of the hydraulic control components, pump, motor, and 25 gallon (94.6
L) oil reservoir and is connected to the crusher, motor control center, remote control panel, and lubrication
package. All of the motor control wiring for the crusher drive motor(s) as well as the hydraulic pump and lube
pump motors pass through the electrical enclosure on the power unit. The wiring for the 15 hp (11.03 kW)
hydraulic pump motor, control power supply to the power unit, and motor control wiring to all motor starters
are supplied by the customer.
55
HYDRAULIC POWER UNIT (HPU)
1 HPU Base
2 External Filler
3 Breather
4 Hydraulic Tank
5 Motor Assembly
6 Gear Pump
7 Pump Adapter & Coupling
8 Manifold Assembly
9 Hydraulic Oil Heater
10 Sight Level Gauge
11 Hydraulic Filter Assembly
12 Hydraulic Return Oil Temperature Switch
13 Accumulators
14 Manual Pump Transfer Assembly
56
CRUSHER HYDRAULIC MANIFOLD ASSEMBLY
Crusher Hydraulic Manifold Assembly

Hydraulic pressure is provided by a gear pump connected to an open circuit hydraulic manifold in which
hydraulic fluid is constantly flowing when the pump is running. The connection is made at the P port located
on the left-hand end. When a directional control valve is energized, the flow of oil is diverted to a particular
circuit. The directional control valves are mounted to the manifold and include solenoids S1 through S7. The
hydraulic manifold return line is connected to the hydraulic oil filter.
57
CRUSHER HYDRAULIC MANIFOLD ASSEMBLY
1 Tramp Iron Relief System Needle Valve (NV1)
2 Pump Discharge Pressure Gauge (GP3)
3 Tramp Iron Pressure Transducer (PT2)
4 TIR Circuit (S1)
5 Rotate Bowl Down (S4)
6 Bowl Clamp Pressure Transducer (PT1)
7 Bowl Clamp Needle Valve (NV2)
8 Rotate Bowl Up (S5)
9 Bowl Clamp Circuit (S3)
10 Hydraulic Clear Circuit (S2)
11 Clear Enabling Valve (S6)
12 Main System Relief Valve (RV1)
13 Bowl Clamp Return Oil Check Valve (CV)
14 Inlet
15 Return
16 TIR P.O. Check Valve (CPV1)
17 Bowl Clamp P.O. Check Valve (CPV2)
18 TIR Make-up Oil Control Valve (S7)
RELATED LINKS:
Depressurize Crusher Hydraulic System Procedure
58
BOWL CLAMP
Bowl Clamp
The bowl clamp is a hydraulic piston that prevents the bowl from spinning when the crusher is operating.
When the bowl clamp circuit is pressurized, the bowl clamp is forced upward. This action causes the threads
in the bowl clamp to push against the bowl threads, thus keeping the bowl from turning. Anti-rotation pins in
the bowl clamp and bowl support keep the bowl clamp ring from spinning. When the bowl is raised or lowered,
the clamp is depressurized to allow the bowl to rotate.
1 Hydraulic Oil Supply Hose
2 Upper Dust Seal
3 Bowl Clamp Piston
4 Bowl Clamp Seal
5 Bowl Clamp Ring
6 Brass Thread Insert
59
BOWL CLAMP
1 Anti-Rotation Pin
60
BOWL CLAMP CIRCUIT
Bowl Clamp Circuit
The Kodiak+ hydraulic system automatically controls the bowl clamp pressure. The pressure is sensed by
and displayed on pressure transducer PT1, mounted on the top right-hand side of the hydraulic manifold. If
the pressure drops below the low set point, the pump starts and solenoid S3 is energized. When S3 is ener-
gized, oil is sent to the bowl clamp and also the bowl clamp accumulator. When the pressure reaches the high
set point, S3 is de-energized and oil is trapped in the circuit by check valve CPV2. After a time delay, the
pump is shut off.
It is necessary to bleed the pressure from the bowl clamp circuit whenever the bowl is removed, as a normal
part of troubleshooting, when adjusting the system pressures, or any time any part of the hydraulic system is
disconnected. When removing the bowl, or any time the bowl is rotated beyond the upper limit of the crushing
zone, bleed all the pressure from the bowl clamp circuit and disconnect the hose to prevent damage to the
bowl clamp seal.
NOTE: Do not disconnect bowl clamp quick coupler without relieving the pressure (NV1). Pressure will be
come trapped in the hose making it difficult to reconnect.
CAUTION: Always relieve the pressure from the bowl clamp circuit prior to
disconnecting or disassembling any part of the hydraulic system. Serious injury or
death can occur from exposure to high pressure oil. Follow all lockout/tagout and
related safety regulations.
61
BOWL ROTATION MOTOR
Bowl Rotation Motor
1 Bowl Rotate Drive Gear Box
2 Bowl Rotate Hydraulic Motor
3 Drive Ring Gear
The bowl rotation drive system is composed of a gear box and a hydraulic motor. A pinion gear on the gear
box shaft meshes with the drive ring gear. When the BOWL UP/BOWL DOWN buttons are pressed, hydraulic
oil is directed to the bowl rotation motor causing the bowl drive ring to turn. Pressure to the bowl clamp is
simultaneously reduced to permit rotation.
NOTICE: Never allow the bottom of the drive ring to move above the “STOP” level on the Crushing Zone decal.
Rotating the bowl above the “STOP” level without following the bowl removal procedures in the Service section can
result in a sudden significant loss of hydraulic oil and could possibly damage the bowl clamp seal. Read and
understand the principles of the Crushing Zone and Bowl Rotation in this manual before attempting to rotate the
bowl.
RELATED LINKS:
Bowl Rotation and CSS Adjustment
The Crushing Zone
62
BOWL ROTATION CIRCUIT
Bowl Rotation Circuit

Bowl rotation works in conjunction with the bowl clamp circuit. Solenoids S4 (down/M2) and S5 (up/M1) are
energized by pressing BOWL DOWN or BOWL UP. Solenoids S4 and S5 direct oil to the hydraulic motor
mounted on the crusher. Pressure builds in the M1 or M2 ports, depending on which rotation direction is
chosen. Regardless of which port is pressurized, the pressure shifts shuttle valve SV and opens check valve
CPV2, which allows the bowl clamp pressure to drop as the bowl clamp accumulator drains back to tank. The
pressure does not drop to zero, however.
It is not unusual for some time to elapse between pressing BOWL UP/BOWL DOWN and the beginning of
the actual bowl rotation. This is due to the time required to drain the accumulator and force the bowl clamp
piston up into its groove. During this time delay, or any time the bowl fails to rotate, the system pressure will
build to the main system relief pressure. Once rotation begins, the pressure will drop to whatever is required
to overcome the current resistance.
When the pushbutton is released, the rotate control valve (S4/S5) returns to neutral and check valve CPV2
reseats. Solenoid S3 is energized until bowl clamp pressure is restored.
NOTE: The bowl rotate and bowl clamp circuit will not function if TIR pressure is not satisfied by PT2 as flow
is diverted upstream in the manifold by S1 solenoid.
63
TRAMP IRON RELIEF (TIR) SYSTEM
Tramp Iron Relief (TIR) System

The system is comprised of a series of TIR cylinders that hold the upper assembly down on the lower
assembly of the crusher. The cylinders have an integral manifold that is equipped with four (4) ports and a
relief valve that sends oil from the retract port to the extend port in the event of an overload condition. Only
half (every other one) of the TIR cylinders have a relief valve. The rest have a plug in the relief port. When
the CLEAR button on the control panel is pressed, oil is pumped into the extend port and oil in the retract end
of the cylinder returns to tank.
1 Tramp Iron Relief Cylinders
2 TIR Cylinder Hydraulic Hose
3 TIR Pressure Relief Valve
64
TRAMP IRON RELIEF (TIR) SYSTEM
1 TIR Cylinder Manifold
2 TIR Cylinder
3 TIR (retract)
4 Clear (extend)
5 TIR Relief Valve
65
TIR PRESSURE CONTROLS
TIR Pressure Controls

The Kodiak+ hydraulic system automatically controls TIR and bowl clamp pressure. Additionally, the bowl can
be rotated up and down and the upper assembly can be raised by remote control. The hydraulic system oper-
ates on demand. Anytime the system senses that the TIR or bowl clamp pressures need adjustment, or the
operator presses BOWL UP, BOWL DOWN, or CLEAR on the Kodiak Crusher Control, the system automat-
ically starts the pump and responds as required. The pump remains on for approximately two (2) minutes after
the last control signal is satisfied.
The TIR return oil temperature switch is provided in the return line so if return oil exceeds the set point (factory
set at 190°F [88°C]), an alarm will sound. Under normal operating conditions there should be no significant
increase in temperature. If the alarm sounds, a malfunction has occurred. This is most likely due to a leak in
the system.
1 TIR System Accumulator
2 TIR Return Oil Temperature Switch
3 TIR Make-up Oil Control Valve
The TIR make-up oil control valve (S7), located on the left-hand side of the manifold behind the pump pres-
sure gauge, allows hydraulic oil to go from the accumulator to the tramp iron relief system but not back to the
accumulators when the system is over-pressurized due to bowl float or tramp iron.
66
TIR PRESSURE CONTROLS
1 TIR Make-up Oil Control Valve (S7)
Whenever the pump is operating, the pressure at the pump discharge port is displayed on the pump pressure
gauge (GP3). If the pump is running and the gauge reads zero, it means that all control signals have been
satisfied.
1 Pump Pressure Gauge (GP3)
67
TRAMP IRON RELIEF (TIR) CIRCUIT
Tramp Iron Relief (TIR) Circuit
The upper assembly is clamped to the baseframe by a group of hydraulic cylinders that are connected in
parallel and spaced equally around the crusher. Every other cylinder is equipped with a relief valve that is
situated in a cavity connected to the retract and extend ports of the cylinder. If the load increases to the point
that the pressure within the cylinder exceeds the set point of the relief valve, the valve opens, allowing oil to
escape from the retract <TIR> end of the cylinder and enter the extend <CLEAR> end of the cylinder. This
allows the cylinders to act as a group of hydraulic latches. If the load within the crushing chamber exceeds
the maximum hold down force, the hydraulic system will unlatch and relieve the load. The resulting sudden
loss of pressure will cause the relief valves to close and the hydraulic system will pump oil back into the cylin-
ders and re-latch the upper assembly in place.
The hydraulic system senses and maintains TIR operating pressure automatically. The current TIR pressure
is displayed on pressure transducer PT2, located on the upper left-hand corner of the hydraulic manifold. An
accumulator is provided in the TIR circuit. Unlike accumulator based TIR systems, this accumulator has no
shock absorbing function. The accumulator provides makeup oil only. The relief valves have a small normal
leak rate. Oil in the TIR accumulator is used to replace the oil lost to this leakage and increases the time
between recharging cycles.
When the TIR pressure drops below the low end of the operating range, the pump starts and energizes TIR
control solenoids S1 and S7. Energizing solenoid S1 allows oil to enter the retract end of the hydraulic cylin-
ders. Energizing S7 allows oil to fill the TIR accumulator. When the high end of the operating range is reached
S1 and S7 are de-energized. Oil is trapped in the circuit by check vale CPV1. After a time delay, the pump is
turned off.
If the automatic control is unable to maintain TIR pressure within the normal operating range, it will indicate
that the pressure is low by a steady blinking indicator light and a warning message. If the TIR pressure falls
below 1500 psi (103.4 bar), the indicator lamp will flash and the system will allow a short delay to see if the
hydraulic system can automatically correct the problem. If after five (5) seconds the low pressure cannot be
corrected, a shutdown sequence will be initiated.
68
CLEAR CIRCUIT
It is necessary to bleed the pressure from the TIR circuit as a normal part of troubleshooting and adjusting
the system pressures or any time any part of the hydraulic system is disconnected.
CAUTION: Always bleed the pressure from the TIR and bowl clamp circuit prior to
disconnecting or disassembling any part of the hydraulic system. Serious injury or
death can occur from exposure to high pressure oil. Follow all lockout/tagout and
related safety regulations.
Clear Circuit
In the event that the crushing chamber becomes plugged, the TIR cylinders may be extended to clear the
chamber.
When the CLEAR pushbutton is pressed, solenoids S2 and S6 are energized. Solenoid S2 directs oil to the
extend port of the hydraulic cylinders. Solenoid S6 closes the port between the extend port and tank and
allows pressure to build in the bottom of the cylinder. This pressure will open the pilot operated check valve
CPV1 and allow the oil in the top end of the cylinder to return to tank. The upper assembly will rise off the
baseframe as oil continues to fill the bottom of the cylinder. It is not unusual for the cylinders to extend at
different rates. If the CLEAR pushbutton is held long enough all the cylinders will reach the end of their stroke,
and the pressure will build to the main system relief pressure. The pressure in the bottom of the cylinders will
be equal to the pump pressure shown on gauge GP3. The TIR transducer should drop to zero once all the oil
has been forced from the top of the cylinders and TIR accumulator has discharged.
CAUTION: Never reach into the gap or insert tools into the gap between the upper
assembly and baseframe when the upper assembly is elevated.
CAUTION: Do not block the upper assembly in the raised position when the hydraulic
system is energized.
RELATED LINKS:
Crusher Clear Function
69
CRUSHER SYSTEM RELIEF PRESSURE
Crusher System Relief Pressure

This limits the maximum hydraulic pump pressure to the crusher and is controlled by relief valve RV1, located
on the bottom of the crusher hydraulic manifold. If pump flow is blocked, the relief valve allows the pump to
come up to the system relief pressure before opening and redirecting flow to the reservoir.
RELATED LINKS:
System Relief Valve Testing and Setting Procedure
TIR Relief Valve Pressure

This pressure controls the maximum hold down force. Accumulator based TIR systems act like a circle of
hydraulic springs holding the upper assembly in place. Relief valve based TIR systems act like a circle of
hydraulic latches. The TIR relief pressure controls the point when the system “unlatches.” There is typically
a relief valve on every other cylinder. If the load at any individual cylinder causes the pressure to exceed the
TIR relief pressure, the valve(s) opens, allowing the upper assembly to lift. Oil in the top (retract) side of the
cylinders flow into the bottom (extend) side of the cylinder. The sudden drop in pressure causes the pump to
come on line and start bringing the pressure back up. If the source of the overload condition is gone, the upper
assembly will be “latched” back in place.
By having relief valves at multiple cylinders, the escape path for displaced oil is minimized regardless of
where the overload condition occurs. This is especially important if the overload is caused by a large uncrush-
able object. In this case, the displacement can be large and hence the flow rate at the cylinders near the over-
load can be quite high. However, if an individual valve malfunctions, the defective valve may be removed and
replaced with a cavity plug. One plug is provided with each crusher. If more than one plug is required, they
should not be installed in adjacent cylinders.
All the relief valves are set to the same pressure. Once a valve opens, the reseat pressure will be somewhat
lower than the original setting and will vary from valve to valve. Typically the reseat pressure will be approx-
imately 85% to 90% of the cracking pressure. Once reseated, the valves will continue to leak a small amount
of oil. This is normal and is typically less than or equal to ten (10) drops per minute. A one (1) gallon (3.8 L)
accumulator is provided to supply make up oil to replenish the oil lost due to this small leakage.
RELATED LINKS:
Individual TIR Cylinder Relief Valve Testing and Setting Procedure
70
HPU CONNECTIONS
HPU Connections
The HPU is connected to the crusher by several hoses and a single electrical cable. It is connected to the
lube assembly by a harness for connecting lube assembly sensors with the PLC and also an SO cord for
providing 120VAC to the lube assembly heaters. Both are provided with the crusher. The HPU may be
mounted anywhere convenient that can be reached by the hoses and cables provided.
71
HPU CONNECTIONS
Prior to working on the hydraulic system, verify that all circuits are depressurized. The
crusher is shipped with the hydraulic system full of oil and accumulator nitrogen
pressure set at 1900 psi (131 bar). The hydraulic system is depressurized prior to
shipment, but the system may gain some pressure due to thermal expansion. There
are two needle valves provided on the manifold inside the hydraulic power unit to allow
the manifold to be depressurized. The valve on the left hand side of the manifold
depressurizes the TIR circuit and the valve on the right hand side depressurizes the
bowl clamp circuit. Each valve has a hand wheel and a lock nut. Unlock the lock nut by
turning it counter clockwise slightly, then open the valve by turning it counterclockwise.
• Five (5) hydraulic hoses connect the crusher to the hydraulic control manifold located on the side of the
HPU enclosure.
• The HPU SLAVE PLC and I/O rack are also located in a separate enclosure mounted here. All input
sensors, control valves, etc., are monitored and/or controlled through I/O components in this enclosure.
Control and feedback connections between the Kodiak Crusher Control and the customer's motor
control center are made in this enclosure as well.
1 Bowl Clamp (C3)
2 Bowl Rotate (M1)
3 Bowl Rotate (M2)
4 Clear (C2)
5 TIR (C1)
6 Slave PLC Enclosure
72
HPU CONNECTIONS
• Two (2) 1/2" (12.7 mm) I.D. hoses connect ports M1 and M2 to the hydraulic motor ports labeled M1
and M2 (bowl rotate) located below the gearbox on the upper assembly.
• One (1) 1/4" (6.35 mm) I.D. hose connects port C3 to the bowl clamp fitting located on the upper
assembly.
• One (1) 1/2” (12.7 mm) I.D. hose connect port C1 to the tramp iron relief (TIR) ports (retract) on the TIR
cylinders.
• One (1) 1/2” (12.7 mm) I.D. hose connects port C2 to the clear (extend) ports on the TIR cylinders.
1 C3 Bowl Clamp Hose
Refer to the installation drawing for hose / cable lengths and termination locations.
73
HOPPER LEVEL SENSOR
Hopper Level Sensor

The Kodiak+ crusher is shipped with an ultrasonic hopper level sensor. Given the wide variety of installation
variables, no mounting hardware is provided as standard equipment. However, an optional mounting bracket
is available, which provides considerable adjustability, mounts on any shape hopper, and can be easily repo-
sitioned when moving a portable plant.
1 Hopper Level Sensor Assembly
2 Sensor Bracket (optional)
The pivoting sensor bracket provides protection against falling rocks and pivots in two directions to accom-
modate alignment of the sensor. The hole required for the sensor is 1.20” [30mm]. A 157” [4m] cable is
provided and should be adequate for most feed hoppers. Longer/shorter cables can be provided as optional
equipment. One end of the sensor cable terminates at the sensor. The other end of the sensor cable termi-
nates at the junction box located on the bowl rotator assembly on the bowl support.
74
HOPPER LEVEL SENSOR
1 Hopper Level Sensor
2 Cable Input
Within MILO, the hopper level sensor may be enabled or disabled as required. If enabled, the sensor is used
by the PLC to determine if the feed conveyor should be stopped or started. If the Kodiak Crusher Control is
wired into the plant such that it has direct control of the feed conveyor, then the hopper level sensor will act
as a hopper overflow control.
The control setup consists of configuring a “Sensor On Delay” and a “Feed Conveyor Off Period.” If the sensor
detects a target within its sensing window for an uninterrupted time period equal to the on delay period, the
PLC disables the feed conveyor output for a time period equal to the conveyor off period. At the end of the
off period, the conveyor will be re-enabled. If the sensor still detects a target within its range, the process will
be repeated. If no target is detected, the conveyor will remain enabled. By requiring that the sensor detect a
target for an uninterrupted period of time, it is possible to avoid incorrectly confusing a full hopper with indi-
vidual rock(s) bouncing momentarily into the sensing window.
Fully automated systems that include control of variable speed feed equipment can access the hopper level
sensor output either directly by rerouting the cable to the main plant computer or by accessing the Kodiak
Crusher Control via modbus network.
75
HOPPER LEVEL SENSOR
Hopper Level Sensor Configuration
1. Choose a location with a clear unimpeded view of the feed hopper that is as high above the full level as
practical while still providing a solid platform.
2. Provide some means for protecting the sensor from physical damage by flying feed material.
3. Mount the sensor.
4. Program the sensing range. The far end of the sensing range is the “full” level. The full level will neces-
sarily be a guess at this point. This guess will be refined in later steps.
5. From the HMI MAIN screen, choose MAINTENANCE MODE.
6. Scroll down to HOPPER LEVEL SENSOR ADJUST and press SELECT.
7. In the HOPPER LEVEL SENSOR SWITCH ADJUST screen set both delay times to the maximum
values.
76
HOPPER LEVEL SENSOR
NOTE: Use the SCROLL button to move within a submenu. Use the TAB button to move from one submenu
to the next.
8. Disable the control by setting Sensor Enable to “OFF.” The purpose of this step is to allow the operator
to establish flow of rock through the crusher using manual controls until it is determined that the sensor's
“full” level is appropriate.
9. Complete all other installation steps and run the crusher using manual feed control until familiar with the
crusher and the crushing circuit in general.
10. As the crusher hopper reaches the desired full level, have someone monitor the sensor LEDs. If the
sensor LEDs come on when rock reaches the desired full level and the LEDs go out when the level
drops lower in the hopper then the sensor is okay. If not, readjust the sensor as required when the
crusher is shut down. Repeat as required until the full level can be reliably detected.
11. When the appropriate full level is reliably detected, go to the configuration screen and enable the feed
control. When the feed reaches the full level and the LEDs come on for an uninterrupted time period
equal to the configured on delay, the feed conveyor should be disabled.
77
HOPPER LEVEL SENSOR
12. If the conveyor stops but the hopper overflows, the on delay period needs to be reduced and/or the full
level needs to be lowered. In general a longer on delay makes the system less sensitive to false indica-
tions. Adjust as required to get the ideal combination of full level and on delay.
13. If the hopper does not overflow, the full level and on delay times are okay. Observe as the feed level
drops in the hopper during the conveyor off time. If the chamber completely empties and the crusher is
no longer choke fed, then reduce the conveyor off time as required to increase the minimum hopper
level. Generally, keep the conveyor off delay as long as practical to reduce the number of motor on/off
cycles while still maintaining a choke fed condition.
ADDITIONAL INFORMATION: The feed control alone is primarily an overflow protection system and can only
enable/disable the feed conveyor. To function as part of a fully automated feed system with a minimum
number of conveyor stop/start cycles, the crusher feed circuit will require some form of variable speed feed
delivery as well. Variable speed feeders with or without controls are available as optional equipment.
Hopper Sensor Calibration Procedure
Program the sensor to detect a window with a “near” and “far” limit. The far target detects the desired hopper
full level. Any time an object is within this window the output LEDs on the sensor will light up and a signal will
be sent to the control system. The system will interpret the signal to indicate that the hopper is full only if a
sustained uninterrupted signal is received for a time period equal to the configured on delay time.
1 Sensing Window
2 Hopper Level Sensor (P/N 027521)
3 Near Target
4 Far Target Surface of Feed Material with Full Hopper
The key point to remember when setting up the sensing range is that the feed conveyor is enabled if the
sensor LEDs are off and the feed conveyor is disabled if the sensor LEDs are on.
78
HOPPER LEVEL SENSOR
Make the sensing window as large as practical. If the window is too small, it is possible to make the sensor
too sensitive and risk missing a full condition.
1 Green Power ON/OFF LED
2 Yellow Analog Output LED
3 Analog Output Programming Pushbutton (Not Used)
4 Red Signal Strength LED
5 Yellow Discrete Output LED
6 Discrete (Switched) Output Programming Pushbutton
1. Choose the output for the first set of window limits (discrete) and push and hold the corresponding
button until the green Power LED goes OFF and the appropriate yellow Output LED turns ON (solid).
This indicates the sensor is waiting for the first limit.
NOTE: Program the “near” target first then the “far” target. The near target should be no closer than 12” from
the sensor.
2. Position a flat metal or wood object (target) for the first limit and briefly “click” the same button. This will
teach the sensor the first limit. The yellow Output LED will flash to acknowledge receiving the first
window limit; it is now waiting for the second limit.
79
STACK LIGHT (OPTIONAL)
NOTE: Press and hold the same button > 2 seconds (before teaching the second limit) to exit PROGRAM
mode without saving any changes. The sensor will revert to the last saved program.
3. Position the target for the second limit and “click” the button again. This will teach the sensor the second
limit. The yellow Output LED turns off and the green Power LED comes on; the sensor is now in normal
RUN mode.
4. When the sensor is programmed, test the sensor by holding a target in front of the sensor until the
sensor output LEDs light up. Move the target back/forth to find the distance where the LEDs first come
on. This is the “full” level. Move the target away. The LEDs should remain off everywhere within the
chamber lower than the “full” level.
5. When the “full” level is acceptable, go to the HOPPER LEVEL SENSOR ADJUST configuration screen
and set up the on delay and conveyor off period.
Stack Light (Optional)

An optional stack light is available that can be mounted in a conspicuous location visible to loader operators
and other personnel that may be in the general area but without line of sight access to the HMI enclosure.
The stack light is not a control device. It is a useful tool for communicating crusher general condition and in
conjunction with the warning horn is highly recommended as a method for alerting nearby personnel when
startup is imminent.
The stack light can communicate the general condition of an unattended crusher but will not allow sufficient
time to react to problems in a timely fashion. The JCI Kodiak Crusher Control has the ability to shut down the
crusher in the event of a loss of lube flow or TIR pressure, but unless fully automated, there will be no
controlled shutdown of other equipment in the plant.
NOTICE: For the safety of plant personnel as well as the crusher and other plant machinery, JCI strongly
recommends constant human oversight of the crusher and all other related heavy equipment.
Interpret the stack light as:
Green Crusher Run Enable + Feed Conveyor Enable + No Communication Failures
Amber Crusher Run Enable but Feed Conveyor is Disabled
Lube Circulation Enable + (Not) Lube Circulation On Pulse + Lube Circulation Pump Enable +
(Not) Lube Level Sensor + (Not) Lube Circulation Fail Sensor
Red Crusher Stopped (not displayed when cold weather oil circulation is enabled)
Communication Failure [Blinking]
80
HYDRAULIC CONE BRAKE (OPTIONAL)
Hydraulic Cone Brake (Optional)

Although the JCI Kodiak+ crusher comes with a mechanical cone brake as standard equipment, JCI also
offers a hydraulic cone brake that uses a hydraulic motor and gear reducer to transfer torque from the cone
to the hydraulic motor. The motor is plumbed into the crusher lube oil with a check valve and relief valve such
that oil can flow unimpeded in one direction but is blocked in the opposite direction. Rotation in the blocked
direction causes pressure to build until it reaches the relief valve setting. The result is a unidirectional,
torque-limiting cone brake with no need for shear bolts.
This option requires a substantial amount of clearance under the crusher. Consequently, it is suitable for most
stationary applications but may not be practical for all portable plants with discharge conveyors located close
to the bottom of the crusher.
The cone brake pressure is displayed on the SENSORS screen. When the crusher is actively crushing, the
cone rotates in the freewheeling direction and the pressure should be near zero. The operator should check
the pressure often during the first few days/weeks of operation to see what the normal pressure is for that
particular crusher and environment. Since the pressure increases with internal resistance, the pressure will
be higher when the oil is cold and will typically go down as the oil warms up. You should be familiar with the
maximum expected pressure at startup and the normal pressure at normal operating temperatures for your
particular crusher. If pressures vary from these norms, it may indicate an abnormal source of internal resis-
tance. Knowing when something is unusual is an excellent troubleshooting tool.
The hydraulic cone brake is typically set to unload at 1000psi. Once unloaded, the flow going through the
relief valve will generate heat. Every effort to detect a spinning cone as quickly as possible is essential to
prevent damage to crusher components. Recognizing abnormal pressures is the best method for doing this.
Electrical Connections
Verify that all power is disconnected prior to making any connections. Refer to the
safety section on lockout/tagout procedures.
JCI recommends that motor control centers be removed from portable plants and placed on the ground during
crushing operation. Provision for removing the motor control center from the trailer needs to be considered
when planning the cable routing between the motor control center and various components.
81
ELECTRICAL CONNECTIONS
Connections at the HPU

Most external electrical connections with the HPU terminate in the electrical enclosure on the side of the HPU.
This electrical enclosure contains the 120VAC power distribution, 24VDC power supply, and SLAVE PLC +
I/O components.
For specific information see the electrical schematic and installation drawing.
The electrical enclosure must be connected to the customer's motor control center. A thorough description of
these connections are included in the electrical schematic. A summary of some of the connections are:
1) 120VAC power supply delivery (50hz or 60hz)
2) Cable for connecting crusher drive motor current transformer/transmitters
3) Control power for all motor starters
See also: Motor Controls for more on this important topic.
4) Feedback from auxiliary contacts of the following motors:
a) lube pump
b) hydraulic pump
82
ELECTRICAL CONNECTIONS
c) crusher drive motor(s)

See also: Motor Feedback Connections for more on this important topic.
5) 120VAC power to hydraulic and lube oil reservoir heaters
6) All 24VDC connections are in the form of harnesses, cables etc with threaded connections. All can be
connected/disconnected without opening the electrical enclosure.
Additionally, 3 ph power for the 15 hp hydraulic pump motor is terminated at the HPU.
RELATED LINKS:
Motor Controls
Motor Feedback Connections
Electrical Connections at the JCI Kodiak+ Crusher

There is one small electrical enclosure mounted on the bowl rotator that is a connection point for the two prox-
imity sensors (bowl rotate counter and max crushing zone detection).
A similar enclosure may be mounted on the opposite side of the bowl rotator assembly. When two enclosures
exist, the second is for connections to the bowl float detection system. Both enclosures are connected to the
HPU with cables that have threaded connectors.
1 Bowl Position Enclosure
2 Bowl Float Detection Enclosure
Crushers equipped with hydraulic cone brakes have a pressure transducer, which is typically located on the
TIR cylinder just to the left of the pinion shaft. The cable for this sensor terminates at the harness on the lube
assembly.
83
POWER SUPPLY CONNECTIONS
Power Supply Connections

Power Cable for Crusher Drive Motor(s)
The direction of rotation is indicated by an arrow attached to the crusher just above the pinion shaft, and is
always clockwise when facing the crusher with the pinion shaft pointing toward you.
Power Cable for the Lube Pump Motor

The direction of rotation is indicated on a tag attached to the pump. Set the motor up to match the tag, but if
the tag should be missing or damaged, set the direction counterclockwise when the motor is viewed from the
cooling fan end with the motor shaft pointing away.
NOTE: 3HP x 480V/60Hz 0r 380V/50 Hz other voltages available on request.
Power Cable for the Lube Oil Cooler Fan Motor

Typically the cooler is delivered in its factory crate with no directional arrows and set up as a blower fan.
NOTE: 1 HP x 480V/60Hz or 380V/50 Hz other voltages available on request.
Protecting the 24VDC Power Supply

Most components in the Kodiak Crusher Control system operate on 24VDC. The system includes a 24VDC
power supply that requires a source of clean 120VAC supply power. Protection against voltage spikes, light-
ening, etc., is required for reliable operation of this component.
Local and/or Non-USA Electrical Voltage Considerations

The Kodiak Crusher Control is designed to make it easy to install in most commonly encountered electrical
environments with little or no modifications. Some voltage considerations when operating outside the USA
include:
• The HPU requires 120VAC power. 60Hz or 50Hz is acceptable. For installations where this is not the
normal single phase voltage, a suitable transformer will be required. Such transformers are common
worldwide or can be provided as optional equipment. JCI recommends a 7.5KVA transformer.
The JCI P/N for the two (2) most common 7.5KVA transformers used for non-USA installations are:
a) 025603 for 380V or 415V x 50Hz electrical systems.
b) 027471 for 600V x 60Hz electrical systems (Eastern Canada).
These transformers are available as optional equipment. If switch gear is ordered from JCI, the appro-
priate transformer will be included.
• The lube pump, hydraulic pump and oil cooler motors supplied with the default Kodiak Crusher Control
are suitable for 480VAC 60Hz, 415VAC 50Hz and 380VAC 50Hz. Motor specifications are available on
request. 575VAC 60Hz motors are available as optional equipment. These voltages cover most
commonly encountered 3ph voltages worldwide. For other voltage requirements consult the factory.
• Although the motors are all suitable for use with common 50Hz voltages, the lower frequency makes
the motor turn slower. Consequently, the lube pump needs to be larger to compensate for the lower
84
MOTOR TOPICS
speed. If 50Hz is specified when the order is placed, the appropriate pump will be installed. When
moving a crusher from a 60Hz to a 50Hz environment or vice versa, consult the factory for the appro-
priate pump conversion. Although the frequency also affects the hydraulic pump, the flow rate is not as
critical as in the case of lube flow and hence no pump conversion is required.
Power Transmission
The maximum efficiency for your production requirements is the proper combination of speed, horsepower
and closed side setting. The pinion shaft speed has a range from 750 to 1000 RPM. This speed is determined
by the desired gradation, production capacity and reduction ratio. In the absence of any specific application
requirements, 900RPM is the default speed. Increasing the pinion speed or horsepower beyond that recom-
mended by JCI may shorten the life of the bearings and other power transmission components.
NOTICE: Running the Kodiak+ crusher outside the JCI operating parameters will void your warranty.
Crusher drive motors should be normal starting torque design A or B, totally enclosed fan cooled housing and
designed for the V-belt drive overhung load. When using a dual motor drive, both motors shall be the same
type, model and manufacture.
Sheave Alignment and Belt Tension

Proper drive belt alignment and tension are essential for belt and sheave life, efficient power transmission,
and pinion shaft component life. The ideal belt tension is the lowest tension at which the belt will not slip under
peak load conditions. Worn belts and sheaves will require much higher belt tension to convey the same power
as normal belts and sheaves. Do not run with badly worn belts or sheaves. This will shorten the life of the
bearings and other power transmission components. When installing new belts check belt tension frequently
during the first 48 hour period.
RELATED LINKS:
Cog Belt Tension Procedure
V-Belt Tension Procedure
Motor Topics
The Kodiak Crusher Control comes with hydraulic pump (15 hp [11 kW]), lube pump (3 hp [2.2 kW]), and oil
cooler fan (1 hp [.75 kW]) motors already provided. The crusher drive motor(s) are typically provided by the
customer but are available as optional equipment. The starting equipment for all of the motors is likewise typi-
cally provided by the customer but is available as optional equipment.
Motor Controls
It is necessary for the Kodiak Crusher Control to have direct operational control of the hydraulic pump, lube
pump and oil cooler motors. No on/off pushbuttons are provided. Motor starter coils are connected directly to
output terminals in the HPU electrical enclosure. Operational control of the crusher drive motor(s)
enable/disable is also required but is somewhat more complex. An on/off switch with an indicator lamp is
provided on the HMI enclosure.
85
MOTOR TOPICS
Crusher Drive Motor Current Transducer(s)

P/N 027242
Special motor current transducer(s) are provided with the control system. They deliver a 4-20mA signal to the
PLC that is proportional to the current delivered to the crusher drive motor(s). These current transducer(s)
are shipped separately in the box of auxiliary parts that comes with the crusher.
1 - Terminal (see schematic)
2 + Terminal (see schematic)
3 Set Dip Switch on 750A (all models)
The transducer is installed so that the motor conductor enters it from the side marked “H1” (shown in photo),
passes through the transducer and the motor is on the side marked “H2”.
They are installed in the customer's Motor Control Center (MCC) during installation and setup of the Kodiak
Crusher Control. These specific motor current transmitters must be connected to the Kodiak Crusher Control
system during installation. Do not substitute.
See also page 3 of the electrical schematic.
86
MOTOR TOPICS
Motor Feedback Connections

There are 120V input terminals provided to connect the auxiliary contacts of the hydraulic and lube pump
motors and crusher drive motor back to the HPU so that the Kodiak Crusher Control is able to verify that those
motors are actually enabled/disabled. JCI strongly recommends wiring these feedback circuits as shown on
the schematic.
If there is no feedback from the lube pump motor or the hydraulic pump motors, the HMI will display a motor
fault message for each motor failure, but the crusher will continue to run.
Upon crusher start, of the PLC fails to receive feedback from the crusher drive motor within 70 seconds the
crusher motor will turn off. This will generate a “Failure - Crusher Motor” fault message on the HMI, requiring
an ACKW/RESET from the operator to clear and resume.
Feed Conveyor “Enable” Output

The Kodiak Crusher Control Slave PLC is provided with a “feed enable” output that provides a signal to
plant-wide control systems whether it is okay to send feed to the crusher or not.
NOTICE: Failure to stop feed conveyors when requested can result in plugging the crushers, which can result in
crusher damage or hours spent digging out piles of rock, or both.
The feed conveyor enable output will remain disabled for one 45 seconds after the crusher starts to allow time
for the crusher to come up to full speed before introducing rock.
Most of the faults that can cause an interlocked crusher shutdown will disable the feed conveyor output with
enough delay time to allow for other equipment to be stopped and the crusher to empty.
I f the crusher motor stops, the feed conveyor signal is disabled immediately.
RELATED LINKS:
Automatic Interlocked Crusher Shutdown
87
INTEGRATING INTO AN EXTERNAL CONTROL SYSTEM
Integrating Into an External Control System

Kodiak+ crushers are typically operated by a supplied remote control panel utilizing the MILO PLC system.
Customers who may already have a larger, master control system can integrate the MILO PLC system within
their own. Remote system control of the JCI Kodiak+ crusher is facilitated by a 14-pin Deutsch connector
located at the bottom of the remote control panel. This connector interface will supply 24 volt DC signals for
monitoring of the tramp iron pressure, bowl clamp pressure, crusher lubrication oil flow, and the start/stop
status of the crusher. This connection will also allow limited external control of the crusher functions which
include start/stop of the crusher, adjustment of the bowl closed-side setting, crushing chamber clear feature,
and external remote emergency stop of the crusher.
JCI offers an optional 10 ft MILO remote HMI receptacle harness, JCI part number 027754, which is used to
interface the MILO remote control panel to the customer’s master control system. This harness allows you to
operate the crusher from a remote set of pushbuttons (provided by customer) and provides a status signal
for lube flow and TIR and bowl clamp pressures.
Monitoring of the MILO system variables is available as well. To facilitate additional monitoring of the
crusher's operational status by an external networked master control system, the following ModBus
addresses are provided for network interface.
PIN NAME FUNCTION
A Ground Connect internally to DC-
B Crusher Start Remote input control signal to start the crusher, (+24Vdc signal)
C Crusher Stop Remote input control signal to stop the crusher, (+24Vdc signal)
D Bowl Rotate Up Remote input control signal to rotate the bowl upward, (+24Vdc signal)
E Bowl Rotate Down Remote input control signal to rotate bowl downward, (+24Vdc signal)
F Bowl Clear Remote input control signal to clear the bowl, (+24Vdc signal)
G +24Vdc Fused power source for remote system control
H E-Stop output Remote E-Stop connection
J E-Stop input Remote E-Stop connection
K Bowl Clamp Pressure Remote output status signal for bowl clamp pressure, (+24Vdc signal)
L TIR Pressure Remote output status signal for TIR pressure, (+24Vdc signal)
M Lube Oil Flow Remote output stuts signal for lube oil flow, (+24Vdc signal)
N Crusher Start/Stop Remote output status signal for crusher start/stop, (+24Vdc signal)
P Spare
Field modifications will be required at the hydraulic power unit to establish a remote data connection. See
drawing.
88
INTEGRATING INTO AN EXTERNAL CONTROL SYSTEM
1 TWIDO RS485 located in the HPU electrical panel. Make connection to the A & B slots.
89
TRANSPORTING THE CRUSHER
Transporting the Crusher

When the Kodiak+ crusher is to be moved to a new crushing site, the cone head must be blocked to prevent
damage to the crusher bearings. The roller bearings are designed to handle heavy crushing loads but not the
sharp impact load caused from the cone head bouncing during transportation. Moves of even short distances
can cause brinelling marks leading to reduced bearing life. Use the cone travel blocks that came with the
crusher to block the cone head. If you do not have the original blocks you can make new ones by cutting two
wedge shaped wooden blocks, each about 30" long, from a 4 by 4.
Place the blocks side by side in the widest part of the opening between the cone mantle and the bowl liner,
and hammer the wedges in place.
1 Cone Travel Blocks Installed
90
KODIAK CRUSHER CONTROL CONFIGURATION
Kodiak Crusher Control Configuration

The configuration screen should be accessed before commissioning a new system. Setting the model in the
configuration screen will allow the Kodiak Crusher Control to maintain pressures in the correct operating
range and verify that the lube oil flow rate is adequate. The software version is also displayed on this screen.
NOTE: Do not start the crusher or perform maintenance operations until the control system has been appro-
priately configured.
1. From the MAIN screen, choose MAINTENANCE MODE.

2. SCROLL down to SYSTEM CONFIGURATION and press SELECT.
3. Press SCROLL in the Crusher Type submenu to specify which crusher you have.
NOTE: It is necessary to specify if one or two drive motors are used. (For example: K400+ or K400+ Dual.)
4. Press TAB to toggle over to the Voltage submenu. Press SCROLL until you highlight the correct voltage.
Choosing the voltage will provide the appropriate scaling of the motor amperage display.
91
CRUSHER PRE-STARTUP INSPECTION
5. Press TAB to toggle down to the Display Units submenu. Press SCROLL to choose between imperial
or metric units for displaying monitored attributes (CSS inches/mm, temperature F/C).
6. Press RETURN to go to the MAIN screen.
Crusher Pre-Startup Inspection

The following checklists are intended to uncover any oversights or incomplete installation tasks prior to
initially test running the crusher. Following these instructions should result in a trouble free startup. Recall that
it is necessary to complete the STARTUP INSPECTION SHEET properly and return it to JCI in order for your
warranty to commence from the date of initial startup. That startup inspection must be witnessed by persons
representing JCI or its dealers as well as the end user. Failure to do this will result in the warranty beginning
from the date it was shipped from JCI rather than from the date of initial startup.
Prior to this first inspection, someone qualified to assess electrical connections should verify that the following
electrical connections have been properly terminated and that all are currently de-energized and locked out
per local lockout/tagout regulations:
• Lube assembly to HPU
• HPU to MCC
• HPU motor
• Lube pump motor
• Hydraulic pump motor
• Cooler motor
• Crusher drive motor(s)
• Emergency Stop (ESTOP) on remote control panel is pressed activated
RELATED LINKS:
92
Crusher Inspection
Item Description Yes No
All hydraulic lines between HPU and crusher have been verified to be connected
1
correctly per the installation drawings.
Electrical cable between upper assembly and the remote control panel is
2
connected at both ends.
3 All TIR cylinders are dry around head gland.
4 Every other TIR cylinder has a relief valve installed.
5 All remaining TIR cylinders have a plug installed.
6 All TIR cylinder rods have split collars installed and keeper rings in place.
All TIR cylinder spherical washers are installed and sitting flat against the bowl
7
support.
The upper assembly is sitting down firmly on the baseframe. It may not be
8 perfectly level and square, but it should be all the way down with all rotation
stops fully engaged.
Bottom of drive ring is within the CRUSHING ZONE shown on the decals found
9
on each gear support.
93
Under Crusher Inspection
1 The crusher is mounted level in all directions.
All crusher supports and/or foundations are on solid ground and/or supported
2
on cribbing that is in solid condition.
3 All mounting bolts are tight.
Crusher discharge area is free of debris all the way from the CSS to the
4
conveyor belt.
Lube supply line is connected and properly placed so it is protected from

5
debris and vibration.
6 Crusher drive sheave and motor sheaves are free of built up dirt or debris.
7 V-belts are properly tensioned and in serviceable condition.
8 Belt guards are in place and sheaves are free to turn.
The cone brake is operating properly. Cone should turn freely from right to left
9
but should turn only a few inches from left to right.
Lube Assembly Inspection
1 Oil level is at the FULL mark on the sight gauge (top off if required).
2 Oil fill cap is in place.
3 Breather is unobstructed.
Oil return line is connected and routing appears to be as per recommended

4
practice.
5 Oil cooler hoses are connected properly.
6 Lube supply line is connected properly.
Electrical conduit between lube assembly and HPU is in place and connected at
7
both ends.
8 Lube motor electrical cable is connected.
94
Hydraulic Power Unit Inspection
Oil level is at or near the full mark on the site gauge (hydraulic oil does not have
1
to be absolutely full)
The pressure reads zero (0) psi on the pressure transducers on the hydraulic
2 manifold. If residual pressure is noted, then open needle valve NV1 and/or NV2
momentarily to reduce the pressure to 0 psi.
The needle valves NV1 and NV2 on hydraulic manifold are closed. Verify that
3
locknuts are not preventing full closure of the valves.
4 Oil fill port on the inlet to the oil filter is capped and tight.
Electrical conduit between HPU and MCC is in place and connected at both
5
ends.
6 Hydraulic motor electrical cable is connected.
All hydraulic lines between HPU and crusher have been verified to be
7
connected correctly per the installation drawing.
Electrical cable between HPU and remote control panel is connected at both
8
ends.
The decal on the inside of the door shows the HPU is clearly marked as having
9 been made specifically for the crusher serial number that has been installed. If
not, consult the factory.
95
SYSTEM TESTING
Hopper and Crushing Chamber Inspection
1 The cone head blocks have been removed and chamber is completely empty.
2 The bowl liner is not in contact with the mantle anywhere (CSS>0)
Hopper is free of overhead obstructions that could prevent rotation of bowl or

3 cause interference during tramp iron events or chamber clearing. See
installation drawing for required overhead clearance.
4 Feed conveyors are properly placed to assure centrally distributed material.
5 The hopper level sensor is properly installed and calibrated.
The maximum vertical drop from the highest feed conveyor to the top of the
6
cone is less than 7'[2.134M].
7 Mantle bolt protector cap is in place.
System Testing
After the crusher and supporting systems are properly installed, persons qualified to work on electrical equip-
ment can energize all the electrical systems. If motor rotations have not been verified, now is the time to check
and/or correct them.
The crusher is now ready for hydraulic and lube functional testing and initial startup. It will be helpful to have
someone at the remote control panel, another at the HPU and another with a clear view of the crusher.
Lubrication System Tests and Initial Startup
1. Prior to startup, verify that the lubrication heaters are connected properly. If the ambient temperature is
below 80°F (26°C) there should be current in both heater circuits whenever the ESTOP switch is closed.
2. Press CRUSHER START on the Kodiak Crusher Control.
• The lube assembly horn should sound.
• The lube flow meter should register flow (8gpm K300+/K400+/K500+, 6gpm K200+).
• The oil level should drop significantly in the sight gauge but will typically not drop out of the sight gauge
altogether.
• After 30 seconds the crusher drive motor(s) should start.
3. Verify the crusher drive proper rotation. A portion of the pinion shaft should be visible between the belt
guard and the crusher. The proper rotation direction is indicated by an arrow in this same vicinity.
4. After a few moments of running, the oil should stop dropping in the lube unit oil reservoir sight gauge
and it will slowly start to come back up.
96
SYSTEM TESTING
5. The crusher should be running and sound like heavy rotating machinery, but there should be no sounds
that would indicate impact is occurring anywhere. If there is any violent movement of the crusher
support structure, verify that all crusher supports are still properly cribbed, all bolts are still tight, all
support structures are rigid etc.
6. Observe the cone head gyration. The cone should clearly gyrate in the chamber, but the cone should
not spin around its own center axis. If the cone is spinning counter clockwise there is a cone brake
malfunction. If it is spinning rapidly in the clockwise direction, the motors are running backward. If it is
turning slowly (approx 5-7 rpm) in the clockwise direction then the bowl liner is contacting the mantle
and you should be hearing some unusual noise as well.
7. If you have elected to zero the bowl position indicator with the crusher running, now is the time.
8. Turn off the crusher.
9. Press ESTOP.
Hydraulic System Testing
1. Verify that all personnel are clear from under, over or around the crusher and/or the feed and discharge
equipment.
2. Pull out the ESTOP button on the remote control panel.
3. The hydraulic motor should start immediately and bring the TIR system and bowl clamp up to their
proper operating pressures. The correct pressures are listed on the hydraulic schematic and should also
be posted on the inside of the HPU door.
4. When the pressures come up to the proper values, the control valves should shift back to neutral, the
pump pressure should drop to 0 psi, but the motor should continue to run for at least another two (2)
minutes.
5. Verify that there are no leaks anywhere within the HPU cabinet, at any hose connections or at the TIR
cylinders or bowl clamp.
6. Test the CLEAR function by pressing the CLEAR pushbutton. It will take several seconds for the all of
the cylinders to press up on the upper assembly.
7. Continue to hold the CLEAR pushbutton as the upper assembly raises off the upper assembly. It is not
unusual for the cylinders to extend at different rates. The horn on the HPU should sound.
8. Continue to hold the CLEAR pushbutton until all cylinders have reached the end of their stroke. It should
be possible to hear the hydraulic system pump over the main relief valve. The pump pressure gauge
should increase to approximately 3300 psi.
9. Release the CLEAR pushbutton. The upper assembly should immediately begin to come back down.
Again, it is not unusual for the cylinders to retract at different rates.
10. The upper assembly should come all the way down and sit firmly on the upper assembly. It may not be
perfectly level and square at this point. All of the rotation stops should be fully engaged. The rotation
stop gaps may not all be even at this point.
11. The TIR pressure should restore itself automatically.
12. Check for leaks at the TIR hoses and cylinders.
13. Press the BOWL UP pushbutton. It will take a few seconds but the bowl should start to rotate from right
to left. If not, then the hoses are reversed. If it does not rotate at all, check to see if the hoses are
97
SYSTEM TESTING
crossed. Rotate only enough to verify that the function works properly. Do not allow the bottom of the
bowl drive ring to pass out of the CRUSHING ZONE indicated on the drive gear supports.
14. Press the BOWL DOWN pushbutton. It will take a few seconds but the bowl should rotate from left to
right. Rotate only enough to verify that the function works properly. Do not rotate far enough for the liner
to touch the mantle.
15. The bowl clamp pressure should restore itself automatically.
16. Check for leaks at the bowl clamp and/or the bowl clamp supply hose.
17. Do not press any other pushbuttons. The hydraulic motor should shut off approximately 2 minutes after
the last function has been satisfied.
18. The bowl position indicator may be zeroed with the crusher running or stopped. If you elect to zero the
bowl position indicator with the crusher stopped, now is the time to do it.
RELATED LINKS:
The Crushing Zone
CSS Reset Procedures
HPU Initial Startup
All of the following steps assume that the following items have been performed by suitably qualified
personnel:
• All motors have been wired and rotations verified.
• All motor lockout/tagout equipment is removed and motor starters are enabled.
• Circuit breakers in the HPU electrical enclosure are closed.
• 120V power supplying the HPU is enabled.
• Crusher installations has been checked against the installation drawing to verify that:
– All hoses and harnesses are properly connected.
– Crusher is securely fastened to support structure.
– Belt guards are in place.
– Lube oil and hydraulic oil are topped off.
After the Kodiak Crusher Control and all motors are installed and rotations verified, but before starting the
crusher, complete the following steps:
1. Verify that the crusher is installed properly, oil levels are topped off and that any shipping blocks and/or
cone tie down cables have been removed and that there is some visible CSS opening between the cone
and liner. Dislodge the shipping blocks and/or tie down cables and remove them. If the shipping blocks
can't be dislodged, another method will be described later (step 8) that employs the control system, but
at this point the controls are not yet operational.
2. Close all ESTOP switches (turn/lift).
3. Read any messages that may be present in the message area of the HMI and take any corrective
actions if required.
98
CRUSHER WARRANTY, RECORD KEEPING, AND STARTUP CHECKLISTS
4. Press ACKW/RESET to clear the HMI screen and enable the control system.
5. If the shipping blocks could not be removed before, rotate the BOWL UP.
6. With the shipping blocks removed: Rotate the bowl down until it contacts the cone. Go to the CSS
RESET screen and reset the CSS to 0.00.
7. Go to MAINTENANCE. Reset Accumulated Liner Wear to set the liner wear counter to 0.00.
8. Use the UP button to raise the CSS to the desired setting.
9. Go to MAINTENANCE and verify that the bin level sensor is disabled. It can be re-enabled later, but it
is generally best to start the first time with it turned off.
10. Disable the Auto Zero feature.
11. Disable cold weather lube oil circulation.
12. The Kodiak Crusher Control is ready to run.
Crusher Warranty, Record Keeping, and Startup Checklists

JCI warrants new equipment for a period of one year from startup or 2,000 hours, whichever occurs first. A
warranty statement is located in the Introduction section of the operation manual. In order to activate your
crusher warranty you must complete and forward the Startup Checklist to JCI within 30 days after you have
started your crusher. Otherwise the warranty will be automatically activated and the warranty time period will
begin with the date the crusher was shipped from the factory.
Start Up Sheets and Inspection Checklists

The startup checklist requires a signature from the customer and the dealer representatives present at the
startup.
The 30-Day and 90-Day Inspection Checklists are designed to help JCI maintain a record of what has
happened with your crusher. They also can serve as a guideline to how often certain items must be checked
on your crusher. Refer to the Maintenance section for daily checks, lubrication checks and required hourly
preventive maintenance inspections and procedures. If you have any questions concerning your Kodiak+
crusher you can contact JCI Service and Warranty claims at 1-866-875-4058.
Keeping Records
A good record keeping program will help extend the life of your crusher as well as help to troubleshoot prob-
lems if they arise during crusher operation. Complete records also help to settle warranty issues quickly while
keeping you informed as to the function and maintenance of your crusher. Document your hourly checks,
keep all oil analysis reports, and record your liner changes.
99
CRUSHER WARRANTY, RECORD KEEPING, AND STARTUP CHECKLISTS
100
OPERATION
CRUSHER SAFETY
Operation
Crusher Safety
WARNING: Do not allow personnel to be on or near the crusher during operation. The
crusher will shake violently should tramp iron be fed into the machine. Stay clear of feed
and discharge areas to prevent being injured or killed by fling or falling rock.
WARNING: 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.
WARNING: 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.
• Verify that all personnel are clear of the crusher prior to starting. This includes verifying that no
personnel are under the crusher.
• 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.
• 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 observation of the
feed arrangement is necessary for troubleshooting or evaluation purposes.
• Do not tamper with crusher alarm components. Never attempt to defeat electrical interlocks or to disable
crusher protective devices.
101
OPERATION
CRUSHER SAFETY
• 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. Lockout/tagout
engine controls to prevent the engine from being accidentally started while the crusher is being
serviced.
• Support the crusher upper frame with hardwood blocking or steel safety spacers and shut off and
lockout and depressurize the hydraulic system before entering the crushing chamber for service work.
Never rely on hydraulic pressure to keep the upper frame raised. You could be crushed and killed if the
upper frame lowers unexpectedly.
• Always stop the crusher immediately if any gauges show abnormal readings, or if there is a sudden
obvious change in operation. Be alert for noises that might indicate trouble.
• Inspect, lubricate, maintain and repair the crusher in accordance with the instructions contained in this
manual and any additional manuals or documentation provided with the crusher.
• Inspect all warning signs and caution decals. If they become torn or not readable contact your local
dealer or JCI for replacement.
• On portable plants be sure that the trailer is properly blocked and level. All blocking must be suitable to
support the trailer dead load weight plus the crusher impact live loading.
• 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
V-seat after a clear for loose or jammed rock.
102
OPERATION
THE KODIAK CRUSHER CONTROL SYSTEM (MILO)
The Kodiak Crusher Control System (MILO)

The JCI Kodiak Crusher Control System (MILO) consists of the following major components:
• Control Panel
a) Master PLC
b) HMI
• HPU
a) HPU Basic (pump, reservoir, manifold, etc.)
b) HPU Electrical Enclosure (Slave PLC, I/O, etc.)
• Lube Assembly
• External sensors located on the crusher, the lube assembly and the HPU
• Cables and/or harnesses to connect the various components
The Kodiak Crusher Control monitors the condition of key operating parameters (hydraulic pressures, lube
flow rate and temperature, etc.), makes adjustments when possible, issues warnings and/or error messages
where appropriate, maintains full operational control of the crusher, and will shut the crusher down in a
controlled manner if necessary. It can also enable/disable feed conveyor(s).
The system is designed to be operated either as a stand-alone control or as part of a plant-wide control
system. It controls five (5) commands (ON/OFF, BOWL UP/BOWL DOWN, and CLEAR), which can be sent
from a separate plant-wide control system. However, operational control of the crusher, including lube and
hydraulic interlocks, is handled exclusively by the MILO PLC. Likewise, sensor data, crusher status, and trou-
bleshooting messages are accessible only on the MILO HMI. Access to this data is available to other
computers in a larger network via modbus.
In the event that a lube oil flow/temp or hydraulic pressure/temp problem is detected, the Kodiak Crusher
Control will shut itself down. Depending on the nature of the malfunction, the control system will attempt to
shut down in a manner that allows for smooth cessation of feed followed by enough run time to clear the
crushing chamber while still allowing the operator or computer control system to stop the crusher immediately
at any time.
A 120V feed conveyor enable output is provided for controlling the feed conveyor. This output is provided as
an input to a plant-wide control system.
RELATED LINKS:
Feed Conveyor “Enable” Output
103
OPERATION
THE KODIAK CRUSHER CONTROL SYSTEM (MILO)
Abbreviations/Definitions
CSS: Closed Side Setting. The smallest distance between the bowl liner and cone mantle. The CSS is
approximately similar to the largest desired particle size.
HMI: Human Machine Interface. Computer controls that include a screen to display images and/or text and a
method for user input to the computer. The standard MILO HMI uses pushbuttons integral to the HMI for user
input (not a touch screen).
HPU: Hydraulic Power Unit. The main assembly of the control system which contains the hydraulic pump,
reservoir, control valves, etc.
INTERLOCK: A control function that occurs automatically due to a change in some operating parameter. Ex:
automated shutdown due to inadequate lube flow results because the crusher motor control is interlocked
with the flow transducer.
LED: Light Emitting Diode. These devices have taken the place of incandescent bulbs in most electronic
applications. LEDs are found in numerous sensors, relays, fuse blocks, etc., in the Kodiak Crusher Control.
MCC: Motor Control Center. Those components used for power distribution to electric motors and related
equipment. The MCC is typically provided by the customer.
NV1 & NV2: Two (2) manually operated needle valves on the hydraulic manifold. These valves are
opened/closed during many maintenance operations to pressurize/depressurize the TIR and BOWL CLAMP
circuits. See also: “Hydraulic Manifold” in the parts book and operations manual.
PENDANT: Enclosure housing the HMI and Master PLC.
PLC: Programmable Logic Controller. The computer(s) that monitor input sensors, user commands, etc., and
control actuating components. The MILO control uses a Master PLC (in the HMI enclosure) containing the
main control logic and a Slave PLC (on the HPU) to handle input and output signals.
SO CORD: Electrical cables containing multiple conductors within a common insulating jacket.
S1, S2….Sn: Solenoid designator symbols. Each solenoid refers to the actuating solenoid for a specific direc-
tional valve. The solenoid number is sometimes used interchangeably with its particular function. (Ex: S1 may
be used to indicate the TIR control valve).
TIR: Tramp Iron Relief. Refers to the hydraulic components and functions that allow the crusher to protect
itself from mechanical overloads such as uncrushable objects within the crushing chamber. The terminology
for this function may be different in languages other than English. The abbreviation TIR is used throughout
this manual to describe this general category of functions and components.
CLEAR: Raising the upper assembly hydraulically to release rocks from a plugged crushing chamber.
104
OPERATION
HMI NAVIGATION
HMI Navigation
The HMI has an LCD screen, manual pushbuttons, and indicator lamps for selected functions. The standard
MILO HMI display is not a “touch” screen. It has pressure-sensitive menu pushbuttons incorporated along the
left-hand side of the display. This arrangement provides a rugged digital control interface that is durable
enough to withstand harsh ambient environments and exposure to the elements. The enclosure has a heater
to enhance display brightness in cold weather. The pushbuttons and indicator lamps provide a familiar inter-
face that is visible even if the crusher operator is some distance from the controls.
The labels for the pushbuttons are in both English and Spanish.
1 Menu pushbuttons
2 Emergency Stop (ESTOP)
3 Menu (use this button to change language)
4 Control pushbuttons
5 Indicator lights
105
OPERATION
HMI NAVIGATION
Main Operating Screen

During normal crushing operations this screen will typically be displayed.
1 Menu pushbuttons
2 Functions controlled by menu pushbuttons that redirect display to function-specific screens
3 Drive motor amps
4 Crusher status area: CSS, lube reservoir temp
5 Messages, alarms, errors, etc.
Maneuvering between screens requires use of the following recurring pushbutton operations:
SCROLL: Moves within an individual menu.
SELECT: Chooses the highlighted menu selection.
TAB: Moves from one menu group to another within a single screen. Tab is used only in a select number of
screens utilizing multiple menus.
RETURN: Moves from any current screen back to the previous screen.
ACKW/RESET: When important crusher status information is displayed on the HMI screen, you must press
ACKW/RESET to acknowledge the condition before the crusher can be started. This may also require that
corrective action be taken to correct the condition. When ACKW/RESET is pressed, the program will proceed
on the assumption that the condition has been appropriately addressed and/or corrected.
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OPERATION
HMI NAVIGATION
1 Error Message
2 ACKW/RESET Button
3 Language Selection
Menu Languages
The HMI messages are available in multiple languages. To change from one language to another, press the
MENU button on the lower left-hand corner of the HMI.
Indicator Lights
The indicator lights provide visual feedback regarding the general condition of:
• Lube Flow
• TIR Pressure
• Bowl Clamp Pressure
• Crusher On/Off Status
A solid light indicates the attribute is within normal operating range.
A slow, steady off/on blinking indicates the pressure has reached the low end of its normal operating range.
Generally whenever this slow, steady blinking is observed, the control system is automatically taking steps
to bring the pressure back to the top of its range. Digital display of these pressure values are available on the
HMI as well.
A quick flash followed by a prolonged pause indicates that a malfunction has occurred. Depending on the
particular malfunction a controlled shut down may follow shortly. When a quick flash signal is observed, you
should assume a problem has occurred that requires correction. Refer to the HMI screen for error messages.
107
OPERATION
HMI NAVIGATION
Monitoring Sensors
The only sensors that are displayed on the main operating screen are:
• Crusher drive motor amps
• Closed Side Setting (CSS)
• Lube oil reservoir temperature
1 Push to go to SENSORS screen
All sensors can be monitored on the SENSORS screen. Some sensors will seldom if ever be associated with
any errors, warnings or automatic shutdowns but may be of interest to maintenance personnel.
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OPERATION
HMI NAVIGATION
Emergency Stop (ESTOP)

When ESTOP is pushed, all crusher, hydraulic, lube and cooler motors, oil heaters and selected sensors are
disabled. See the electrical schematic regarding what is turned off. The PLCs and HMI remain energized.
This effectively disables all mechanical equipment while still maintaining PLC control. To power off the PLC
and HMI, disable the main control power source.
Pull up and twist the ESTOP button(s) to operate the Kodiak Crusher Control. There is one ESTOP on the
HMI enclosure. There may be any number of other remote ESTOPs added as well. See the electrical sche-
matic included with a specific HPU for details. Follow all local electrical and safety regulations pertaining to
multiple ESTOPs.
As soon as the ESTOP (and all remote ESTOPS) contacts are closed, the Kodiak Crusher Control will bring
the TIR and bowl clamp pressures up to their recommended operating ranges. Consequently, the TIR and
bowl clamp pressure indicator lamps should turn on solid quickly after energizing the system. The lube flow
indicator lamp should flash with sustained pauses between flashes until the Crusher Start pushbutton is
pressed. This is normal.
The lube and hydraulic oil heaters are enabled whenever all the ESTOP contacts are closed. Each has an
internal thermostat that controls if it is actually on or off.
HMI Troubleshooting
SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION
E-stops are open/engaged. Pull out all E-stops.
System does not respond to user Read any messages on HMI Main
input. There are messages on the HMI screen and take the recommended
awaiting acknowledgment. corrective action, if necessary. Press
ACKW/RESET.
Look for LED on/off conditions at

Possible wiring issue. fuses, PLC I/O relays, hydraulic
valve solenoids, and sensors.
Power and Run LEDs should be ON

There is a problem with the and Status and Err LEDs should be
The crusher stopped but there are MASTER PLC. (Horn sounds). OFF. If not, there is a problem with
no error messages displayed on the the MASTER PLC.
HMI.
All SLAVE PLC outputs should be off
except: Q0.5 (horn) should be ON;
There is a problem with the SLAVE Q0.9 should be blinking; Power and
PLC. Run LEDs should be ON; Status and
Err LEDs should be off. If not, there
is a problem with the SLAVE PLC.
The MASTER PLC is not Check to make sure there is a

The HMI screen contains no data communicating with the HMI, most secure data cable connection
and is filled with dashes. likely due to a loose data cable between the MASTER PLC and
between the two. HMI.
109
OPERATION
BOWL ROTATION AND CSS ADJUSTMENT
Items to check:
1. Are there any auxiliary ESTOPS
in the circuit pressed in?
The HMI screen displays “ESTOP 2. Is the LED on relay CR142 lit?
Shutdown,” but pressing There is an ESTOP fault. Each 3. Is the LED on relay CR8 lit?
ACKW/RESET does not clear the press of ACKW/RESET is 4. Is the LED for fuse 109 off?
error message and all controls are generating a new ESTOP error. 5. Is SLAVE PLC 10.0 lit? If so, try
disabled. rebooting the MASTER PLC and
HMI by unplugging the
power/modbus cable or turning the
main control power off/on.
Check 24VDC power supply. Check

Electrical malfunction.
No green lights on TIR or bowl F201, F205, F219. Check wiring.
clamp pressure.
Bulb burned out. Check/replace bulbs
Bowl Rotation and CSS Adjustment

The Kodiak Crusher Control allows the closed side setting to be remotely adjusted. The crusher is designed
to permit adjustment under load or with the chamber empty. You can expect less wear and tear on the threads
and other components if the bowl is rotated with the chamber empty and this is the preferred practice when
possible.
If adjusting the crusher under load, the procedure is no different than when adjusting with the chamber empty.
However, it is more difficult to tell if the bowl liner is about to contact the cone mantle when adjusting under
load.
Because the crusher can be adjusted under load, some residual hydraulic pressure is maintained in the bowl
clamp circuit as the bowl is rotated. This prevents bouncing of the bowl as it is moved under load.
The HMI has two (2) pushbuttons labeled BOWL UP and BOWL DOWN. Pressing BOWL UP will automati-
cally release the bowl clamp and rotate the bowl clockwise. The bowl drive ring must not be rotated above
the orange “Crushing Zone” decal on the upper assembly without first depressurizing and disconnecting the
bowl clamp. Although a sensor is provided to detect when the bowl has reached its maximum vertical position,
you are well advised to be aware of the “Crushing Zone” decal. Pressing BOWL DOWN will automatically
release the bowl clamp and rotate the bowl counterclockwise.
NOTICE: Before pressing BOWL UP or BOWL DOWN be sure to know if this will cause the bowl liner to run down
into the cone mantle or if the bowl drive ring will rotate up out of the crushing zone. Either of these conditions can
damage the crusher.
110
OPERATION
The Crushing Zone

The JCI Kodiak+ crusher comes equipped with a decal applied to all the drive gear support posts that defines
the “Crushing Zone.” This crushing zone is the region where the bottom of the bowl drive ring can be posi-
tioned.
1 Bottom of the Drive Ring
2 Crushing Zone
The bottom of the crushing zone is labeled “MIN” and indicates the point at which the bowl drive ring bottoms
out and no further movement is possible. It is seldom possible to ever rotate all the way down to the “MIN”
level without bringing the bowl liner into contact with the cone mantle unless the wear liners are very thin.
When the liners are new it will never be possible to rotate all the way down to the minimum level. When a
particular chamber is worn out and in need of replacement, it is useful to note where the drive ring is within
the crushing zone. Under similar crushing conditions, the next set of liners can be expected to wear out at or
near the same point. During the life of the next set of liners, it is a good idea to step up daily inspection of the
liners as the drive ring approaches this point, and be on alert for any indication that the liner and/or mantle
are loose, cracked, or otherwise in need of replacement.
The top of the crushing zone is labeled “STOP.” The bowl drive ring should never go above this point unless
the bowl is being removed.
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OPERATION
Closed Side Setting (CSS)

The CSS is the smallest distance between the bowl liner and the cone mantle and is adjusted by rotating the
bowl up/down to achieve a particular minimum product size.
NOTE: The minimum closed side setting for any chamber configuration or crushing condition is that setting
that can be maintained without bowl float.
The actual closed side setting that is chosen is necessarily site-specific and depends on a variety of factors.
If a particular closed side setting results in bowl float, then the closed side setting must be increased until the
bowl float stops. If this results in an undesired product specification, then changes to the chamber, the crusher
speed, and/or the input feed material must be made, as required.
RELATED LINKS:
Kodiak+ Series Crusher Theory of Operation

The current CSS displayed on the MAIN screen is measured relative to the last time that the CSS was reset
to zero.
Reset as often as necessary to result in a CSS display that is accurate enough for the needs of a specific
application. How often this needs to be done is site-specific and depends on how quickly the liners wear at a
particular site and how critical it is to hold a particular product specification.
The Kodiak Crusher Control will calculate how much wear material has been worn off of the liner and mantle
since the last time the wear calculator was reset and will also keep track of the hours since the last liner
change.
Crusher maintenance personnel can use this information to predict when the next liner change is due and
plan accordingly for minimal disruption. The liner wear displayed on the screen represents the amount of
material worn off both parts. (Ex: if the display says .250" then .125" has been worn off the liner and .125"
has been worn off the mantle).
There are three (3) basic methods to reset the CSS bowl position counter.
112
OPERATION
Bowl Position Counter Reset Procedure with the Crusher Turned Off
This method requires two people. The problem with this method is that rocks in the feed hopper can occa-
sionally roll down into the chamber before the liner contacts the mantle. If that is a problem, consider the
method of resetting with the crusher running.
1. One person looks down into the crushing chamber from a vantage point that presents a clear view of
the cone.
2. The other person presses BOWL DOWN until the bowl contacts the cone.
3. Once the bowl contacts the cone, the cone will move counterclockwise. The observer alerts the operator
to release the BOWL DOWN pushbutton.
NOTICE: It is essential to stop bowl rotation as soon as the bowl contacts the cone in order to avoid damage to the
cone brake components.
4. After the pushbutton is released, press CSS RESET.
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OPERATION
5. Press YES to reset the bowl counter to zero. Press NO to return to the previous screen without making
changes.
Bowl Position Counter Reset Procedure with the Crusher Running
This method can be done by one person if the controls are located within a few feet of the crusher. If the
controls are remotely located, it will take two people.
NOTE: To reset the bowl position counter with the crusher running, the chamber should be empty.
1. Press BOWL DOWN until the bowl contacts the cone, then release. When the bowl contacts the cone
a very distinct clunking noise will be heard.
NOTICE: It is essential to stop bowl rotation as soon as the bowl contacts the cone in order to avoid damage to the
cone brake components.
NOTE: This incidental contact will not damage the crusher but resetting the crusher in this manner should be
executed in a timely fashion. If the BOWL DOWN pushbutton is held down after initial contact is made, the
clunking sound will develop into a much louder steady state noise and the cone will begin to rotate clockwise
as if it were actually crushing.
114
OPERATION
2. As soon as contact has been verified, press CSS RESET.
3. Press YES to reset the bowl counter to zero. Press NO to return to the previous screen without making
changes.
115
OPERATION
Bowl Position Counter Reset Procedure Using the Bowl Auto Zero Function
When the JCI Kodiak Crusher Control is used in conjunction with the hydraulic cone brake it is possible to
utilize the built in Bowl Auto Zero function to reset the bowl position counter automatically.
It is best if someone acts as observer when using this method.
1. Verify that the crusher motor(s) are off and that the crusher has come to a complete stop before using
the Bowl Auto Zero feature. The Bowl Auto Zero function will ignore attempts to enable if the crusher is
running.
2. Access the Auto Zero function through the Maintenance Mode screen. Scroll down to Bowl Auto Zero
and press Select.
3. The default mode is DISABLE. Scroll up to ENABLE.
NOTICE: If there is a problem detected, the Bowl Auto Zero function will not enable. An error message will alert you
to the issue. You will have to manually reset the bowl counter and fix the issues before attempting Bowl Auto Zero
again.
116
OPERATION
Possible errors could include:

• If the control does not detect the presence of a hydraulic cone brake (not installed or sensor malfunc-
tion):
• If the cone brake pressure is too high:
117
OPERATION
4. Pres YES to confirm you want to use the Bowl Auto Zero feature.
The Bowl Auto Zero function will record the current CSS value and then automatically rotate the bowl down
until it contacts the cone. As soon as the bowl contacts the cone, any further rotation will cause the cone to
rotate counterclockwise and cause pressure to build in the hydraulic cone brake. When the control system
detects an increase in pressure, it will stop rotating, reset the counter to zero, and rotate back up to the previ-
ously recorded CSS.
Possible errors you may encounter:
• While rotating down, if there is no decrement in the bowl position counter:
118
OPERATION
• While rotating up, if there is a problem with the bowl limit proximity sensor:
• If ESTOP is pressed during Bowl Auto Zero process:
NOTE: You can cancel Bowl Auto Zero at any time by pressing Cancel/Return. When the Bowl Auto Zero func-
tion is canceled by the operator, the initial value of the CSS is still recorded. As part of the cancellation
process, the bowl will rotate back up to this initial recorded CSS. However, be aware that the resulting CSS
value will be uncalibrated. To re-zero the bowl, use the manual CSS reset, or engage once again the Bowl
Auto Zero function.
119
OPERATION
5. If the Bowl Auto Zero proceeds without incident, and when the CSS is back to its original value, you will
get an Autozero Successful confirmation screen. Push OK/Return to go back to the Main screen.
Bowl Rotation Troubleshooting
SYMPTOM PROBABLE CAUSE
Damaged or worn brass segments.
Bowl rotate electrical/hydraulic failure.

Thread system does not work.
Clamp ring piston not retracting due to piston damage.
No electrical power to hydraulic package.
120
OPERATION
CRUSHER PRE-START CHECKS AND PROCEDURES
Crusher Pre-Start Checks and Procedures

For optimum performance and maximum life as well as safety of personnel working around the crusher,
certain items must be checked on a daily basis. In the Maintenance section of this manual there is a checklist
and instructions on how to conduct the checks.
This section is intended only for daily, routine start-ups and addresses only those items necessary for starting
a crusher that is in good working order and has already been maintained and/or serviced and is ready for use.
If you are starting the crusher for the first time, please refer to the end of the Installation section for a much
more comprehensive checklist. You should be aware of how many hours are on the machine and should time
any periodic maintenance checks and/or service procedures accordingly.
1. Pull up on the ESTOP(s) to warm the oil prior to starting, especially in cold weather.
NOTE: The heaters will automatically keep the reservoir between 80°F (26.7°C) and 100°F (37.8°C) any time
the ESTOP contacts are closed. Energizing the system upon arrival at the job site will ensure the control
system will have the lube oil warmed up and all hydraulic pressures at the correct levels by the time the other
pre-start activities are complete.
2. Lockout/tagout the crusher drive motors and any feed/discharge conveyors. Follow all local
lockout/tagout regulations.
3. Inspect under the crusher.
Items to check under the crusher include:
• Verify that the discharge area is free of debris from the CSS to the discharge conveyor. Pay particular
attention to unusual buildup on the pinion tunnel and/or struts.
• Check for any unusual wear on the top of the wedgeplate guard or exposed portions of the cone seal.
Normally there should be no appreciable wear in this area. If wear begins to appear, a root cause anal-
ysis should be implemented right away to avoid costly, preventable damage.
• Assess the condition of the baseframe tub liners. These are wear items that will erode over time. Daily
inspections will avoid tub liner failures and subsequent baseframe damage.
• Check the condition of the lube supply hose. If it shows signs of abrasion or other deterioration, plan for
a replacement.
• Check the condition of the liners. A daily inspection of the exposed portion of the parallel zone will
expose not only the general condition indicated by the thickness but also the development of hooks in
the liner or mantle, which can give clues to application problems and also to the presence of missing
chunks caused by uncrushable objects passing through the chamber.
• Check cone brake function by rotating the cone by hand. It should turn right to left but not left to right.
• Check the condition of bowl liner fit. Look for indications that the liner is loose or cracked or evidence of
water leaking between the liner and bowl, which indicates that a loose liner may be imminent.
4. Check the lube oil level in the reservoir sight glass. Top it off if required but do not overfill. The oil should
only be checked after the crusher has sat unused for an appreciable period of time (overnight is ideal).
Any time the lube pump has run, it take a considerable period for the oil to return to its original level.
5. Verify that the breather is not obstructed and is free of accumulated debris.
121
OPERATION
6. Check crusher drive sheave and motor sheave for any accumulated dirt. If dirt accumulates in either
sheave, it will cause vibration that is often mistaken for crusher imbalance.
7. Verify hydraulic oil level is near the full mark on the sight glass. It does not have to absolutely full.
8. If the ESTOP was pulled prior to the inspection, the TIR and bowl clamp pressures should be up to their
prescribed pressure.
9. Give the crusher an overall review looking for any changes since the day before, such as:
• Missing TIR cylinder rod coupler keeper rings
• Oil leaks at TIR cylinders, bowl clamp, bowl rotation motor, etc.
• Damaged TIR cylinders
• Accumulation of black powder under the rotation stops indicating that bowl float has occurred
10. Verify that the crushing chamber is empty. Starting with anything (including rocks) in the chamber can
potentially cause cone brake problems.
11. Verify that the bottom of the bowl drive ring is in the “Crushing Zone” defined by the decals on the gear
supports.
12. If it is your practice to zero the bowl position indicator with the crusher stopped, do so now. Refer to the
bowl rotation section if required.
13. Press the ACKW button to clear the message area of any errors or warnings. The crusher will not start
until the message area is clear. If any errors appear, the problem must be corrected prior to starting.
RELATED LINKS:
Emergency Stop (ESTOP)
Lube and HPU Reservoir Air Breather Change Procedure
Hydraulic Power Unit Oil Reservoir Fill Procedure
Lube Oil Reservoir Fill Procedure
Bowl Position Counter Reset Procedure with the Crusher Turned Off
Crusher Daily Inspection Checklist
122
OPERATION
Crusher Pre-Start Troubleshooting
Excessive feed segregation.
Inappropriate chamber.
Uneven manganese wear. Feed to crusher not properly centered.
Oversized or undersized material.
Failure to choke feed.
Too much near-size material in crusher chamber.
Close side setting (CSS) not appropriate for chamber.

Hook on manganese in parallel zone.
Hook on liner indicates CSS too small; hook on mantle
indicates CSS too large for particular chamber
configuration.
Shear bolts broken.
Cone brake malfunction.

Cone spins with wedgeplate.
Excess friction or interference at the cone seal ring.
Damaged crusher bearings.
Dirt buildup on crusher sheave.
Crusher shakes excessively. Bearing failure.
Cone spinning (cone brake failure).
Cone head or wedgeplate wont turn by hand. Interference at seal rings.
Cracked liner casting.

Loose bowl liner manganese.
Loose bowl retentions hardware.
Mantle bolt threads bottomed out.
Loose mantle manganese. Cracked mantle casting.
Mantle washer failure.
Broken TIR cylinder Bowl float.
123
OPERATION
CRUSHER STARTUP PROCEDURE
Crusher Startup Procedure
WARNING: Verify that no one is under the crusher or near any moving machinery prior
to starting any crusher-related equipment.
1. The crusher drive motors as well as the feed and discharge conveyors that were previously locked out
can now be energized.
2. Verify one more time that all personnel are out from under, on, or around the crusher or its
feed/discharge conveyors.
3. Start the discharge conveyor and any other parts of the plant as required, but do not start the feed
conveyor(s) yet.
4. When the message area is clear, press and hold CRUSHER START for two (2) seconds. The light on
the pushbutton will come on when the Crusher Start Sequence has begun and the pushbutton can be
released.
124
OPERATION
1 CRUSHER START
NOTE: If you are pressing CLEAR, the CRUSHER START button will not engage and the Crusher Start
Sequence is disabled.
5. The lube pump will start and a horn will sound for 30 seconds announcing that the crusher startup is
imminent.
• If there is inadequate lube flow, the Crusher Start Sequence will terminate after 25 seconds (just prior
to actual crusher start). A “Shutdown - Low Lube Flow” message will then be displayed, requiring an
ACKW/RESET to clear.
• If there is inadequate TIR pressure prior to crusher start, the start button is deactivated. A “Warning -
Low TIR Pressure” message will be displayed. This message is non-latching and will automatically clear
from the screen once adequate TIR pressure has resumed.
• If there is inadequate TIR pressure subsequent to crusher start, the start sequence will proceed. A
non-latching “Warning - Low TIR Pressure” message will be displayed. If adequate TIR pressure has
not resumed, the crusher will start after the normal 30 second countdown, but will only run for 10
seconds before shutting down. After the crusher shutdown, a latching “Shutdown - Low TIR Pressure”
message will be displayed, requiring an ACKW/RESET to clear.
6. When the crusher has run successfully for 45 seconds, the feed conveyor “enable” output will be ener-
gized. Feed enable indicates that it is safe to start feed equipment. At this time evaluate the general
condition of the crusher.
• Are there any new sounds?
• Are there any new smells?
• Does the structure shake more than usual?
7. If it is your practice to zero the bowl position indicator with the crusher running, do so now. Refer to the
bowl rotation section if required.
8. When satisfied that all is right with the crusher, start the feed material.
9. It sometimes takes a little while for the circuit to stabilize. During that time it may be necessary to make
temporary CSS adjustments until the circuit reaches a steady state condition. This is site-specific.
During this transient period, be extra vigilant for bowl float and the level of rock in the hopper.
RELATED LINKS:
Bowl Position Counter Reset Procedure with the Crusher Running
125
OPERATION
Crusher Operational Troubleshooting

For the most part you can avoid many of the problems below by maintaining a choke feed, preventing bowl
float, and using the proper liner, closed side setting, and reduction ratio for the material you are crushing and
producing.
Worn or damaged gears.
Excessive gear noise. Backlash setting not properly set.
Pinion shaft bearing damage.
Excessive oil being thrown out of seal rings. Oil deflector band on bearing missing (upper seal only).
Motor going out or incorrectly sized.
Crusher bearings failing.
Reduction ratio too high.
Bowl float.
High amp draw on crusher motor.
CSS too tight.
Excessive near-size material.
Voltage too low.
Drive belt imbalance in a two motor drive system.
Insufficient oil flow.
Flow meter set incorrectly.
Pinched hose.
Start delay timer malfunction.

Warning horn sounds after crusher starts or crusher fails
to start after 30 second start delay period.
Oil reservoir level too low and starving pump.
Pump cavitation or failure.
Pump motor failure or starter malfunction.
Pump motor coupler failure.
Dirt buildup on crusher sheave.
Crusher shakes excessively. Bearing failure.
Cone spinning (cone brake failure).
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OPERATION
Pinion bearing failing.

Excessive heat buildup at pinion housing.
Lack of lubrication.
Rumbling noise emitted from crusher. Bearing failing.
Hammering noise when crushing rock. Crusher not choke fed.
Hydraulic fluid leaking down side of bowl support. Damaged bowl clamp seal; fitting connection leaking.
Restricted return line.
Oil leaking out pinion labyrinth. seals. Damaged seals.
Plugged pinion housing return port.
Electrical malfunctioning.
Crusher won’t start. Low lube oil flow.
Low TIR pressure.
One motor draws more amps. Belt tension imbalance.
127
OPERATION
BOWL FLOAT
Bowl Float
Bowl float occurs when material in the crushing chamber is able to overcome the Tramp Iron Relief (TIR) hold
down force and the upper assembly lifts off the baseframe repeatedly. Bowl float indicates that the crusher is
overloaded. It is extremely damaging and causes deterioration of the surfaces at the joint between the upper
assembly and the baseframe, as well as a variety of other types of damage. You and any personnel working
in the vicinity of the Kodiak+ crusher must always be on alert for bowl float. Conditions that could cause bowl
float should be anticipated and avoided. Any time bowl float occurs, immediate correct action is required. The
reference lists a number of conditions that can cause bowl float as well as corrective remedies. If bowl float
occurs, do not let it continue. Doing so will void the warranty.
NOTICE: Whenever bowl float occurs, regardless of the underlying cause or crushing conditions, the CSS is too
small, by definition. The minimum CSS for any chamber configuration or crushing condition is the closest setting that
can be maintained without causing bowl float. If bowl float is encountered, stop crushing immediately until the CSS is
opened up and/or the underlying condition corrected. It may be necessary to choose a different chamber
configuration or speed in order to run the crusher at the desired CSS.
Monitoring for bowl float is a continuous process and you should pay especially close attention any time the
liners have been changed, whenever the close side setting (CSS) has been changed, when the feed material
has been changed, or if the feed rate has changed. Bowl float prevention is a process of knowing your feed
material, the desired reduction ratio, maintaining the proper CSS, continuous monitoring, and maintaining a
choke feed.
RELATED LINKS:
Causes of Bowl Float
128
OPERATION
BOWL FLOAT
Bowl Float Detection System

A bowl float detection kit is standard equipment on all Kodiak+ crushers equipped with MILO controls.
How it Works
The MILO bowl float detection system is a reporting/recording device only. It is not interlocked with the
crusher control. It will not turn the crusher off or interfere with crushing operation. It is a tool for the user to
detect the level of crusher overload so that they may take appropriate measures to prevent damage.
The MILO control increments two resettable counters (WARNING and DANGER) each time an overload
corresponding to those levels is detected. The upper assembly movement is detected using vibration sensors
mounted on the underside of the bowl support flange.
Whenever the device detects movement large enough to trigger a WARNING or DANGER event, a timer is
started. The timer will continue to count until the sensor output drops below the threshold. The time of the
event is shown on the Bowl Float Detection screen along with the event counters. When the bowl float detec-
tion system is enabled, a warning message will be displayed on the MAIN screen whenever a WARNING or
DANGER event is detected.
Sensitivity
The MILO control has two configurable levels of sensitivity: WARNING and DANGER. The two levels coincide
with sensor output level somewhere between 0 and 1000 of the maximum sensor output. Setting the sensi-
tivity at 0 would result in MILO reporting a continuous state of bowl float. Setting the level at 1000 would
require an uncrushable object of considerable size to cause MILO to report any problem at all. The degree of
sensitivity is adjusted by a slider control that divides the range into 1,000 segments.
The sensitivity can be adjusted at any time.
The recommended procedure is to set the WARNING level of sensitivity to detect very low amplitude move-
ment. Make it as sensitive as possible without triggering an unreasonable number of false positives. Set the
DANGER level of sensitivity to pick up larger amplitude movements that are larger than the occasional tran-
sient bump and represent serious overload events.
Optional Equipment
A CF memory card is installed in the HMI display to log time stamped data each time an event occurs. The
time, level of severity and length of the event will be recorded. The counters on the Bowl Float Detection
screen can be reset by the user at any time. The data on the chip, however, cannot be reset from within the
MILO program. This provides maintenance personnel with a means for determining what times tend to coin-
cide with overload activity. The media must be removed and processed on another computer for evaluation
of data. The data is stored in a .csv file which can be imported into an Excel spreadsheet.
The MILO crusher control is designed so that an external plant-wide control system can control the Kodiak +
crusher remotely. This is accomplished by connecting to the MILO control enclosure via a receptacle provided
for this purpose. One of the pins in that receptacle can be configured to send a signal each time a DANGER
or WARNING event occurs. Plant-wide control systems that use this remote control capability can elect to
take corrective action in response to bowl float conditions from a remote location. Additionally, direct access
to the sensor 4-20mA output is available via modbus. Contact JCI for information on these options.
129
OPERATION
BOWL FLOAT
Bowl Float Detection System Enable Procedure
The MILO bowl float detection system may be enabled or disabled by the user. The crusher must be running
in order to enable/disable or adjust the device.
1. Start the crusher.

2. From the MAIN screen, push the MAINTENANCE MODE pushbutton.
3. SCROLL down to BOWL FLOAT DETECTION and press SELECT.
4. SCROLL down to ENABLE.
130
OPERATION
BOWL FLOAT
Each sensor has an individual display. 0°, 120°, and 240°. Each box gives real time output for the specific
sensor.
1 Sensor display
User configurable thresholds for triggering WARNING or DANGER events. Threshold = range of 0-1,000
2
with 1,000 = max output.
3 Danger event counter and timer
4 Warning event counter and timer
In this example, two (2) sensors are above the DANGER threshold of 400.
131
OPERATION
BOWL FLOAT
1 Sensors that are above the DANGER threshold
2 Danger message - will remain for five (5) seconds after event is over
3 Number of DANGER events since the last reset
4 Number of seconds the event has lasted so far
If a sensor is disconnected or fails to send a signal for any reason, the output display changes to:
132
OPERATION
BOWL FLOAT
1 SENSOR FAIL display
5. Press RESET WARNING to reset the events counter/timer.
133
OPERATION
BOWL FLOAT
1 RESET WARNING pushbutton
2 WARNING event counter and timer
6. Press RESET DANGER to reset the danger events counter/timer.

7. Press RETURN to return to the previous screen.
WARNING/DANGER Threshold Adjustment Procedure While Not Crushing
This procedure allows the system to be adjusted while simulating bowl float under controlled, no load condi-
tions without affecting crushing in progress or risking an automated shutdown.
NOTE: The MILO control will not allow the DANGER threshold to be lower than the WARNING threshold.
The final settings will be made with the crusher running and upper assembly actively floating. This can be
unnerving so it is best to be familiar with the adjustment process before actively floating the machine.
NOTE: All bowl float is, by definition, an overload condition. The steps that follow only allow the user to detect
a configurable degree of overload. During this step no rock will be allowed to enter the chamber. Verifying the
setting by inducing bowl float while actually crushing will be discussed later.
1. It will be necessary to have the TIR system depressurized during this operation, so prior to startup, open
NV1 and NV2 to depressurize the hydraulic manifold.
2. Disconnect hoses C1 and C2.
3. Close NV1and NV2.
NOTE: The TIR system on the crusher is now disabled. Do not introduce rock into the crusher until the TIR
system is re-enabled after all adjustments have been made.
4. With the crusher running but the TIR system disabled, and the MILO control BOWL FLOAT DETEC-
TION screen active and enabled, SCROLL down to THRESHOLD ADJUST - WARNING.
134
OPERATION
BOWL FLOAT
NOTICE: Someone must be in the immediate vicinity of the crusher to verify when the desired WARNING threshold
has been reached. Watching a rotation stop for movement is an adequate method for visually detecting bowl float.
5. Set the WARNING threshold. Press INCR or DECR to adjust the sensitivity.
NOTE: Each individual press adjusts the sensitivity by one. Press and hold to move the slider in larger incre-
ments.
Set the WARNING threshold to detect any persistent movement, but not so sensitive that vibration of the
entire plant results in warning when no bowl float is present.
NOTE: For a new system startup, a reasonable place to start would be WARNING = 200 and DANGER = 300.
6. Rotate the bowl down until contact between the cone and liner is heard but no bowl float is observed.
7. Check all the rotation stops. Movement may be occurring on the other side of the machine.
8. Raise the bowl up/down a few times until the mantle is hitting the liner but there is no movement or until
the movement is as small as you can get it.
NOTE: If the screen is registering a warning event but no bowl float is observed, then the threshold is set too
low. Adjust it up.
9. If the screen is not registering a warning event, continue to rotate down until the upper assembly just
begins to move.
10. Increase the WARNING threshold until the MILO bowl float detection registers a warning event reliably
whenever the upper assembly just begins to move. Rotate up/down a couple of times to verify you have
the right spot. Err on the side of making it a little too sensitive but make sure that whenever an event is
registered, some movement also occurs.
11. Rotate the bowl back up until no noise is heard.
12. SCROLL up to THRESHOLD ADJUST - DANGER.
13. Set DANGER threshold using the INC/DECR buttons.

NOTE: This step works exactly like setting the warning sensitivity, but is significantly more nerve wracking
because the noise will be louder and the movement will be larger. The person stationed at the crusher should
135
OPERATION
BOWL FLOAT
keep their hands free of the crusher and move away from the immediate vicinity, yet close enough to see
upper assembly movement clearly.
NOTE: The DANGER threshold should be set higher than the WARNING threshold. Start at 100 units higher.
The DANGER level should correspond to movement that is considered unacceptable. Discrete movements
of this magnitude may occur if an uncrushable object enters the chamber, but the crusher should never
sustain this level of movement in normal operation.
14. Rotate the bowl down until a DANGER event is registered, or until the movement is large enough to
correspond to the severity you hope to detect, whichever comes first, and then immediately rotate up
until no contact noise is heard.
15. Prior to shutdown, reset the WARNING and DANGER counters, if desired.
16. Shut down crusher.
17. Open NV1and NV2.
18. Reconnect hoses C1 and C2.
19. Close NV1and NV2.
RELATED LINKS:
WARNING/DANGER Threshold Adjustment Procedure While Crushing
The WARNING / DANGER thresholds can be checked and/or adjusted while the crusher is under load by
simply opening NV1 far enough that the hydraulic system cannot keep up with the leak, but do not allow the
TIR pressure to drop below 1500 psi (103.4 bar).
If the pressure drops below 1500 psi (103.4 bar) for more than 5 seconds, an automated shut down sequence
will start. Bringing the pressure up above 1500 psi (103.4 bar) any time during that sequence will cancel the
shut down and resume normal crushing.
1. Open NV1.
2. Continue to unscrew until the pressure can be held at any desired pressure > 1500 psi (103.4 bar).
3. Adjust the threshold up or down until the desired level of sensitivity is achieved.
4. Lower the pressure until movement consistent with a WARNING condition occurs.
5. Continue opening NV1 until movement consistent with a DANGER condition occurs or the pressure
approaches 1500psi (103.4 bar), whichever comes first. If movement cannot be induced, rotate down a
little and try again.
6. Adjust the threshold up or down until the desired level of sensitivity is achieved.
136
OPERATION
KIDNEY LOOP FILTER (OPTIONAL)
Bowl Float Troubleshooting
Inappropriate chamber.
Excessive reduction ratio.
High compressive strength material (tramp iron).
Gap in parallel zone (CSS) too close.

Bowl float.
Low hold down pressure.
Feed concentrated on one side.
Too much clay in feed material.
Too much near-size material.
Kidney Loop Filter (optional)
The kidney loop filter has two (2) modes.
137
OPERATION
Kidney Loop Filtration Mode

Oil is pulled from the reservoir, pumped through a filter and returned to the reservoir. The objective is to
provide an additional level of oil filtration. During normal lubrication, oil returning from the crusher is intro-
ducing new contamination to the lube oil. The kidney loop is working behind the scenes attempting to clean
up as much of that contamination as possible. The flow rate is relatively low, so the pressure across the filter
element is lower and less likely to cause filter bypass. The lower pressure also allows the filter element to
hold more dirt, which in turn extends the life of the main filter.
The kidney loop can run continuously all day providing additional real time filtration. It can also be set up to
run an additional four hours after the crusher is turned off at the end of the day to provide another level of lube
oil conditioning.
Oil Circulation Mode

Oil is pulled from the reservoir and pumped out to the crusher. This mode requires changing the position of
a manually operated valve to redirect the flow of oil. When this mode is employed, the motor does not run
continuously. The Kodiak Crusher Control monitors the reservoir temperature and the return oil temperature
and determines how long to run the pump. Depending on how quickly the crusher temperature is dropping, it
may leave the pump off for three (3) minutes minimum to one (1) hour maximum.
138
OPERATION
Kidney Loop Filter Enable Procedure
1. From the MAIN screen, press the MAINTENANCE MODE pushbutton.

2. Once in Maintenance Mode, SCROLL down to KIDNEY LOOP PUMP and press SELECT.
3. SCROLL down to the ON to turn the system on.
4. Press RETURN to return to the main screen.
139
OPERATION
LUBE CIRCULATION
Lube Circulation
Use of thinner oils in cold climates is discouraged. Rather than using thinner oil, JCI recommends heating the
oil prior to startup. The lubrication assembly is equipped with two (2) 1500W heaters and the reservoir is rela-
tively small, so the oil can be heated quickly even in cold weather.
The use of this feature is for after-hours lube oil circulation with an extra option for extra lube oil filtration.
NOTICE: Starting with very cold oil results in significantly abnormal lube oil pressure and can cause oil filter damage,
oil filter element bypass, or both.
The Kodiak Crusher Control provides four (4) possible after hours oil filtration options. The first two (2) are
standard features. The second two (2) require that the optional kidney loop components are installed. All
require that the crusher be turned off but that the MILO control be turned on.
When either in Heaters and Lube Circ (3 phase), or Heaters and Lube Circ (1 phase), the lube circulation
activity is as follows. The lube pump will turn on and run for 10 minutes. At the end of 10 minutes, the tempera-
ture of the reservoir return oil is measured. The lube pump off time is calculated based on this return tempera-
ture. If the return lube oil temperature is less than 32°F, (0°C), then the lube pump off time will be three (3)
minutes. If the return lube oil temperature is more than 60°F, (16°C), then the lube pump off time will be 60
minutes. Pump off time will be proportional to temperature within these two (2) limits. While in Lube Circulation
mode, this on/off cycle will repeat.
All outputs will be disabled, so no motors (except lube pump) or solenoid valves will be energized. The push-
buttons will be disabled. Sensors will still be on-line. If the oil level should drop too low, the heaters will turn
off. In the event of a lube flow failure, the motor will be turned off. At the beginning of each new cycle, the
pump will restart. If there is still no flow, it will turn off again, etc.
Heaters Only
This standard option keeps the reservoir heaters on overnight. To utilize this function, 1ph power is required
at night. If the oil level drops too low, the heaters will be disabled.
Heaters and Lube Circ (3 Phase)

This standard option requires 3ph power at night and will circulate oil using the same pump employed while
the crusher is running. Hence, the flow rate will be the same as during normal crushing operations (varies by
model). No additional hardware is required.
Heaters and Lube Circ (1 Phase)

Optional kidney loop components must be installed to use this feature. This option provides a means for circu-
lating oil at sites where 3ph power is not available at night. It uses a smaller 1ph pump and requires that a
manual valve be actuated to redirect oil flow. This valve must be returned to the original position prior to
restarting the crusher. The circulated oil also passes through a separate filter to provide an added measure
of oil filtration.
140
OPERATION
LUBE CIRCULATION
Heaters and 4 Hour Kidney Loop Only

Optional kidney loop components must be installed to use this feature. This option is similar to Heaters Only
but provides kidney loop filtration continuously for four hours to provide an added measure of oil filtration. At
the end of the four hour oil filtration cycle, the lube pump will turn off but heaters will remain on.
Lube Circulation Procedure
1. Ensure that the crusher is off before accessing this feature.

3. Once in Maintenance Mode, SCROLL down to LUBE RECIRCULATION and press SELECT.
4. SCROLL down to the desired function and press ENABLE to turn the system on.
NOTE: All hydraulic functions are disabled in this mode. The entire system is essentially disabled except for
the lube pump and heaters. The crusher will not start when this mode is enabled.
141
OPERATION
LUBE CIRCULATION
5. The HMI will display when the lube pump is on or off.
6. Press DISABLE & RETURN to turn the system off and return to the main screen.
142
OPERATION
CRUSHER CLEAR FUNCTION

If the crusher becomes plugged with material, the clear function releases the TIR pressure, extends the TIR
cylinders and raises the upper assembly. In most cases, simply raising the upper assembly will provide
enough clearance to allow the trapped material to fall through onto the discharge belt.
While the clear button is pressed, the TIR cylinders extend until they have all reached the end of their stroke.
It is not unusual for the cylinders to extend at different rates.
The crusher must be completely stopped before extending the TIR cylinders. The recommended procedure
is to manually shut down the crusher and any feed equipment prior to pressing CLEAR. Leave the discharge
conveyor on if possible to carry away any material that drops from the crushing chamber. The crusher will not
start if the CLEAR pushbutton is pressed.
NOTE: If CLEAR is pressed with the crusher running, a message will be displayed alerting you that the Clear
function is disabled.
The horn will sound whenever the CLEAR function is active and will continue to sound until the upper
assembly is back in its original position and TIR pressure is restored. This is intended as an all-clear warning
to discourage anyone from approaching the crusher.
This feature is provided for allowing feed material to be evacuated from the crushing chamber only. It is NOT
a maintenance and/or inspection aid. If maintenance access is required, the upper assembly should be
removed or blocked in the raised position with they hydraulic system turned off. If the upper assembly is
blocked with they hydraulic system operating, the full combined force of all the TIR cylinders will be exerted
on the upper assembly.
143
OPERATION
AUTOMATIC INTERLOCKED CRUSHER SHUTDOWN
WARNING: Never reach into the gap or insert tools into the gap between the upper
assembly and baseframe when the upper assembly is elevated.
When the pushbutton is released the TIR cylinders will automatically retract and the upper assembly will lower
as the hydraulic system restores pressure.
The CLEAR button is seldom required unless the chamber becomes plugged and stops the crusher under
load. JCI strongly recommends a visual inspection of the crusher prior to restarting. In particular, verify that
both the crushing chamber and the discharge area are free of rock and debris. Verify that the upper assembly
is sitting firmly on the lower assembly and all TIR cylinders are fully retracted and attachments are secure. It
is acceptable for the upper assembly to sit slightly out of level and/or the rotation stops may not make full
contact. These should self-correct once crushing resumes.
Once the crusher is restarted, be aware of any new sounds, smells or vibrations. Verify that the cone head is
not spinning.
Automatic Interlocked Crusher Shutdown

Certain critical conditions will cause the Kodiak Crusher Control to shut the crusher down automatically.
When possible, these interlocked shutdowns will include time to stop feed equipment and empty the crushing
chamber.
144
OPERATION
Low Lube Oil Flow

Lube flow is measured by a positive displacement flow transducer and the flow rate is available on the HMI
SENSORS screen. The flow rate value displayed is updated every six (6) seconds.
1 Flow Rate Transducer
If the lube flow falls critically low the crusher will shut down. As the lube flow approaches this critical level the
light will blink and a warning will be displayed on the HMI. If the flow rate drops below the critical level, a shut
down sequence will begin.
The interlock and warning flow rates are listed in reference section.
When the lube oil flow rate drops below the acceptable range:
1) The control system will monitor the flow for 6 seconds and see if the problem is transient.
2) If the flow is still low after 6 seconds the horn will sound and the lube flow light will flash.
3) The HMI will display instructions to stop the feed conveyor within 5 seconds.
4) At the end of 5 seconds the feed conveyor enable relay contact will open.
5) The HMI will display an error message that crusher shut down will begin in 10 seconds.
6) The time remaining until shutdown will be displayed on the HMI.
You may press Crusher STOP or ESTOP at any time to stop sooner.
145
OPERATION
High Lube Oil Reservoir Temperature

180°F (82°C) is the high end of the acceptable operating range for most crusher lube oils. The normal lube
oil reservoir operating temperature is typically significantly below 180°F (82°C). If the lube oil reservoir
temperature reaches 190°F (88°C) a warning will be displayed on the HMI but the crusher will continue to run.
If the lube oil reservoir temperature reaches 220°F (104°C) a serious malfunction has occurred. The control
system will display a warning on the HMI and will allow a time delay prior to initiating a controlled shut down.
This does NOT imply that 220°F (104°C) is the maximum operating temperature. Oil temperature this high
indicates that a significant problem has developed but has gone unnoticed. If oil temperature exceeds 180°F
(82°C) on a regular basis, it should be investigated. A larger oil cooler may be required.
When the lube reservoir temperature reaches 190°F (88°C):
1) A warning will be displayed on the HMI screen.
When the lube oil reservoir temperature exceeds 220°F (104°C):
1) The horn will sound
2) The HMI will display instructions to stop the feed conveyor in 60 seconds.
3) At the end of 60 seconds the feed conveyor enable relay contact will open.
4) The HMI will display an error message that crusher shut down will begin in 10 seconds.
You may press Crusher STOP at any time to stop sooner.
JCI recommends that you become familiar with the normal full load operating temperature at their particular
site. In some climates, operating slightly outside the normal operating range and steady state temperatures
greater than 180°F (80°C) may be unavoidable. In such cases, heavier oil and/or synthetic lubricants may be
used and may require more frequent oil replacement (see Maintenance section). Even in those cases, 220°F
(104°C) will indicate that something is seriously amiss.
Although a time delay is provided to allow a somewhat controlled shutdown, you should be making plans for
shutting down the crusher in a fully controlled fashion well before the lube oil reservoir temperature
approaches 220°F (104°C).
Low TIR Pressure

The control system will attempt to maintain the TIR pressure within an acceptable operating range. The pres-
sure range is model specific and is listed in the appendix. The TIR pressure is displayed on the SENSORS
screen.
If the TIR pressure falls below the normal operating range, it will indicate that the pressure is low by a steady
blinking indicator light and a warning message on the HMI, but the crusher will continue to operate. If the TIR
pressure falls below 1500 psi (103.4 bar), the indicator lamp will flash and the system will allow a short delay
to see if the hydraulic system can automatically correct the problem. The hydraulic system can typically react
quickly enough that the TIR will seldom drop to 1500 psi (103.4). A large uncrushable object that can't be
discharged from the crushing chamber or a sudden significant oil leak or pump failure are the only situations
where this would normally occur.
146
OPERATION
If after five (5) seconds the low pressure (<1500 psi [103.4 bar]) condition cannot be corrected:
1) The horn will sound and indicator lamp will flash.
2) The HMI will display instructions to stop the feed conveyor in five (5) seconds.
3) At the end of five (5) seconds the feed conveyor enable relay contact will open.
4) The HMI will display an error message that crusher shut down will begin in Ten (10) seconds.
You may press Crusher STOP at any time to stop sooner.
After an interlocked shutdown, the HMI will display an error reminder explaining the cause of the shutdown.
The next time a CRUSHER START is attempted, it will be necessary to press ACKW to acknowledge the
error before it will be possible to start the crusher. Pressing ACKW implies that the appropriate repairs and/or
corrections have been made.
Communication Fault
The Kodiak Crusher Control constantly monitors communications between the MASTER and SLAVE PLCs.
Communication failure may be catastrophic and permanent or transient. Catastrophic failures, such as a
severed communication cable, are typically easily traced. Transient problems, such as interference caused
by radio signals or other electrical noise, may be difficult to detect and/or correct. The control system will shut
down the crusher if a serious fault is detected but will alert you if significant transient problems are detected
and allow personnel to investigate/correct the problem without shutting the crusher down unexpectedly.
If a communication fault is detected the Kodiak Crusher Control will respond by:
1) Monitoring for two (2) seconds to see if the interference goes away on its own.
2) If the interference persists beyond two (2) seconds, it will sound the horn and display a warning
message “Communication Failure Detected.” The horn will sound only while the communication fault
exists. The error message will remain on the screen until the ACKW/RESET button is pressed. The
ACKW/RESET button can be pressed while the crusher is running.
3) If the communication fault persists for more than 10 seconds, the crusher will shut down. The message
will change to “Shutdown - Communication Failure.” The feed enable relay output will open at the same
time.
Depending on the nature of the communication failure, normal shutdown using the STOP pushbutton may
not be possible, but ESTOP will still work. You can initiate the crusher shutdown at any time.
If the horn sounds and a communication fault has been detected, you should attempt a controlled shutdown
of equipment feeding the crusher in anticipation of an automated crusher shutdown.
If the cable is severed or disconnected, there is power loss and a communication loss. This has the same
effect as pressing ESTOP and the crusher will stop without warning.
147
OPERATION
Automatic Shutdown Troubleshooting
Loss of motor signal could be due to:

Failure of the crusher motor
Fault condition detected by crusher
There must be a signal at the softstart
crusher motor “sense” input in order Failure of the crusher motor softstart
for the control system to function. If Failure of the crusher motor softstart
Crusher stops without warning.
signal is lost, the PLC outputs to the aux contacts
“Failure Crusher Motor” is displayed
lube pump, crusher, cooler pump, Failure of the cursher motor sense
on HMI.
hydraulic pump, and feed conveyor relay, (either coil or contacts)
are disabled. The horn will not Failure of fuse F118
sound. Failure of SLAVE PLCA input I0.10
Wiring failure anywhere between
crusher motor softstart aux contacts
and SLAVE PLC input
Test the flow sensor circuit in the

harness:
1. Close (pull out) all EStops.
2. Check I0.0 on the SLAVE PLC
(wire 109A). The LED at I0.0 should
The flow sensor is reading low. If the be lit. If not, then there will be
problem occurs suddenly, suspect multiple errors displayed.
the sensor. 3. Check fuse 109.
HMI displays a low lube flow fault but
4. Disconnect the sensor from the
the sensor screen shows that there
harness by disconnecting the plug.
is some flow.
There should be 24VDC across the
two terminals in the plug at the end
of the harness.
The lube pump is worn to the point

where the flow rate is inadequate. If
Replace lube pump.
the flow has been dropping over
time, suspect the pump.
148
OPERATION
Test the continuity of the electrical

Wiring issues. connections from one PLC to the
other.
1. Error messages can be removed

by pressing ACKW/RESET at any
time.
2. Make note of the time and
frequency of all messages. If
frequent communication faults are
detected, investigate possible
sources of external interference.
Make note of any activities that
Unusual transient electrical activity, coincide with the appearance of
Communication faults.
such as radio frequency error messages.
interference. 3. If a communication fault causes
an irreversible shut down, note if the
shut down coincided with any
obvious source of external electrical
interference such as lightening or
welding on or around the crusher.
4. If the horn sounds and an error
message is displayed, stop feed to
the crusher to avoid plugging the
chamber.
Problem in RS485 communication The module must be ordered and

module (either in master or slave). installed separately from the PLC.
Check fan motor and/or bypass

Oil cooler not functioning.
valve.
Lube oil temperature too high.
Oil cooler dirty.
Low oil level.
149
OPERATION
WARNING CONDITIONS AND/OR REMINDERS
Warning Conditions and/or Reminders

Anytime a monitored attribute is operating outside its normal range, a warning or error will be sent to the main
screen.
Lube Oil Filter Bypass

A warning is generated whenever the bypass indicator switch is closed. The lube oil filter has a 50psi (3.45
bar) bypass spring. The electric bypass indicator switch closes at approximately 40psi (2.76 bar) to indicate
that full bypass is imminent. A visual indicator on the filter head is also provided, which is a little more sensi-
tive. If the visual indicator is showing bypass, it may be that bypass is just about to occur, but if the visual
indicator shows OK then the filter is certainly working properly. Warming the oil until the visual indicator shows
OK is perhaps the best way to protect against filter bypass.
The normal lube oil pressure with warm oil is well below 50psi (3.45 bar). The reservoir heaters will automat-
ically keep the minimum reservoir temperature between 80°F (27°C) and 100°F (38°C). This is warm enough
to avoid most bypass incidents if the oil is clean and the filter is still serviceable.
NOTE: JCI strongly recommends to always preheat the lube oil resveroir to 70°F (21°C) prior to crusher
startup.
The lube oil is quite viscous and takes a little pressure to get it moving when the pump first comes on. This
is more pronounced when the oil is cold. Even with warm oil the filter may go into bypass momentarily when
the pump first turns on.
If the filter is in bypass and the oil is warmer than 70°F (21°C), the crusher should be stopped and the filter
changed.
The crusher will continue to function normally even when the bypass warning is displayed. There is no inter-
lock for shutting down the crusher because of filter bypass, but bypass warnings should be monitored and
taken seriously.
NOTE: For optimum bearing life, avoid operating in bypass. The best way to accomplish this is to make sure
the filters are changed regularly and to warm the oil prior to startup.
In cold environments JCI strongly recommends using the oil circulation function, whenever 3ph power is avail-
able, when the crusher is turned off.
RELATED LINKS:
Lube Circulation
Lube Oil Filter Change Procedure
Low Bowl Clamp Pressure

The control system will attempt to maintain the bowl clamp pressure within an acceptable operating range.
The pressure range is model specific. The bowl clamp pressure is displayed on the SENSORS screen.
If the bowl clamp pressure drops below its normal operating range, the indicator lamp will blink slowly. The
crusher will continue to operate. The bowl clamp will continue to operate at pressures well below its operating
range, but a persistent blinking light indicates that the hydraulic system is unable to compensate for a leak
and should be investigated immediately.
The bowl clamp is automatically depressurized when the BOWL UP or BOWL DOWN pushbuttons are
pressed. In this situation, the blinking light indicates that the system is working normally.
150
OPERATION
High Hydraulic Oil Temperature

The JCI Kodiak hydraulic system only operates on demand. Typically, this demand is not adequate to
generate any appreciable heat. A temperature switch is provided to detect if the oil return reaches 190°F
(88°C). Any time the oil gets this hot some serious malfunction has occurred and should be investigated
immediately. If the hydraulic oil temp switch opens a warning message “Hydraulic Temperature >190F (88C)”
will be displayed and the horn will beep slowly, but the crusher will continue to operate. The crusher should
be stopped in a controlled manner and the system de-energized until the oil can cool down and the source of
the problem can be corrected.
Maximum Bowl Position

It is important to prevent the bottom edge of the bowl drive ring from rotating above the top of the orange decal
that defines the specified “Crushing Zone” unless the bowl clamp has been depressurized and disabled. If
the bowl rotates too far beyond this point, the amount of thread engagement between the bowl and bowl
support will eventually be inadequate to resist the substantial upward thrust of the bowl clamp and the bowl
threads and/or the bowl clamp could be damaged. For this reason a sensor is attached to the bowl support
to detect when the drive ring has reached its maximum vertical position. Nonetheless, anyone involved with
the operation and/or maintenance of the crusher should always be aware if the drive ring approaches the top
of the orange decal.
The sensor normally sends a constant 24VDC signal to the PLC indicating that the drive ring is detected.
When the drive ring passes above the sensor, this signal is interrupted. The sensor has two LEDs near its
bottom edge. One LED indicates if the sensor has power and should always be on whenever the control
system is turned on. The other LED indicates if the sensor detects the bowl drive ring. This LED should be
on whenever the drive ring is in the crushing zone and off whenever the bowl drive ring is too high.
1 Bowl Drive Ring
2 Max Position Decal
3 Max Bowl Position Sensor
4 Max Bowl Position
151
OPERATION
NOTICE: The bowl should not be rotated up when the bottom of the bowl drive ring reaches the top of the orange
decal on the bowl support until the bowl clamp has been depressurized and disconnected. Doing so can result in
damage to the bowl clamp or a dramatic hydraulic leak or both.
If the bowl position sensor detects that the top of the crushing zone has been reached, the system will no
longer respond to the UP button. The DOWN button will continue to function and the crusher will continue to
run.
A warning message will be displayed and you will be given the opportunity to exit normal operating mode if
your intent is to remove the bowl.
RELATED LINKS:
Crushing Zone Upper Limit
152
MAINTENANCE
MAINTENANCE AND REPAIR SAFETY
Maintenance
Maintenance and Repair Safety
WARNING: Always lockout/tagout power to machinery and conveying equipment

before performing any maintenance or repairs. Warn all personnel that the machinery
is being serviced.
General Precautions
• To help ensure safe machine operation, use only genuine Original equipment manufacturer (OEM)
replacement parts that are sold or approved by the machine’s manufacturer. Use of non-OEM parts may
adversely affect machine operation and could result in an a hazardous situation.
• Always tighten all fasteners to the proper torque as described in the repair procedures. When torque
specifications are not listed, use the values in the torque table at the back of this manual.
• Be sure all replacement fasteners are of the proper grade and specifications. Replace any worn or
damaged fasteners.
Electrical Systems
• Always read, understand and follow appropriate electrical system troubleshooting, maintenance and
repair instructions in the machinery manufacturers’ manuals.
• Allow only trained and licensed electricians to install, troubleshoot and repair electrical equipment. All
procedures must be in compliance with the National Electric Code and any applicable state or local
regulations.
• When servicing an electrical system, work with the power locked out and tagged. Always assume that
an electrical system is live until it has been locked out.
• Always tag and lockout power before removing cables with quick-disconnect plugs.
• Repair any obviously worn or damaged wires and connectors.
• Inspect power cables and connections daily for signs of wear, cracked insulation and worn or damaged
connectors. Repair or replace as required.
• Do not store tools inside electrical cabinets.
• Verify that all tools are grounded with a three wire plug or double insulated. Be sure that all extension
cords are grounded with a three wire plug.
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Pressurized Systems
• Adjust, maintain and repair all pressurized systems only in accordance with the instructions contained
in the manufacturer’s manuals provided with the machinery.
• Never attempt to work on a pressurized system while it is pressurized or in operation.
• Before performing maintenance or repairs on any pressurized system:—Cycle the controls through all
operating positions to relieve any trapped pressure.—Check that ALL pressure is relieved from the
system. The pressure gauge must read zero (0) PSI.—Lockout and tagout all controls. Be sure electrical
power is properly locked out and tagged.
burns.
the system. The pressure gauge must read zero (0) PSI.
• Never attempt to loosen a hydraulic fitting while a hydraulic system is pressurized. You could be injured
or killed by a stream of high pressure oil.
• Never have your face near, or stand directly in front of a hydraulic line when cracking a fitting, even after
can penetrate the skin, resulting in serious personal injury.
• Clean-up any spilled hydraulic fluid. Hydraulic fluid is extremely slippery, and can be especially
• Never attempt to adjust pressure relief valves to above the machinery manufacturer’s recommended
settings. Serious personal injury and/or equipment damage could result. Do not operate any hydraulic
or air system with obviously worn or damaged, or leaking components. Always replace any defective
components immediately.
hydraulic relief cylinder hoses when climbing on the crusher.
accumulators.
Welding On Machinery
• Be sure to provide adequate ventilation when welding inside enclosed areas to prevent the buildup of
hazardous fumes. Special concern should be exercised when welding chromium, manganese,
cadmium, copper, cobalt, lead and nickel, as these materials are considered to be potentially carcino-
genic.
• Be sure to wear the proper welding shield, welding gloves and clothing. Do not wear synthetic fabric
clothing or clothing which could be easily ignited by sparks.
• Always follow all standard safety procedures when welding. Be sure that all systems are shut down,
power is locked out, and controls are tagged. Provide welding screens to protect other employees
working in the area.
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• Relieve all hydraulic pressure before welding near hydraulic components and lines. Cover hydraulic
components to protect them from weld spatter and sparks.
• Do not weld near flammable liquids or hydraulic oils.
• Welding lifting eyes or hooks to manganese steel castings is strongly discouraged, and should be done
only if absolutely necessary. Always use a stainless steel or manganese weld rod. Never allow
personnel to walk or work underneath castings being lifted or supported.
• Never ground the welder so that the electrical power will flow through bearings, hydraulic components
or electrical equipment. Serious damage could result.
• Be sure all compressed gas cylinders are stored upright, chained and capped. Turn-off all cylinders
when not in use.
Clearing Jammed Material
WARNING: To prevent serious personal injury or death, never attempt to remove

jammed material while the machinery is in operation.
WARNING: Never stick any part of a person’s body into the crushing chamber when
the upper assembly is raised.
• If material becomes jammed in the machinery:

Immediately stop the machinery.
Lockout/tagout power. Warn others that the machinery is being serviced.
Follow the instructions in the operation and maintenance manual of the affected equipment.
• Always remove all jammed material before restarting the machinery. To prevent damage, never attempt
to restart a stalled machine without first removing the jammed material.
• Never use dynamite or other explosives to clear jams. Explosives are dangerous and can injure or kill
personnel. Damage to machinery could also occur.
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MAINTENANCE
Hazardous Materials
• Be aware potentially hazardous chemicals or materials. Such items can be harmful if they are improp-
erly used, stored, mixed transported, if they are inhaled, swallowed or allowed to contact the skin.
• Consult your employer’s hazard communications plan for instructions regarding the proper handling and
use of hazardous materials. Read and understand the labels attached to the product containers. Always
follow the instructions carefully.
• Consult the manufacturer’s material safety data sheet (MSDS) for potential hazards and appropriate
medical procedures should an accident occur.
• Store hazardous materials only in approved containers. Be sure containers are clearly labeled.
• To avoid potential health hazards, persons in regular contact with hydraulic oils must be aware of the
importance of thorough hygiene, and the proper methods for handling mineral oils.
• Mineral-based hydraulic oils act as solvents on the natural oils of the skin. Frequent and prolonged skin
contact can cause dermatitis or severe irritation.
• Always wear suitable protective clothing when handling hydraulic oil.
• Be sure protective clothing and proper wash-up facilities are available to all personnel that may come
in contact with mineral-based hydraulic oils.
• Always dispose of used rags or paper towels in the correct and safe fashion.
Disposal Of Excess Fuels, Lubricants And Liquids

Quarry personnel are responsible for the proper disposal of unused fuels, used lubricating oils, used hydraulic
oils, and other toxic materials. DO NOT dispose of these materials in an unapproved manner. Follow all appli-
cable federal, state and local regulations.
• Store flammable liquids in a safe place, away from quarry machinery and personnel. Use approved
safety containers and be sure that they are clearly marked. Containers must be covered when not in
use.
• Keep flammable liquids away from sparks, open flame, and other ignition sources. Do not smoke around
flammable liquids. Always obey posted “no smoking” signs.
• Be familiar with the locations of fire extinguishers throughout the quarry. Be sure they remain accessible
at all times, and are not blocked by obstructions.
• Do not use gasoline or other flammable liquids to clean tools or parts. Use only approved non-flam-
mable solvents.
• Always shut-off engines before refueling. Ground fuel spout against the filler neck to prevent static elec-
tricity. Never smoke while refueling.
• Use only approved safety containers for storing and transporting small quantities of flammable liquids.
Keep containers covered when not in use.
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MAINTENANCE

General Precautions
lifted.
Wire Rope

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MAINTENANCE
Chains
ranges.
lifting hooks.


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MAINTENANCE
OFFSET CONE LIFTING EYE SAFETY
Offset Cone Lifting Eye Safety

One piece off set lifting eyes are available from JCI, part numbers 456531 for the K200+ and K300+, and
546849 for the K400+. These eyes are approved for lifting straight up/down only when installing/removing a
cone assembly from the crusher without removing the mantle bolt cap.
WARNING: Offset lifting eyes are not

allowed for turning the cone assembly or
subcomponents over. Injury or death may
result from improper used of this device.
• Do not exceed load rating displayed on the device.

• Remove from service if any evidence of permanent deformation or cracks are evident.
• Do not use for lifting personnel.
• Do not suspend load over personnel.
• All personnel shall keep clear of the suspended load.
• Do not leave suspended load unattended.
• Do not remove or obscure warning label affixed to device.
• Do not use without first reading and understanding these written instructions.
• Do not lift load higher than required.
• Do not alter or modify this device without JCI Engineering approval.
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MAINTENANCE
WELDING CONSIDERATIONS
Welding Considerations
Whenever welding on or around heavy machinery, care must be taken to place the welding ground clamp as
close to the weld as possible. Special care is required to avoid placing bearings, hydraulic cylinders and/or
electronic components between the weld and the ground clamp. Attach the ground clamp to clean dry base
metal only. Whenever possible, the base metal should be freshly ground and the ground clamp should have
clean, dry contact surfaces, free of debris, corrosion, etc., firmly connected to the workpiece.
The minimum precaution for protecting electronic equipment on MILO equipped Kodiak+ crushers begins
with de-energizing the HPU power supply at the source. Follow all local lockout/tagout regulations.
Secondly, any potential current pathways between sensors and other external electronic components and the
HPU should be interrupted by disconnecting all of the cables and harnesses that connect to the bottom of the
electrical enclosure on the HPU. There are several cables and harnesses that have threaded or locking
connectors. All are located on the bottom of the electrical enclosure. Disconnect the cable that connects the
HPU to the remote control. This may be on the bottom or on the side of the electrical enclosure. These should
all be disconnected. These connections are all 24VDC connections and do NOT require opening the HPU
electrical enclosure.
Heater cables and other conductors that are connected to screw terminals inside the electrical enclosure do
NOT require disconnecting.
There are sensors mounted on the crusher that can be damaged by electrical fields commonly generated by
welding. JCI recommends that these sensors be removed when welding on the crusher or its support
structure. Most of the sensors are mounted on the upper assembly. Generally speaking there is some
welding associated with any liner change, but the upper assembly is removed during this operation so the
removal of those sensors is automatically accomplished. But there is frequently welding on or near the
crusher during installation of the crusher, and protecting these sensors could be easily overlooked. Therefore
during crusher installation be aware of these sensors and take appropriate precautions.
Follow the minimum recommended precautions whenever welding on the crusher or its support structure. If
welding near any sensors extra care is required. Removal of the sensor(s) is always 100% effective protec-
tion.
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MAINTENANCE
CRUSHER DAILY INSPECTION CHECKLIST
Crusher Daily Inspection Checklist
WARNING: Always lockout/tagout the equipment and depressurize the hydraulic

system prior to conducting these inspections.
OPERATOR’S SERVICE
INITIALS INSPECTION ITEM OKAY REQUIRED
Check under the crusher and inside the baseframe.
Observe any changes in general appearance or signs of

progressive wear.
Remove any accumulated debris from struts and/or pinion

tunnel.
Look for physical damage to seal between bowl and bowl

support.
Check rotation stops for wear. Monitor and plan for

maintenance, if required.
Check lube and hydraulic oil levels prior to startup. Top off as
required.
Remove any accumulated dirt from drive sheaves.
Observe drive belt general condition. Service, if required.
Verify that there is no accumulation of rocks inside belt guard

that could damage belts and/or the pinion shaft.
Verify that belt guards are in place and in serviceable

condition.
Check for oil leaks anywhere in the lubrication or hydraulic

systems and hoses.
Check for physical damage to seal between the bowl drive ring
and bowl support.
Check for physical damage to TIR cylinder bellows and/or

hydraulic hoses.
Verify that there are no rocks in crushing chamber.
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MAINTENANCE
CRUSHER MAINTENANCE SCHEDULES
OPERATOR’S SERVICE
INITIALS INSPECTION ITEM OKAY REQUIRED
Adjust CSS and/or reset counter before or after startup per

local preference.
Check lube and hydraulic filter indicators after startup. Stop

crusher and service, if required.
Verify that cone brake is functioning properly (cone head not

spinning) after startup but prior to start of feed material. Stop
crusher and service, if required.
Crusher Maintenance Schedules

Use the following checklists to guide you through routine maintenance time lines and procedures.
After First 200 Hours of Operation
ITEM INSTRUCTIONS
Lube Oil and Filter Change.
Lube Oil Breather Inspect.
Bowl Rotation Gearbox Lube Oil Check and top off, if required.
Bowl Rotation Gearbox Output Shaft Grease Replenish, if required. Be sure to remove vent plug.
Every 500 Hours of Operation
ITEM INSTRUCTIONS
Bowl Rotation Gearbox Lube Oil Check and top off, if required.
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MAINTENANCE
Annually or 4,000 Hours
ITEM INSTRUCTIONS
Bowl Rotation Gearbox Oil Change.
Bowl Rotation Gearbox Output Shaft Grease Replenish. Be sure to remove vent plug.
Bowl Threads Lubricate.
Hydraulic Oil and Filter Change.
At Every Liner Change
ITEM INSTRUCTIONS
Mantle Hold-Down Components Inspect and re-lubricate.
Bowl Liner Retention Hardware Inspect and repair.
Hour Meter Check. Is it time to service bowl threads?
Liner and Mantle Contact Areas on Cone and Bowl Inspect and repair, if required.
Areas not normally visible during normal daily inspections,

including the areas between the cone and top surface of Thoroughly inspect.
wedgeplate and wedgeplate guard
Rotation Stop Spacers Replace if heavily worn.
V-Seat Liners Replace if heavily worn or damaged.
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MAINTENANCE
Before Recommissioning the Crusher

If the crusher has been out of commission for a prolonged, unknown period, a complete tear down and inspec-
tion may be required. If a complete tear down is considered unnecessary:
ITEM INSTRUCTIONS
Bowl Rotation Gear Box Lube Oil Top off, if required.
TIR Cylinder Pin Bushings Lubricate.
Bowl Rotation Gearbox Oil Change.
Bowl Threads Lubricate.
Hydraulic Oil and Filter Change.
TIR Cylinder Bellows Inspect and/or repair.
Upper Assembly Dust Seals Inspect and/or repair.
Rotation Stop Shims Evaluate condition. Repair/replace, if required.
V-Seat Liners Evaluate condition. Repair/replace, if required.
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MAINTENANCE
MAINTENANCE MODE
Maintenance Mode
There are a few maintenance operations that require that the Kodiak Crusher Control operate differently than
it does during normal crushing operations. In some cases, the hydraulic system needs to temporarily maintain
different hydraulic pressures for selected functions. The system allows the user to exit normal crushing mode
and enter Maintenance Mode, where several function-specific screens are available.
Each function-specific screen gives a brief step-by-step description of what is required. Generally, once the
adjustment or procedure is complete, simply reversing those steps will put the crusher and/or control system
back in an operational condition and ready to return to the main screen.
Press SCROLL to highlight the desired function. Press SELECT to enter that screen.
NOTE: A few of the functions will require the crusher to be turned off before you can access the screen. A
warning will remind you to turn the crusher off before continuing.
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MAINTENANCE
DEPRESSURIZE CRUSHER HYDRAULIC SYSTEM PROCEDURE

It is necessary to relieve hydraulic pressure as a normal part of troubleshooting and adjusting the system
pressures or any time any part of the hydraulic system is disconnected.
WARNING: Follow all local safety regulations with respect to working around
energized electrical and hydraulic circuits. Familiarize yourself with how these circuits
operate before working on them. Never disconnect any hose until you are certain that
it is depressurized. Serious injury or death can occur from exposure to high pressure
oil.
Tools needed:
• 1/4” (6.35 mm) Allen wrench
1. Lockout/tagout the hydraulic power unit, the lubrication unit and electrical system.
2. To relieve the TIR pressure, open the needle valve NV1, located on the lower left-hand corner of the
manifold. You will have to first loosen the jam nut behind the valve before turning the knob.
1 NV1 Needle Valve (TIR Pressure)
2 NV2 Needle Valve (Bowl Clamp Pressure)
3. To relieve the bowl clamp pressure, open needle valve NV2, located on the lower right-hand corner of
the manifold. You will have to first loosen the jam nut behind the valve before turning the knob.
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MAINTENANCE
OIL SAMPLE PROCEDURE
NOTE: To prevent hydraulic pressure from building up, leave NV1 and NV2 needle valves open while working
on the hydraulic system.
1 TIR Pressure Transducer (PT2)
2 Bowl Clamp Transducer (PT1)
4. Verify that the pressure reads zero on the pressure transducers at the top of the manifold.
RELATED LINKS:
Oil Sample Procedure

Tools and supplies needed:
• Clean rags
• Sampling tube (P/N:083074)
• Small clean bottle with tight lid
• 7/16” [25.4mm] wrench
Some guidelines to follow when taking oil samples:
• Test often.
• Test between oil changes to detect trends.
• Look at the viscosity. Change before viscosity changes by 20%.
• Look at silica, iron, and copper. Compare against maximum values in the lube oil analysis chart and/or
look for trends.
• Look at particle count. If changes are detected, take a second look at silica, iron, and copper to see if
the particle count change corresponds with a change in one of these contaminant/wear elements.
• If any values are flagged by the test lab, find out why. If in doubt, change oil.
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NOTICE: When taking an oil sample be very careful to prevent contamination of the sample.
1. With the lube pump running, clean the area around the sampling port located by the lube pump.
NOTE: The lube assembly has two (2) sampling ports: one before the filter (shown above), and one after the
filter below the bypass valve (shown below). You will want to take most of your samples from the one before
the filter to get a reading of unfiltered oil.
2. Remove the protective cap (7/16” [25.4mm] wrench required) and clear away any debris.
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MAINTENANCE
3. Attach the brass fitting to the sampling tube provided in the box of auxiliary parts delivered with the
crusher.
4. Attach the sampling tube to the oil sampling port.
5. Prior to collecting the sample, allow a small amount of oil to flow into a spare container to flush away
any contamination.
6. Open the clean sample container and fill with lubricant.
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MAINTENANCE
LUBE OIL RESERVOIR FILL PROCEDURE
7. Install the protective cap on the oil sampling port.

8. Send the sample to your local supplier or analysis lab or contact the JCI Service department to arrange
to have the sample analyzed. JCI can also supply sampling containers, spare sampling tubes, ports,
etc.
RELATED LINKS:
Lube Oil Analysis

Check and/or add oil when the crusher has been stopped long enough that any oil remaining in the crusher
is able to return to the reservoir.
1. Check the oil in the sight glass.
NOTICE: Do not fill when the crusher is running. It is normal for the level to be below full when the crusher is
running. Overfilling or filling with the crusher running will not damage the crusher, but could cause an overflow and/or
fill the breather with oil, causing it to clog prematurely.
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MAINTENANCE
LUBE OIL RESERVOIR FILL PROCEDURE
2. Clean the area around the fill opening thoroughly before removing the fill cap to avoid introducing dirt
directly into the reservoir. Verify that dirt will not be knocked into the opening once the cap is removed.
3. Verify that the spout on oil dispensing equipment and/or buckets, funnels, etc. are clean.
4. Remove fill cap.
5. Top off oil, but do not overfill.

6. Replace fill cap.
7. Clean up any spilled oil.
RELATED LINKS:
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MAINTENANCE
OIL FILTER RESTRICTION INDICATOR
Oil Filter Restriction Indicator

The lube oil filter and the hydraulic oil filter each have a filter restriction indicator mounted on the filter head.
When the filter becomes restricted, the plug inside the glass tube will be pushed into the red zone, indicating
it is time to change the filter.
1 Indicator Plug
2 Restricted Filter (Red Zone)
3 Flow Direction
RELATED LINKS:
Hydraulic Oil Filter Change Procedure
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MAINTENANCE
LUBE OIL FILTER CHANGE PROCEDURE

Change the filter when the plug on the oil filter restriction indicator reaches the red zone. Also change the filter
at every lube oil change.
1. Relieve all hydraulic pressure.

2. Lockout/tagout the crusher and power supply.
3. Locate the lube oil filter.
4. Unscrew the filter.
5. Inspect filter for any contamination and dispose properly.

6. Remove new filter from packaging.
7. Apply a light coat of oil to the o-ring.
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MAINTENANCE
LUBE OIL FILTER CHANGE PROCEDURE
8. Remove the protective paper.
9. Install onto the filter head.
10. Clean up any spilled lube oil.

11. After re-pressurizing the hydraulic system, check for leaks around the oil filter.
RELATED LINKS:
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MAINTENANCE
LUBE OIL CHANGE PROCEDURE
Lube Oil Change Procedure
WARNING: The hydraulic system operates at high pressures. Do not attempt to

perform any service without depressurizing the system. Serious injury could result
from high pressure oil.
Guidelines:
• Replace the factory installed Mobilgear 600XP 150 oil 200 hours after initial startup. Following this initial
change, replace the oil every 500 hours, or more often if oil samples indicate.
• The life of synthetic oil such as Mobilgear SHC150 may be extended beyond the recommended 500
hours but should be monitored by oil sample analysis and should not exceed 1,000 hours.
• Higher viscosity oil and synthetic oil offer additional protection when running at elevated temperatures,
but do not offer significant protection against thermal breakdown when run at temperatures exceeding
180°F (82°C). If running at temperatures higher than this maximum cannot be avoided, then oil changes
may be needed more frequently. Monitor changes in viscosity by oil sample analysis.

3. Locate the drain plug.
NOTE: The lubrication oil reservoir has several drain plugs. The drain plug on the bottom surface of the reser-
voir is the ideal choice, if accessible, to drain the most oil.
1 Drain Locations
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MAINTENANCE
LUBE OIL CHANGE PROCEDURE
4. Place a container underneath the reservoir drain.

5. Remove the drain plug from the reservoir and drain the oil.
6. Reinstall the reservoir drain plug.

7. Add new oil to the lube oil reservoir.
8. Change the oil filter.
RELATED LINKS:
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MAINTENANCE
LUBE AND HPU RESERVOIR AIR BREATHER CHANGE PROCEDURE
Lube and HPU Reservoir Air Breather Change Procedure

In normal service, replace the breathers once a year even if they appear to be serviceable.
The lube oil reservoir air breather is located on the top of the reservoir.
The HPU oil reservoir is located inside the HPU cabinet on the left side of the reservoir tank.

3. Inspect the area around the breather frequently to verify that the bottom surface is free to draw in clean
air.
NOTE: If the breather becomes completely covered with dirt, consider remotely mounting to a cleaner loca-
tion. If remotely mounted, keep the hose run as short as possible.
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MAINTENANCE
HYDRAULIC POWER UNIT OIL RESERVOIR FILL PROCEDURE
4. Remove the breather from the reservoir. If the breather is basically clean, it can be considered service-
able. If there is some doubt, remove the breather and blow into the pipe-threaded port. There should be
little resistance. If it is difficult to blow into the breather, replace it.
5. Install the breather onto the reservoir. You may choose to use a filter strap to secure it.
RELATED LINKS:

The Kodiak+ stand-alone HPU is designed to be filled through the filter. The reservoir also has a filler on the
top of the hydraulic power unit, but JCI strongly recommends pumping oil through the filter fitting to ensure it
is filtered before it enters the hydraulic system. As long as the oil is showing in the sight glass, the oil level is
high enough.

3. Check the oil level on the hydraulic power unit reservoir in the sight glass on the front of the reservoir,
inside the cabinet.
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MAINTENANCE
HYDRAULIC POWER UNIT OIL RESERVOIR FILL PROCEDURE
4. Locate the filler fitting on the tee mounted to the inlet side of the filter head.
1 Filler Cap
2 Filler Fitting
NOTE: The port has a camlock type quick disconnect fitting. Given the wide variety of dispensing equipment
and infrequent refill requirement, a 3/4” NPT plug is provided for connection to a customer-provided pumping
apparatus. A hand-operated pump with the mating quick disconnect fitting is also included for topping off
through the filter from an open container.
5. Remove the cap on the filler fitting.
6. Connect the pumping apparatus to the filler fitting and pump oil until it is it reaches the top level on the
sight glass.
NOTE: The hydraulic oil installed at the factory is Mobil Humble H46. Any AW46 or AW32 hydraulic oil will be
suitable.
NOTICE: Do not fill the reservoir through the breather.
7. Detach pumping apparatus from filler and replace filler cap.

RELATED LINKS:
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MAINTENANCE
HYDRAULIC OIL FILTER CHANGE PROCEDURE

Change the filter when the plug on the oil filter restriction indicator reaches the red zone. Also change the filter
at every hydraulic oil change.

3. Locate the hydraulic oil filter inside the HPU cabinet.
4. Unscrew the filter.
5. Inspect filter for any contamination and dispose properly.

6. Remove new filter from packaging.
7. Apply a light coat of oil to the o-ring.
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MAINTENANCE
HYDRAULIC OIL CHANGE PROCEDURE
8. Remove the protective paper.
9. Install onto the filter head.

10. Clean up any spilled hydraulic oil.
11. After re-pressurizing the hydraulic system, check for leaks around the oil filter.
RELATED LINKS:
Hydraulic Oil Change Procedure
WARNING: The hydraulic system operates at high pressures. Do not attempt to

perform any service without depressurizing the system. Serious injury could result
from high pressure oil.
Guidelines:
• In the case of stand-alone standard Kodiak+ HPUs, change the oil once per year or every 4,000 hours
(whichever comes first), or before recommissioning the crusher after it has been out of service for a
prolonged unknown period. For crushers connected to larger hydraulic systems that serve multiple func-
tions besides the crusher (Fast Trax plants, for instance), the guidelines for hydraulic oil service for that
system should be used. Alternatively, hydraulic oil service based on oil sampling testing is highly recom-
mended.

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MAINTENANCE
HYDRAULIC OIL CHANGE PROCEDURE
3. Locate the hydraulic oil reservoir drain plug on the bottom of the reservoir.
4. Place a container underneath the reservoir drain to catch the oil.

5. Remove the drain plug from the reservoir and drain the oil.
6. Change the oil filter.
7. Reinstall the reservoir drain plug.
8. Add new oil to the HPU reservoir.
RELATED LINKS:
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MAINTENANCE
HYDRAULIC ACCUMULATOR REMOVAL PROCEDURE
Hydraulic Accumulator Removal Procedure

• Wrench set
• Socket set
• Clean rags

NOTE: The following steps can be done for either accumulator or both.
3. Disconnect hydraulic lines from accumulator.
4. Plug hydraulic lines to prevent contamination of the hydraulic system.

5. Protect the threads of the fitting by installing a cover.
NOTE: The accumulator weighs about 30 pounds (14kg) and can be slippery; use care when removing.
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MAINTENANCE
6. Support the accumulator as you loosen the clamp.
7. Remove the accumulator.

8. Place accumulator on work surface and stabilize to prevent from falling off.
9. Clean up any spilled hydraulic fluid.
RELATED LINKS:
Hydraulic Accumulator Refill Procedure

• Nitrogen bottle with 2000+psi nitrogen
• High pressure hose with valve and gauge
• Wrench set

2. Lockout/tagout the power supply, following all local rules and regulations.
3. Remove the hydraulic accumulators from the hydraulic power unit.
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MAINTENANCE
4. Check the nitrogen pressure in the accumulator by attaching valve and gauge. Pressure should be 1900
+/- 50 psi.
5. Attach the nitrogen bottle high pressure hose to the accumulator with a gauge.
WARNING: Do not overfill the hydraulic accumulator. Filling above 1900+/- 50psi can
damage the accumulator or cause it to rupture, which can cause serious injury or
death.
6. Open the valve on the accumulator.
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MAINTENANCE
7. Slowly open the valve to the nitrogen bottle watching the gauge pressure.
8. Once the nitrogen pressure is 1900 +/- 50psi close the valve on the accumulator.
9. Close the valve on the nitrogen bottle.

10. Remove the valve from the accumulator and install the cap to protect the fitting.
11. Remove the hose and secure the nitrogen bottle.
RELATED LINKS:
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MAINTENANCE
HYDRAULIC ACCUMULATOR INSTALLATION PROCEDURE
Hydraulic Accumulator Installation Procedure

• Wrench set
• Socket set
• Clean rags
1. Make sure accumulator is serviced with nitrogen prior to installation.

NOTE: The accumulator weighs about 30 pounds (14kg) and can be slippery; use care when installing.
NOTE: The following steps can be done for either accumulator or both.
2. Install accumulator. Make sure there is room for the hydraulic lines to be installed.
3. Tighten the clamps.
4. Remove the cap and plug and install the hydraulic line from NV1 to accumulator two.
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MAINTENANCE
BOWL ROTATION GEAR BOX LUBRICATION PROCEDURE
5. Remove the cap and plug and install the hydraulic line from NV2 to accumulator one.
RELATED LINKS:
Hydraulic Accumulator Refill Procedure
Bowl Rotation Gear Box Lubrication Procedure

• Crusher lube oil
• Grease
• Set of Allen wrenches
• Clean rags
The gear box used to rotate the bowl has oil in the lower portion to lubricate the gears and grease in the upper
portion to lubricate the shaft bearings. The gearbox holds approximately .34 gallons (1.3L) of oil. In normal
service, the gear box should not require much lubrication maintenance unless a leak is present.
Check and/or top off oil at each lube oil change.

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MAINTENANCE
BOWL ROTATION GEAR BOX LUBRICATION PROCEDURE
1 Overflow Hole/Oil Fill Plug
3. Using 5/16” (7.9 mm) Allen wrench, remove the gearbox oil fill plug.
4. Check the oil level. If no oil is visible, insert a screwdriver or something similar in the hole. If it comes
out oily, no further filling is required.
5. If it is determined that filling is necessary, fill the gear box until oil seeps out of the overflow hole. Use
the same ISO150EP gear oil used in the crusher lubrication oil reservoir.
6. Reinstall the gear box oil fill plug.
1 Grease Zerk
2 Vent Hole/Grease Pan Head Screw
8. Remove the vent hole pan head screw next to the grease zerk fitting on the upper portion of the gearbox.
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MAINTENANCE
BOWL ROTATION GEAR BOX OIL CHANGE PROCEDURE
9. Add grease through the grease zerk.

NOTE: One or two pumps of grease per year should be adequate. Do not over grease. Grease is for the output
shaft bearings only. Adding too much grease, or pumping grease in without removing the pan head screw will
force grease into the gear box lower cavity.
NOTE: Mobilegrease CM-S or CM-W are general purpose greases without Molybdenum Disulfide and are the
preferred grease. Mobilgrease CM-P contains low levels of Molybdenum Disulfide but is acceptable. Mobilith
SHC-220 synthetic grease is also acceptable.
10. Install the pan head screw and clean the zerk fitting of extra grease.
RELATED LINKS:
Bowl Rotation Gear Box Oil Change Procedure

• Crusher lube oil
• Empty container
• Clean rags
Change the gear oil and add grease to the shaft bearings once per year or after 4,000 hours (whichever
comes first), or before recommissioning the crusher after it has been out of service for a prolonged, unknown
period.

3. Using a 5/16” (7.9 mm) Allen wrench, remove the oil drain plug underneath the gear box and allow the
oil to drain.
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HOPPER ASSEMBLY REMOVAL PROCEDURE
4. When oil is drained, reinstall the drain plug.

5. Add new oil to the gearbox.
RELATED LINKS:
Bowl Rotation Gear Box Lubrication Procedure

• Socket set
• Wrench set
• Properly rated hoist
WARNING: The hopper assembly is extremely heavy. Use a lifting device and rigging
rated for the weight of the hopper. Do not reach under the hopper as it is being raised
from the crusher. Do not allow anyone under or near the hopper as it is being lifted.
Serious injury or death could occur if the lift failed and a person was under the hopper.
The hopper comes in many different configurations. One option for a crusher may be a closed circuit config-
uration, in which case moving a conveyor will be necessary prior to removing the hopper. Other applications
could have a bin level detector that may need to be disconnected before removing the hopper. If the crusher
is fed by a screen, a chute from the screen may have to be removed to gain access to the hopper. Once
access is gained to the hopper, follow these steps to remove it.

3. Mark the orientation of the hopper to the crusher to aid in alignment during installation.
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HOPPER ASSEMBLY REMOVAL PROCEDURE
4. Remove the bolts that attach the hopper to the upper assembly.
5. Attach hoist to the hopper.

6. Remove the hopper.
RELATED LINKS:
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HOPPER ASSEMBLY INSTALLATION PROCEDURE
Hopper Assembly Installation Procedure

Tools and Supplies
• Socket set
• Wrench set
WARNING: The hopper assembly is extremely heavy. Use a lifting device and rigging
rated for the weight of the hopper. Do not reach under the hopper as it is being raised
from the crusher. Do not allow anyone under or near the hopper as it is being lifted.
Serious injury or death could occur if the lift failed and a person was under the hopper.
1. Attach the hoist to the hopper.

2. Lift the hopper over the upper assembly.
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HOPPER ASSEMBLY INSTALLATION PROCEDURE
3. Align the hopper with the orientation marks that were done during the removal and install the hopper
onto the crusher.
4. Install the bolts that attach the hopper to the upper assembly.
5. Remove the hoist.
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UPPER ASSEMBLY REMOVAL PROCEDURE
Upper Assembly Removal Procedure

• Leather gloves
• Clean rags
• Pry bar
• Hammer
• Silicone
Prior to removing the upper assembly it may be advantageous (but not required) to rotate the bowl to a higher
position. This is especially important if the upper assembly is being removed for the purpose of changing
liners. It is also advantageous to rotate the bowl drive ring to the top of the Crushing Zone decal located on
the bowl drive ring gear supports prior to upper assembly removal.
NOTE: If the bowl is repositioned, make sure the bowl drive ring does not rotate above the top of the Crushing
Zone decal.
1. Energize the hydraulic system and press CLEAR until all the TIR cylinders begin to extend, but stop
before the upper assembly begins to move.
2. As soon as all the TIR cylinder rods are in contact with the underside of the bowl support, press ESTOP
to de-energize the hydraulic system and hold the TIR cylinder rods in their partially extended position.
4. Lockout/tagout any feed conveyors, discharge conveyors, etc., that could pose a hazard to personnel
working on or around the crusher.
5. Remove the hopper.
6. Disconnect the bowl rotation hoses.
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7. Disconnect the bowl clamp hose at the quick disconnect.
8. Disconnect the bowl position proximity sensor cable.

9. Disconnect the bowl float indicator cable, if equipped.
WARNING: Be careful when removing the upper assembly as the possibility of

pinching yourself exists.
10. Remove the keepers from each of the TIR cylinder rod ends.
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11. Remove the two-piece split collars from each of the TIR cylinder rod ends. It may be necessary to use
a small pry bar to extend the TIR cylinder rod far enough to remove the split collars, but if the TIR
hydraulic circuit was de-energized as described earlier, the cylinder should extend easily.
12. Remove the spherical washers from each TIR cylinder position.
WARNING: The upper assembly is extremely heavy. Use a lifting device and rigging
rated for the weight of the assembly. Do not reach under the upper assembly as it is
being raised from the crusher. Do not allow anyone under or near it as it is being lifted.
Serious injury or death could occur if the lift failed and a person was under the upper
assembly.
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13. Attach appropriately rated rigging to the three lifting eyes on the inside of the bowl.
NOTE: Raise the upper assembly no higher than required. Do not leave the load suspended unattended.
14. Remove the upper assembly.
15. Place the upper assembly in a way that will not damage the fitting on the bottom edge of the upper
assembly.
16. Remove hoist.
RELATED LINKS:
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UPPER ASSEMBLY INSTALLATION PROCEDURE
Upper Assembly Installation Procedure

• Leather gloves
• Clean rags
• Pry bar
• Hammer
• Silicone
WARNING: The upper assembly is extremely heavy. Use a lifting device and rigging
rated for the weight of the assembly. Do not reach under the upper assembly as it is
being raised from the crusher. Do not allow anyone under or near it as it is being lifted.
Serious injury or death could occur if the lift failed and a person was under the upper
assembly.
1. If necessary, press CLEAR to extend all cylinders then press ESTOP.

2. Attach appropriately rated hoist to the upper assembly.
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3. Hoist the upper assembly over the lower assembly and align the anti-rotation blocks.
NOTE: Get help to align the cylinders to make sure all the cylinders pass through the upper assembly.
4. As you slowly the upper assembly, position each TIR cylinder to pass through the holes in the upper
assembly.
5. Once all TIR cylinders are aligned, slowly lower the upper assembly while checking all TIR cylinders as
you lower.
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6. Make sure the anti-rotation blocks are against the pads. Use a pry bar if needed.
7. Install spherical washer.
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WARNING: Be careful when installing the split collar as the possibility of pinching
yourself exists.
8. Install the split collar.
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9. Install the keepers.
10. Install bowl clamp hydraulic line.
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11. Install hydraulic lines to the bowl rotation motor.
12. Install the proximity sensor cable if installed.

13. Install the bowl float indicator cable if installed.
14. Energize the hydraulic system and engage the TIR cylinders to secure the upper assembly to the lower
assembly.
15. Install the hopper.
RELATED LINKS:
Hopper Assembly Installation Procedure
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CRUSHING ZONE UPPER LIMIT

When the bowl position sensor detects the drive ring has reached its maximum vertical position, a warning
screen will automatically be generated with options and instructions.
If this screen is displayed and the bowl drive ring is still within the Crushing Zone decal, then there may be a
malfunction of the bowl limit sensor. Check the LEDs on the sensor, if possible, as this will indicate if the
sensor is signaling properly.
NOTE: When the CRUSHING ZONE UPPER LIMIT screen is displayed, both the BOWL UP and BOWL
DOWN pushbuttons will be disabled. You will have to choose either YES or NO to exit the screen and resume
normal functional control.
• Pressing YES will take you to the BOWL REMOVAL screen.
• Pressing NO will exit and return back to the MAIN screen. However, if you attempt to rotate the bowl
down, another warning screen will be generated and require your acknowledgment.
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BOWL REMOVAL PROCEDURE
• Pressing NO will exit and return to the MAIN screen, but the BOWL UP and BOWL DOWN pushbuttons
will still be disabled. Should you press them you will get these warning screens again.
• Pressing YES will enable the BOWL DOWN pushbutton allowing you to rotate the bowl down.
RELATED LINKS:
Bowl Removal Procedure
Bowl Installation Procedure

• Leather gloves
• Clean rags
• Allen wrench set
• Lifting device rated for the upper assembly
WARNING: The crusher bowl assembly is extremely heavy, use a lifting device and
rigging rated for the weight of the bowl assembly. Do not reach under the bowl as it is
being raised from the crusher. Do not allow anyone under or near the raised bowl as it
is being lifted. Serious injury or death could occur if the lift failed and a person was
under the bowl.
1. Press the ESTOP button to de-energize the Hydraulic Power Unit (HPU) and stop the drive motors.
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2. Enter the BOWL REMOVAL PROCEDURE screen via the MAINTENANCE MODE screen.
NOTE: You can also access this screen by rotating the bowl up until the CRUSHING ZONE UPPER LIMIT
warning screen appears and pressing “Yes.”
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3. Once BOWL REMOVAL mode is enabled, open needle valve NV2 to depressurize the bowl clamp,
which is located on the lower right hand corner of the hydraulic manifold.
4. Observe the bowl clamp pressure on the gauge located on the upper right hand corner of the manifold.
Verify the pressure has dropped to zero.
NOTICE: The Kodiak+ HPU maintains some residual hydraulic pressure in the bowl
clamp circuit to prevent bouncing of the bowl when adjusting under load. If the bowl is
rotated above the STOP level on the crushing zone decal, the bowl threads will rotate
out of the bowl and residual pressure will force the bowl clamp piston and seal out of
the clamp ring. If the seal is ejected, a very large hydraulic oil leak will result and there
is a high probability of damage to the piston and seal.
5. Close the needle valve NV2.

6. When the clamp pressure is zero, disconnect the bowl clamp hose (C3) either at the HPU or at the quick
disconnect at the crusher. This will stop the ring from being pressurized while you rotate the bowl.
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7. Remove the hopper to gain access to the lifting ears on the bowl assembly.
8. Attach a lifting device rated for the weight of the bowl assembly (see Specification section for specific
model weights). The rigging needs to be able to rotate with the bowl. Follow all local safety precautions
pertaining to rigging, cranes etc.
9. Turn on the Hydraulic Power Unit (HPU) by pulling up on the E-Stop button.
10. Press and hold the BOWL UP button.
NOTICE: As you rotate the bowl up you must also take up slack on the lifting rigging.
11. As the threads near the end of their engagement, the threads will be visible from below the bottom of
the bowl drive ring. Take up the slack until the lifting device is holding the weight of the bowl but not
enough to lift the bowl clamp. The bowl should rotate up until the drive ring becomes disengaged from
the drive gear. Although the lifting device is holding the weight of the bowl, there is still significant
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engagement between the bowl and bowl support. Alternatively lift and turn until the bowl threads are
fully disengaged.
NOTICE: When the bowl is supported solely by the lifting device and the threads are fully disengaged, all personnel
should move away from the crusher.
12. Carefully lift the bowl assembly free of the crusher and place on the ground, blocks, or other suitable
supports rated for the weight of the bowl assembly. If additional control of the suspended load is
required, attach a tag line of sufficient length that the bowl may be controlled safely with no direct contact
by personnel.
WARNING: Stay clear of the suspended load until it has been lowered to the ground.
Pressing NEXT on the BOWL REMOVAL PROCEDURE screen will take you to the BOWL INSTALL screen.
However, do not press NEXT if the crusher will be out of service long enough that the control system will be
shut down. The control system will return to this screen the next time it is energized.
13. Shut down the HPU.
RELATED LINKS:
The Crushing Zone
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BOWL INSTALLATION PROCEDURE

• Leather gloves
• Clean rags
WARNING: The crusher bowl assembly is extremely heavy, use a lifting device and
rigging rated for the weight of the bowl assembly. Do not reach under the bowl as it is
being raised from the crusher. Do not allow anyone under or near the raised bowl as it
is being lifted. Serious injury or death could occur if the lift failed and a person was
under the bowl.
1. Verify that the threads of both bowl and bowl support are clean and suitably lubricated, that the bowl
seal (attached to the top of the bowl clamp) is in good working order, and that the drive ring inner surface
is clean and free of dings, scrapes etc that might damage the seal.
2. Attach a properly rated lifting device to the bowl assembly and carefully lift the bowl assembly.
3. Suspend the bowl assembly above the bowl support.
WARNING: All personnel should stay clear of the suspended load until it is partially
engaged in the bowl support.
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4. Line up the threads on the bowl assembly with the start of the threads in the bowl support. As the
threads are just about to come into contact, rotate the bowl by hand as it is lowered until the threads
come into engagement.
5. Continue lowering until the drive ring guide bars are aligned with the gear extension.
NOTICE: Be aware of pinch points between the bowl drive ring and the drive gear extensions.
WARNING: Do not allow personnel to put hands anywhere inside or under the drive
ring. There is no reason for reaching into the area under the drive ring. Keep all hands
on the outside of the drive ring until threads are fully engaged.
WARNING: As in the case of bowl removal, verify that the hose connecting the bow
clamp to the HPU is disconnected. Failure to do this will cause a massive oil leak and
potentially damage the seal and/or piston.
6. Once the drive ring is engaged with the drive gear extensions, start up the Hydraulic Power Unit by
pulling up on the E-Stop button on the control panel.
7. Press BOWL DOWN while lowering the bowl with the lifting device until the threads are thoroughly
engaged.The bowl drive ring should move from left to right as it threads into the bowl clamp. The lifting
device has to continue lowering as the bowl rotates. During the first full rotation, the bowl is threaded
only into the bowl clamp. If the bowl clamp lifts up, the bowl needs to be lowered a bit. If the rigging lines
go slack, the lifting device needs to take up the weight of the bowl.
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8. Continue lowering and rotating until the drive ring guide rods move into the crushing zone indicated on
the decal located on the drive ring supports.
9. Once within the crushing zone, disconnect the lifting device.
10. De-energize the HPU and relieve the bowl clamp pressure by opening needle valve NV2 on the lower
right hand corner of the hydraulic manifold.
11. Verify the pressure is zero on the pressure gauge located on the upper right corner of the hydraulic
manifold.
12. Reconnect the hose connecting the HPU to the bowl clamp (C3).
13. Verify that the LEDs on the bowl position sensor are lit.
14. Close NV2.
15. Follow the directions for zeroing out the bowl position counter and reset the CSS.
16. Press RETURN to access the MAIN screen.
RELATED LINKS:
The Crushing Zone
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MANGANESE LINER CHANGES
Manganese Liner Changes

The steps outlined in the following pages will guide you through the disassembly and re-assembly of the
crusher so that the manganese liners can be changed.
WARNING: The manganese liners are extremely heavy and will cause serious injury
or death if they are not handled properly. Use hoisting devices designed to lift the
weights of the bowl liner and mantle and keep all bystanders away from the lifting
areas. Never place any part of your body under a liner being hoisted.
Bowl Liner Change Procedure
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1 Retaining Ring Keepers with Bolts
2 Locking Ring
3 Retaining Ring Bolts and Lock Nuts
4 Retaining Ring
5 Foam Rubber Inserts
6 Bowl
7 Lock Nut
Tools needed:
• Crane, rigging, and shackles capable of lifting the crusher upper assembly (see weight chart in Speci-
fications Section)
• Two (2) lifting eyes w/ 3/4-10NC male threads
• 1-1/8 end wrench and socket
• 1-1/2” socket
• 1-7/8” deep socket
• Ratchet or impact w/ extension x 12” (305mm) min
• Two (2) pry bars (36” is just right)
• Sledge hammer (10 lb or more)
• Cribbing or blocks
• Seven (7) 4x4’s approximately 12” thick
• Backing material (see parts book)
• Silicone sealant
• Grease and anti-seize compound
The bowl liner is held in place by a retaining ring that exerts an upward thrust force on a flange that encircles
the top opening of the liner. The retaining ring connects to the bowl liner flange by means of a rolled locking
ring that works in much the same way as a large snap ring. Upward thrust is exerted by an array of vertically
oriented bolts, and the liner can be precisely centered in the bowl by an arrangement of three (3) radially
oriented centering bolts.
The procedure described is one possible way to remove and replace a bowl liner in a JCI Kodiak+ crusher.
You may find a different method works best at your site, but the procedure below will minimize the number of
lifting operations.
1. Press BOWL UP to unscrew the bowl until the drive ring is approximately 2-1/2” below the top of the
crushing zone. This is to make room for the new set of liners.
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1 Drive Ring
2 Crushing Zone Indicator

3. Lockout/tagout the crusher and any related components. Follow all local lockout/tagout procedures and
regulations.
4. Remove the bowl rotation hoses, bowl clamp hose, and position indicator cable.
NOTE: Pressure will be trapped behind the ball checks if the pressure was not relieved prior to being discon-
nected. This will make reconnecting nearly impossible.
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1 Position Indicator Cable
2 Bowl Rotation Hoses (not shown)
3 Bowl Rotation Hoses
5. Mark the upper assembly to the lower assembly to help with the orientation when reassembling.
6. Follow the procedure to remove the hopper.
7. Follow the procedure to remove the upper assembly.
8. Set the upper assembly down on blocks with clearance under the liner.
9. Clean away any mud and loose debris to expose the bowl liner retention hardware.
10. Remove retaining ring keepers and bolts.
1 Retaining Ring Keepers and Bolts
2 Retaining Ring Bolts (jack bolts)
11. Remove retaining ring bolts (jack bolts).

12. Clean out old foam and any material left in the bowl retention area.
13. Loosen the three (3) radially oriented centering bolts (1-1/8” end wrench required) and jam nuts.
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1 Centering Bolt
2 Retaining Ring
NOTE: The retaining ring should drop, giving access to the split ring. If the retaining ring does not move down
as the bolts are backed out, strike with a hammer, if necessary.
NOTE: The rolled locking ring should now be loose. If the bottom of the bowl liner is off the ground, be aware
that the bowl liner is only held in place by friction once the locking ring is loose.
CAUTION: Do not try to remove the locking ring with your hands. Until the locking ring
springs free, it is under considerable tension.
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14. Find the split in the locking ring, insert one of the pry bars, and pry the free end of the ring until it starts
to come out from under the lip in the liner.
15. Insert the second pry bar and work the free end of the locking ring out from under the flange on the bowl
liner. Continue working around the circumference of the locking ring, alternating between the two pry
bars until the locking ring snaps off.
NOTE: Hold the locking ring with one pry bar as the other is moved to a new location along the circumference
of the locking ring. Use both pry bars to work the locking ring out of the groove and over the top of the flange.
16. Strike the top of the bowl liner with a sledgehammer until it drops out.
17. Lift and remove the bowl from the used liner.
18. Prepare the bowl and liner for installation. Clean up the liner contact seat on the bottom of the bowl by
removing any traces of mud, rust, backing material, etc.
19. If minor wear has occurred to the bowl, burnish wear lip with an air sander. If severe damage has
occurred, consult the factory. Clean up any nicks, dings, or rust that could prevent good, solid contact
between the liner and the bowl.
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20. Clean up and grease the inside of the bowl and inside clevis pockets, applying grease only to those
areas that will be in contact with backing material.
NOTE: Do NOT grease the bowl liner contact surface on the bottom of the bowl.
21. Sand paint from the manganese seat and the retaining lip of the new liner.
1 Retaining Lip
2 Manganese Seat
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22. Install the bowl over the new liner.
23. Check to see that the liner is roughly centered in the bowl by measuring from the OD of the liner to the
ID of the bowl in 3-4 places. The bowl can be adjusted side to side with a pry bar. The bowl need only
be roughly centered at this point. More precise alignment will be possible at a later step.
NOTICE: Precut foam rubber inserts are available that can be placed under the retainer ring to help exclude mud
and debris. Do not install bowl liners without some form of excluding material. Any backing material that flows under
the retainer ring will be difficult to remove during the next liner change. Applying grease to the underside of the insert
along the inside edge can help increase the probability that the insert can be reused. Other material like fiberglass
bat insulation will also work, but not as well.
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24. Install the foam rubber inserts so that the cutouts are aligned with the backing material pour holes as
shown.
25. Install the retaining ring with the 1” bolt holes lined up with the holes in the foam rubber inserts.
26. Install the locking ring. Set the locking ring on top of the bowl liner. Press one end of the locking ring
over the edge of the liner and install one of the retaining ring keeper bolts to hold it in place.
1 Retaining Ring Keeper Bolt
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CAUTION: Do not try to install the locking ring with your hands. Until the locking ring
springs free, it is under considerable tension.
27. Using two pry bars, work the locking ring over the flange onto the top of the liner in a manner similar to
that used to remove it.
NOTE: The ring will typically install with little difficulty using the pry bars. Avoid the temptation to help it along
with your hands. If it is difficult to install, it is probably because the bolt was not installed as described in the
previous step. Reinstall the bolt and the installation should be easier.
28. Center the retaining ring using the centering bolts. The liner must be centered evenly in the bowl.
NOTE: Liner should be centered at the bottom of the manganese seat as well as above.
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29. Install the retaining ring keepers with bolts starting at a location next to the split in the locking ring and
working sequentially around the locking ring until all the keepers are installed.
NOTE: The locking ring keepers are beveled along the edge. They must be installed with the bevel against
the locking ring.
30. Install the retaining ring bolts (jack bolts) with lock nuts and take up the slack in the retention system
hardware. Alternate from side to side until the bowl liner is snug but not tight.
NOTE: The retaining ring/locking ring assembly should be centered around the flange on the top of the liner
with the locking ring making solid contact all around the flange. Adjust as required.
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31. Re-check to make sure the liner is centered at both the top and bottom.
NOTE: Do not tighten the radial centering bolts at this time.They should only be finger tight so they don’t
prevent tensioning of the retainer bolts during the next step.
32. Torque the retainer bolts uniformly to 450-475 ft lbs dry [350-375 lubed]. Alternate from side to side in
a star pattern rather than going around sequentially. When all retainer bolts are torqued, tighten the
retainer ring lock nuts. If a torque wrench is not available, 450-475 ft lbs translates roughly into a strong
steady pull on a 3/4” drive ratchet or breaker bar with a 3 foot handle.
NOTE: The tightening process is easier if an extension is used. This puts the torque wrench above the top of
the bowl. As shown in the photo above, a 4x4 provides a convenient support surface for supporting the exten-
sion.
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33. Install precut foam rubber dirt-excluding inserts, fiberglass insulation, or other material around the
outside of the retainer ring.
NOTE: These inserts are different from those used under the retainer ring. See parts book.
34. The final step is to pour backing material, but as the mantle and bowl both require backing material, it
is best to pour it at the same time. See the mantle liner change procedure, or skip ahead to the backing
material procedure.
RELATED LINKS:
Backing Material Procedure
Mantle Liner Change Procedure
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Mantle Liner Change Procedure
It is preferable to change the mantle without removing the cone from the lower assembly.
NOTE: The following instructions are assuming the cone remains in the lower assembly.
WARNING: The manganese liners are extremely heavy and will cause serious injury
or death if they are not handled properly. Use hoisting devices designed to lift the
weights of the bowl liner and mantle and keep all bystanders away from the lifting
areas. Never place any part of your body under a liner being hoisted.
1. Remove the mantle cap.

2. Cut the mantle washer all the way through and around the at the angle shown with a cutting torch. This
will relieve the tension on the threads of the mantle bolt.
1 Mantle Washer
2 Mantle
3 Torch here
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NOTICE: Take care to note the correct angle and location of the cut shown in the illustration above. Failure to cut in
the correct manner can result in damage to the cone stem.
NOTE: Allow metal slag to flow into and through the cavity underneath the mantle washer and out the pour
hole.
3. Place the mantle nut wrench into the recess on top of the mantle bolt. Secure the wrench in place by
inserting the 1-1/4” x 1-1/2” bolt and tightening.
4. Unscrew the mantle bolt by striking the wrench with a sledgehammer. The bolt has left-hand threads.
5. Weld two (2) temporary lifting ears onto the old and new mantle liners 180° apart using stainless steel
or manganese welding rod.
WARNING: Failure to burn the weld into the manganese could result in the weld
breaking and causing personal injury.
6. Lift the worn mantle from the cone head and set aside.
WARNING: Stay well away from the mantle while it is being removed from the cone.
Use a lifting device rated for the weight of the mantle.
NOTICE: Be careful to not lift the cone head! If this happens, the floating plate and torque bar can disengage and
will require further disassembly to re-align.
7. Clean off any remaining backing material adhering to the cone head surface using a chisel and a
hammer. Clean all traces of backing material from the seating surface using a disc sander.
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8. Coat the cone head with grease using a paintbrush. Do not apply grease to the seating surface. The
grease will keep the backing material from adhering to the cone surface, allowing the mantle to
self-tighten during crushing and make mantle removal that much easier next time.
9. Lay the new mantle on its side and remove the paint and/or rust from the seating surface using a disc
sander.
10. Sand the top opening of the mantle liner for metal-to-metal contact with the washer.
11. Pre-fit the new mantle washer in the mantle.
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1 Dowel Key Notch
2 Pour Hole
NOTE: It may be necessary to grind or cut the notch for the dowel key to allow the washer to sit flat.
12. Lift the mantle into position on the cone head and center the part as close as possible.
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13. Place a foam rubber ring around the cone stem sitting on top of the cone head so that it will fit and seal
underneath the liner and washer. This foam is installed to prevent backing material from flowing under
the torch ring. It also creates a space for slag to escape in future disassembly.
14. Install the mantle washer making sure the lug is in the smaller of the two (2) notches cut in the top bore
of the mantle.
15. Apply a coating of Never Seize to the threads on the mantle bolt and to the mating threads in the cone
stem. Install the mantle bolt turning it counter-clockwise (left-hand thread).
16. Tighten the mantle bolt to refusal using the mantle wrench and a sledgehammer.
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17. Drill two 1/2” holes at the joint of the mantle bolt and mantle washer 180° apart for the 1/2” diameter pins
that will key the two parts together. Start the drilling using a pilot drill bit. Follow the 45° slope of the
parts. Drill the holes 1” deep.
18. Insert the two (2) 1/2 dowel pins into the holes and stake over using a punch and hammer.
19. Follow procedure to add backing material.
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20. Install the mantle cap on the bolt with the Allen head capscrew. Apply Never Seize to the threads prior
to installation.
21. Weld the cap to the washer in three (3) places with a 3” long weld bead using stainless steel rod or
equivalent.
NOTE: Ground only to mantle to prevent bearing damage.

22. Seal the mantle cap bolt with silicon to aid in future disassembly.
23. Install the upper assembly. Check for original orientation of rotation stop blocks and hose connections.
24. Reconnect all hoses and bowl position indicator cable.
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25. Fully close NV1 and NV2 on the hydraulic manifold.

26. Remove locks and tags. Notify others in the area you will be starting the crusher and related equipment.
27. Follow procedure on resetting the accumulated liner wear value to zero.
RELATED LINKS:
Reset Accumulated Liner Wear Procedure
Pour the backing material for the bowl liner and mantle at the same time.
1. Mix backing material thoroughly. Scrape the bottom and sides of the bucket with the stir paddle attached
to an electric drill.
NOTE: Keep backing material buckets in a warm environment prior to use to assist with mixing and pouring.
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2. Pour backing material through the holes in the flange at the top of the bowl liner. Pour backing until it
overflows through the holes provided in the bore of the liner.
3. When pouring is complete, plug the pour holes. Similarly, plug the overflow holes with silicone.
NOTE: Although not absolutely necessary for the proper functioning of the bowl liner, plugging the pour holes
is another way to prevent mud and debris from getting under the retaining ring and will make the next liner
change easier and faster.
4. There are special reusable pour hole caps (p/n 406206) available that can be used with silicone to seal
the pour holes. Kodiak+ series crushers leave the factory with these caps in place or they can be easily
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fashioned. Alternatively, anything handy, such as rags, paper, insulation, etc., can be stuffed in the
holes, leaving some space near the top to form a well. Fill the well with backing material or silicone. If
backing material is used to plug the holes, be sure that the plug seals sufficiently to keep backing mate-
rial from flowing into the space between the liner and the retention hardware.
5. Next, fill the void between the mantle and cone head. Fill until backing material comes out of the pour
hole.
6. Allow backing material to harden for 24 hours, if possible, before operating the crusher.
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Reset Accumulated Liner Wear Procedure
This screen is typically only accessed during liner changes and/or when setting the crusher up for the first
time after delivery. It allows the user to indicate that new liners have been installed so that the liner wear can
be measured in terms of material consumed as well as crushing hours during the life of the newly installed
chamber.
Whenever the CSS is reset the control system calculates how much liner wear material has been worn off
since the last CSS RESET. The value displayed is based on the amount of bowl movement since the liners
were first installed. This screen allows the operator to inform the JCI Kodiak Crusher Control that new liners
have just been installed.
1. After the new liners have been installed, reset the CSS.
2. Press RETURN to return to the MAIN screen.
3. Press MAINT MODE.
4. Press RESET ACCUMULATED LINER WEAR; then press YES. The accumulated liner wear value will
be reset to 0.00.
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BOWL THREAD LUBRICATION PROCEDURE
Bowl Thread Lubrication Procedure

Thoroughly clean the threads and replace the grease at least once a year or at 4,000 hours (whichever comes
first), or before recommissioning the crusher after it has been out of service for a prolonged unknown period.

3. Disconnect the bowl clamp.
NOTICE: Read and understand the directions for bowl removal prior to removing the bowl. In particular,
depressurize and disconnect the bowl clamp prior to removal. Failure to do so can result in a large oil leak and
possible damage to the bowl clamp seal.

5. Remove the bowl.
NOTE: The bowl must be removed in order to service the bowl threads. It is easier to remove/install the bowl
with the bowl support installed in the crusher because the bowl rotation hoses will be conveniently routed.
6. Remove the drive ring.
NOTE: Although not absolutely required, the job will be much easier if the drive ring is removed from the bowl
after the bowl is removed from the crusher.
7. With the drive ring removed, the inside surface can damage the dust seals. Clean up as required with
a sander and protect from rain or other sources of water spray until reassembled.
8. Completely remove all grease from the threads on the bowl and bowl support.
NOTICE: Use care when wiping the old grease away. Any damaged surfaces may have sharp edges that may not
be visible through the grease.
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9. Inspect the threads for scrapes, nicks, tears, etc., and use a sander to refurbish any damaged surfaces.
Similarly, inspect and/or repair the smooth cylindrical surface on the outside of the bowl, below the
threads.
10. Inspect the rubber dust seals at the bottom and top of the bowl support for any tears. Replace any
damaged sections.
11. The seals can be used dry and do not require lubrication, but remove any old grease and/or dirt that
could cause undue friction and wear. Talcum powder can be applied directly to the rubber as an optional
lubricant if desired to cut down on friction without attracting dirt.
1 Upper and Lower Dust Seals
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12. When all surfaces are clean and smooth, and the seals are in good working order, apply Mobilgrease
XHP322 Mine (formerly Mobilgrease Moly52) grease to the threads of both the bowl and bowl support
using a brush. Cover all surfaces completely, but the coating does not have to be thick.
NOTE: If working from a reusable open container, take care to avoid allowing windblown dirt and debris from
being deposited in the container and applied to the threads during subsequent service.
13. Have the lifting equipment available as soon as the grease is applied so that the bowl can be reinstalled
promptly in order to avoid undue contamination from windblown dirt. If the lifting equipment must be
delayed, cover all exposed surfaces with plastic sheathing to avoid contamination until lifting equipment
is available.
14. Reinstall the bowl.
15. Reinstall drive ring.
16. Reinstall the upper assembly.
17. Reconnect the bowl clamp connections.
RELATED LINKS:
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MANTLE BOLT THREAD MAINTENANCE
Mantle Bolt Thread Maintenance

Thoroughly clean the mantle bolt threads at every liner change.
WARNING: Take care when wiping away existing lubricant. Damaged threads may
have sharp edges.
1. If the cone or cone stem were damaged during cutting torch removal of the mantle washer, evaluate the
damage and repair if required.
2. Take special care to clean up the mantle washer pilot surface on the cone stem. Inspect for nicks,
galling, etc., and clean up as required with a file, but take care not to remove any more material than
necessary.
3. Inspect carefully and remove any visible contamination. If thread damage or cone stem bore damage
is visible, remove the mantle bolt and repair as required.
NOTE: Complete removal of existing lubricant from the mantle bolt threads on K200+ crushers may not be
possible.
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MANTLE BOLT THREAD MAINTENANCE
4. When all threads and load-bearing surfaces are clean, inspected, and/or repaired, apply anti-seize
compound generously to the threads, (and outside of the mantle nut in the case of K200+).
5. Have lifting equipment available for prompt re-installation of the mantle to avoid contamination of the
newly lubricated surfaces.
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FEED CONVEYOR MOTOR TEST
Feed Conveyor Motor Test

The Kodiak Crusher Control has a feature that allows you to isolate and run the feed conveyor for belt tracking
and motor rotation testing purposes.

2. Once in Maintenance Mode, SCROLL down to FEED CONVEYOR MOTOR TEST and press SELECT.
3. SCROLL down to ENABLE to turn the feed conveyor on.
NOTE: Scroll to disable and re-enable as needed.

4. Press OFF & RETURN to turn the conveyor off (if it is not off already) and return to the MAIN screen.
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SYSTEM RELIEF VALVE TESTING AND SETTING PROCEDURE

• End wrench 3/4”
The instructions that follow assume that the system relief valve is installed already. The relief valve setting
for normal operations is 3300 psi (227.5 bar) for all models. Consequently, the system relief valve will typically
be set at 3300psi (227.5 bar) when starting this procedure.
If installing a new valve, start by screwing the adjustment screw out until no appreciable spring pressure is
felt and then screw in 1-2 turns and adjust from there. During this procedure, the PLC will limit the pressure
to 3800 psi (262 bar), but it is good practice when the current setting is unknown to start from a low set point
and adjust upward.
The system relief valve is located on the bottom of the hydraulic manifold. The system relief valve needs to
be adjusted whenever a new valve is installed or it may need to be temporarily set higher than normal before
attempting to adjust an individual TIR cylinder relief valve.
1. From the MAIN screen choose MAINTENANCE MODE.

2. From the MAINTENANCE MODE screen SCROLL down to SYSTEM RELIEF VALVE ADJUST and
press SELECT.
NOTE: Upon entering the SYSTEM RELIEF ADJUST screen, the control system will disable the hydraulic
pump temporarily. At this point is it safe to relieve all hydraulic pressure.
3. Depressurize the hydraulic system.
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5. Clean the area around the quick disconnect before disconnecting the hoses going to the bowl rotation
motors (M1/M2) on the outside of the HPU. Cap and plug to prevent contamination.
NOTE: It is very important to prevent contamination of the hydraulic system.

6. Close needle valves NV1 and NV2.
7. Press and hold TEST. The control system will energize the hydraulic pump and attempt to bring the
pressure up to a value slightly higher than the recommended TIR relief valve pressure setting for the
specified model.
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8. Note the recommended system relief valve pressure setting on HMI screen. There are two values
shown. Use the lower value for normal crushing operations. Use the higher value if temporarily adjusting
the system relief as part of TIR relief valve adjustment.
9. If the pressure fails to come up to this pressure and oil can be heard passing through the system relief
valve, then the valve is set too low. Turn the adjustment screw in (clockwise) until the desired pressure
is reached. If the pressure comes up higher than the desired pressure setting and no oil is heard, then
the valve is set too high. Turn the adjustment screw out (counterclockwise) until the desired setting is
reached.
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10. Press TEST a few times to verify that the SYSTEM relief pressure repeats.
11. Open NV1 and NV2 to bleed off any pressure that may have accumulated in the manifold. Close NV1
and NV2.
12. If the next step is to test individual TIR cylinder relief valves, then leave the hoses off. If the next step is
to return to normal operation, connect hoses M1 and M2.
13. Close valves NV1 and NV2.
14. Press CANCEL/RETURN when finished. This will bring up the MAINTENANCE MODE screen.
15. Press RETURN again to go back to the MAIN screen.
RELATED LINKS:
Individual TIR Cylinder Relief Valve Testing and Setting Procedure
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INDIVIDUAL TIR CYLINDER RELIEF VALVE TESTING AND SETTING PROCEDURE
Individual TIR Cylinder Relief Valve Testing and Setting

Procedure
• TIR Relief Valve Test Block
• TIR Relief Valve
• End wrenches 3/4” (19.05mm) and 1-1/4” (31.75mm)
NOTE: In most cases, it will be necessary to temporarily increase the system relief valve pressure prior to
adjusting the TIR relief valves. It will be necessary to temporarily set the system relief pressure slightly higher
than the TIR relief valve setting. The instructions on the HMI screen will specify the correct temporary system
relief pressure setting for a particular model.
1. From the MAIN screen choose MAINTENANCE MODE.

2. From the MAINTENANCE MODE screen, SCROLL down to TIR RELIEF VALVE ADJUST and press
SELECT.
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NOTE: Upon entering the SYSTEM RELIEF ADJUST screen, the control system will disable the hydraulic
pump temporarily. At this point is it safe to relieve all hydraulic pressure.

5. Disconnect hoses C1 & C2 on the outside of the HPU.
6. Close valves NV1 and NV2.
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7. Verify that the TIR Relief Valve Test Block is free of any dirt and debris and install. Port 1 of the test
block connects to port C1 on the HPU. Port 2 connects to C2.
8. Visually inspect the relief valve high pressure seals closely for damage and install into the test block.
9. Loosen the locknut on the relief valve adjusting screw.

10. Note the recommended TIR relief valve pressure setting on the HMI screen.
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11. Press and hold TEST. The control system will energize the hydraulic pump and attempt to bring the
pressure up to a value slightly higher than the recommended TIR relief valve pressure setting.
12. If the pressure fails to come up to this pressure and oil can be heard passing through the TIR relief valve,
then the valve is set too low. Turn the adjustment screw in (clockwise) until the desired pressure is
reached. If the pressure comes up higher than the recommended pressure setting and no oil is heard,
then the valve is set too high. Turn the adjustment screw out (counterclockwise) until the desired setting
is reached.
13. Bleed off pressure and retest. (Release the TEST button. Open NV1 to bleed off the pressure. Close
NV1).
14. Repeat steps 11-13 three to four (3-4) times to verify that the TIR relief valve bypasses at the recom-
mended setting.
15. Check leak rate. After the last test, do NOT open NV1. The pressure on the test block gauge should
drop briefly after the TEST button is released and then stabilize at the “reseat” pressure. The pressure
will continue to drop after reseating, but this drop should be markedly slower than before (approximately
10 drops per minute). The reseat pressure should be approximately 85% of the bypass pressure.
16. Repeat steps 11-15 until all TIR valves are complete.
17. Record bypass and reseat pressures. It is a good idea to record the reseat pressure values and location
of the valve so that they will be available for future reference. If a leaky valve is suspected at a later date,
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this information may be useful for tracking down the likely culprit. The diagram below is provided as an
example.
18. When all valves are complete, open NV1 & NV2.
19. Reconnect hoses C1 and C2.
20. Close NV1 and NV2.
21. Press RETURN to go back to the MAINTENANCE MODE screen.
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V-BELT TENSION PROCEDURE
22. Reset the system relief valve to the recommended setting for normal operation (typically 3300 ± 100psi
[227.5 ± 6.9 bar]).
23. When complete, press RETURN to return to the MAINTENANCE MODE screen and then press
RETURN again to get to the MAIN screen.
RELATED LINKS:

Proper belt tension is essential for v-belt and sheave life, efficient power transmission, and pinion shaft
component life.
Guidelines:
• To extend the life of the belt, keep the sheaves straight and the belts free of abrasives, oils and acids.
Rock dust and rust are very abrasive.
• Over time the belt will wear and stretch--make sure to keep the belts under the proper tension. The ideal
belt tension is the lowest tension at which the belt will not slip under peak load conditions.
• Do not run with badly worn belts or sheaves. This will shorten the life of the bearings and other power
transmission components.
• Worn belts and sheaves will require much higher belt tension to convey the same power as normal belts
and sheaves.
NOTE: Since the belts are a matched set, it is not necessary to check the tension of every belt on the drive.
The tension for one will be the same for all in the series.
NOTE: If the V-belts slip or squeal during startup or when the crusher is using full power, the belts will need
more tension.
NOTICE: In the case where two motors are driving the crusher, you must make sure they are properly balanced and
tensioned.
1. Measure the center-to-center distance between the pinion shaft and the motor shaft.
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V-BELT TENSION PROCEDURE
1 Force (f)
2 Deflection (d)
3 Center (c)
2. Divide the center-to-center (c) distance by 64 to obtain the deflection distance (d). For example: K=40
inches (1016mm). Divide 40 by 64 = 0.625 or 5/8” (16mm.)
3. At the center of the belt span, apply force (f) perpendicular to the span, large enough to move the V-belt
to the deflection distance (d).
4. If the force applied is less than 30lbs (13 Kg), tighten the belt by turning the belt tension adjusting
screws.
5. If the force applied is greater than 50lbs (22 Kg), loosen the belt by turning the belt tension adjusting
screws.
RELATED LINKS:
V-Belt Change Procedure
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V-BELT CHANGE PROCEDURE
V-Belt Change Procedure
NOTICE: Always replace the V-belts in matched sets. A matched set of belts lasts longer because loading is evenly
spread among all the belts. Replace all the belts at the same time; do not use new and old belts together.

3. Remove the V-belt guarding. Make sure that the guarding is serviceable. Replace or repair prior to
putting the crusher back into service.
4. Inspect the belts for cuts, fraying, tears, or wear. If necessary, replace them.
1 Worn belt
2 Proper belt fit
NOTE:Check the tension and condition of the belts and sheaves daily. Clean the belts and sheaves daily with
compressed air.
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5. Loosen the motor drive so that there will be enough slack to remove the belts by loosening the four bolts
that secure the motor mount to the base.
6. Loosen the adjustment bolts until the belts can be removed from the sheaves.
7. Remove the old belts.

8. Place the new belts on the sheave and tighten to the proper tension using the adjusting screws.
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9. The proper alignment of both the drive and driven sheaves is very important to the life and efficiency of
the V-belts. Make sure both the drive and driven sheaves are aligned correctly.
A Drive Sheave
B Driven Sheave
1 Properly aligned
2 Not aligned
3 Not aligned
10. Tighten the four bolts that secure the motor mount to the base.
11. Check the belt tension frequently during the first 48 hour period.
RELATED LINKS:
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COG BELT TENSION PROCEDURE
Cog Belt Tension Procedure

Proper belt tension is essential for v-belt and sheave life, efficient power transmission, and pinion shaft
component life.
Guidelines:
• To extend the life of the belt, keep the sheaves straight and the belts free of abrasives, oils and acids.
Rock dust and rust are very abrasive.
• Over time the belt will wear and stretch--make sure to keep the belts under the proper tension. The ideal
belt tension is the lowest tension at which the belt will not slip under peak load conditions.
• Do not run with badly worn belts or sheaves. This will shorten the life of the bearings and other power
transmission components.
• Worn belts and sheaves will require much higher belt tension to convey the same power as normal belts
and sheaves.
The proper alignment of both the drive and driven sheaves is very important to the life and efficiency of the
cog-belt. Make sure both the drive and driven sheaves are aligned correctly. Indication of a sheave that needs
to be changed are worn teeth or rusted edges on the sheave.
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A Drive Sheave
B Driven Sheave
1 Properly aligned
2 Not aligned
3 Not aligned
Tools needed:
Sonic Tension Meter - JCI P/N 090417 (Refer to the sonic meter manual for complete operational details).
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Setting the Cog Belt Meter
1. Press the POWER key.
2. If this is the first time you have used your meter, the screen will appear as below. If this is not the first
time, the last settings used will appear.
3. Press the “MASS” key.
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4. The “MASS” window will be shown.
PLANT MASS WIDTH SPAN SETTING
FT200 7.9 90 1011 39-41
FT300 7.9 90 1011 41-44
GT200DF 7.9 90 910 47-50
FT300DF 7.9 90 910 47-50
GT200CC 7.9 90 910 47-50
FAST PACK 7.9 125 1011 38-40
NOTE: For configurations other than listed above contact your dealer.
5. Enter the “MASS” value from the above chart on the keypad. This entry will be in grams per meter.
Ensure the decimal is in the correct place in the display panel. If your entry is incorrect, press “MASS”
again and the cursor will return to the starting position.
6. Press the “WIDTH” key.
7. The “WIDTH” screen will be shown.
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8. Enter the “WIDTH” value from the above chart on the keypad. Ensure the decimal is in the correct place
in the display panel. If your entry is incorrect, press “WIDTH” again and the cursor will return to the
starting position.
9. Press the “SPAN” key.
10. The “SPAN” screen will be shown.
11. Enter the “SPAN” value from the above chart on the keypad. This entry will be in grams per meter. If
your entry is incorrect press “SPAN” again and the cursor will return to the starting position.
Using the Cog Belt Meter

3. Remove the belt guard.
4. Make sure the meter is on and the proper, mass, weight and span settings are displayed.
5. Press the “Hz” key. You are now ready to use the meter to determine your belt tension.
6. Press the “MEASURE” key, the green LED will begin flashing.
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7. Hold the sensor 0.4 inch (1cm) or closer to the belt.
NOTE: Do not touch the belt with the sensor.

8. Strike the belt with a large wrench. The meter will display a measurement in Hz.
9. Repeat the above step three (3) times to ensure accuracy.
10. If the measurement is lower than the range listed in the belt setting chart, tighten the belt by turning the
belt tension adjusting screws.
11. If the measurement is higher than the range listed in the belt setting chart, loosen the belt by turning the
belt tension adjusting screws.
12. Perform the steps until the correct tension is achieved.
RELATED LINKS:
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DRIVEN SHEAVE CHANGE PROCEDURE
Driven Sheave Change Procedure

Inspect the driven sheave for dirt buildup. Dust can collect on the sheaves during operation and affect the
balance of the system. It is important to make sure the area is cleaned daily. Make sure that the V-belt
guarding is adequate for safety and keeping dirt and rocks from falling into the drive area.
• Anti-Seize
• Torque wrench
• Leather gloves
• Clean rags
• Lifting device rated for the sheave assembly

3. Remove the drive guard.
4. Inspect and clean the driven sheave. If the sheave is worn excessively, replace it.
1 Worn sheave
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5. Loosen the motor drive until there is enough slack to remove the belts.
6. Remove the drive belt.

7. Remove the bolts from the sheave.
8. Install two pusher bolts into the sheave.
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9. Support the sheave with a appropriately rated hoist.
NOTE: It may be necessary to apply heat to the coupler to help loosen the sheave.
WARNING: The sheave is heavy and will cause serious injury or death if not handled
properly. Use appropriately rated lifting device and tools when moving heavy items.
Keep all bystanders away from the lifting area. Never place any part of your body
under the item being hoisted.
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10. Tighten the pusher bolts until the sheave separates from the coupler.
11. Remove the coupler if needed.
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12. Rotate the pinion shaft until the key slot is at the 12 o’clock position.
13. Apply anti-seize to the entire pinion shaft.
14. Tap a wedge pin into the cut on the bushing to ease installation onto the shaft.
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15. Align the key slot of the bushing to the key slot on the pinion shaft and install.
16. Install the key and remove the wedge pin.
17. Inspect the center of the sheave for burrs and dried paint and remove with a scotch-brite or a stone.
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WARNING: The sheave is heavy and will cause serious injury or death if not handled
properly. Use appropriately rated lifting device and tools when moving heavy items.
Keep all bystanders away from the lifting area. Never place any part of your body
under the item being hoisted.
18. Apply a light coat of oil such as WD-40 (or equivalent) and install the sheave onto the bushing.
19. Install the bolts.
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NOTE: To determine the torque value of the bolts refer to the information included with the bushing.
20. Determine the torque value and follow the torque sequence shown below. The bolt closest to the split
in the bushing is the last bolt to be torqued.
RELATED LINKS:
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CRUSHER SERVICE
Crusher Service
Maintenance and Repair Safety
WARNING: Always lockout/tagout power to machinery and conveying equipment

before performing any maintenance or repairs. Warn all personnel that the machinery
is being serviced.
General Precautions
• To help ensure safe machine operation, use only genuine Original equipment manufacturer (OEM)
replacement parts that are sold or approved by the machine’s manufacturer. Use of non-OEM parts may
adversely affect machine operation and could result in an a hazardous situation.
• Always tighten all fasteners to the proper torque as described in the repair procedures. When torque
specifications are not listed, use the values in the torque table at the back of this manual.
• Be sure all replacement fasteners are of the proper grade and specifications. Replace any worn or
damaged fasteners.
Electrical Systems
• Always read, understand and follow appropriate electrical system troubleshooting, maintenance and
repair instructions in the machinery manufacturers’ manuals.
• Allow only trained and licensed electricians to install, troubleshoot and repair electrical equipment. All
procedures must be in compliance with the National Electric Code and any applicable state or local
regulations.
• When servicing an electrical system, work with the power locked out and tagged. Always assume that
an electrical system is live until it has been locked out.
• Always tag and lockout power before removing cables with quick-disconnect plugs.
• Repair any obviously worn or damaged wires and connectors.
• Inspect power cables and connections daily for signs of wear, cracked insulation and worn or damaged
connectors. Repair or replace as required.
• Do not store tools inside electrical cabinets.
• Verify that all tools are grounded with a three wire plug or double insulated. Be sure that all extension
cords are grounded with a three wire plug.
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CRUSHER SERVICE
Pressurized Systems
• Adjust, maintain and repair all pressurized systems only in accordance with the instructions contained
in the manufacturer’s manuals provided with the machinery.
• Never attempt to work on a pressurized system while it is pressurized or in operation.
• Before performing maintenance or repairs on any pressurized system:—Cycle the controls through all
operating positions to relieve any trapped pressure.—Check that ALL pressure is relieved from the
system. The pressure gauge must read zero (0) PSI.—Lockout and tagout all controls. Be sure electrical
power is properly locked out and tagged.
burns.
the system. The pressure gauge must read zero (0) PSI.
• Never attempt to loosen a hydraulic fitting while a hydraulic system is pressurized. You could be injured
or killed by a stream of high pressure oil.
• Never have your face near, or stand directly in front of a hydraulic line when cracking a fitting, even after
can penetrate the skin, resulting in serious personal injury.
• Clean-up any spilled hydraulic fluid. Hydraulic fluid is extremely slippery, and can be especially
• Never attempt to adjust pressure relief valves to above the machinery manufacturer’s recommended
settings. Serious personal injury and/or equipment damage could result. Do not operate any hydraulic
or air system with obviously worn or damaged, or leaking components. Always replace any defective
components immediately.
hydraulic relief cylinder hoses when climbing on the crusher.
accumulators.
Welding On Machinery
• Be sure to provide adequate ventilation when welding inside enclosed areas to prevent the buildup of
hazardous fumes. Special concern should be exercised when welding chromium, manganese,
cadmium, copper, cobalt, lead and nickel, as these materials are considered to be potentially carcino-
genic.
• Be sure to wear the proper welding shield, welding gloves and clothing. Do not wear synthetic fabric
clothing or clothing which could be easily ignited by sparks.
• Always follow all standard safety procedures when welding. Be sure that all systems are shut down,
power is locked out, and controls are tagged. Provide welding screens to protect other employees
working in the area.
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• Relieve all hydraulic pressure before welding near hydraulic components and lines. Cover hydraulic
components to protect them from weld spatter and sparks.
• Do not weld near flammable liquids or hydraulic oils.
• Welding lifting eyes or hooks to manganese steel castings is strongly discouraged, and should be done
only if absolutely necessary. Always use a stainless steel or manganese weld rod. Never allow
personnel to walk or work underneath castings being lifted or supported.
• Never ground the welder so that the electrical power will flow through bearings, hydraulic components
or electrical equipment. Serious damage could result.
• Be sure all compressed gas cylinders are stored upright, chained and capped. Turn-off all cylinders
when not in use.
Clearing Jammed Material
WARNING: To prevent serious personal injury or death, never attempt to remove

jammed material while the machinery is in operation.
WARNING: Never stick any part of a person’s body into the crushing chamber when
the upper assembly is raised.
• If material becomes jammed in the machinery:

Immediately stop the machinery.
Lockout/tagout power. Warn others that the machinery is being serviced.
Follow the instructions in the operation and maintenance manual of the affected equipment.
• Always remove all jammed material before restarting the machinery. To prevent damage, never attempt
to restart a stalled machine without first removing the jammed material.
• Never use dynamite or other explosives to clear jams. Explosives are dangerous and can injure or kill
personnel. Damage to machinery could also occur.
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Hazardous Materials
• Be aware potentially hazardous chemicals or materials. Such items can be harmful if they are improp-
erly used, stored, mixed transported, if they are inhaled, swallowed or allowed to contact the skin.
• Consult your employer’s hazard communications plan for instructions regarding the proper handling and
use of hazardous materials. Read and understand the labels attached to the product containers. Always
follow the instructions carefully.
• Consult the manufacturer’s material safety data sheet (MSDS) for potential hazards and appropriate
medical procedures should an accident occur.
• Store hazardous materials only in approved containers. Be sure containers are clearly labeled.
• To avoid potential health hazards, persons in regular contact with hydraulic oils must be aware of the
importance of thorough hygiene, and the proper methods for handling mineral oils.
• Mineral-based hydraulic oils act as solvents on the natural oils of the skin. Frequent and prolonged skin
contact can cause dermatitis or severe irritation.
• Always wear suitable protective clothing when handling hydraulic oil.
• Be sure protective clothing and proper wash-up facilities are available to all personnel that may come
in contact with mineral-based hydraulic oils.
• Always dispose of used rags or paper towels in the correct and safe fashion.
Disposal Of Excess Fuels, Lubricants And Liquids

Quarry personnel are responsible for the proper disposal of unused fuels, used lubricating oils, used hydraulic
oils, and other toxic materials. DO NOT dispose of these materials in an unapproved manner. Follow all appli-
cable federal, state and local regulations.
• Store flammable liquids in a safe place, away from quarry machinery and personnel. Use approved
safety containers and be sure that they are clearly marked. Containers must be covered when not in
use.
• Keep flammable liquids away from sparks, open flame, and other ignition sources. Do not smoke around
flammable liquids. Always obey posted “no smoking” signs.
• Be familiar with the locations of fire extinguishers throughout the quarry. Be sure they remain accessible
at all times, and are not blocked by obstructions.
• Do not use gasoline or other flammable liquids to clean tools or parts. Use only approved non-flam-
mable solvents.
• Always shut-off engines before refueling. Ground fuel spout against the filler neck to prevent static elec-
tricity. Never smoke while refueling.
• Use only approved safety containers for storing and transporting small quantities of flammable liquids.
Keep containers covered when not in use.
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WELDING CONSIDERATIONS
Welding Considerations
Whenever welding on or around heavy machinery, care must be taken to place the welding ground clamp as
close to the weld as possible. Special care is required to avoid placing bearings, hydraulic cylinders and/or
electronic components between the weld and the ground clamp. Attach the ground clamp to clean dry base
metal only. Whenever possible, the base metal should be freshly ground and the ground clamp should have
clean, dry contact surfaces, free of debris, corrosion, etc., firmly connected to the workpiece.
The minimum precaution for protecting electronic equipment on MILO equipped Kodiak+ crushers begins
with de-energizing the HPU power supply at the source. Follow all local lockout/tagout regulations.
Secondly, any potential current pathways between sensors and other external electronic components and the
HPU should be interrupted by disconnecting all of the cables and harnesses that connect to the bottom of the
electrical enclosure on the HPU. There are several cables and harnesses that have threaded or locking
connectors. All are located on the bottom of the electrical enclosure. Disconnect the cable that connects the
HPU to the remote control. This may be on the bottom or on the side of the electrical enclosure. These should
all be disconnected. These connections are all 24VDC connections and do NOT require opening the HPU
electrical enclosure.
Heater cables and other conductors that are connected to screw terminals inside the electrical enclosure do
NOT require disconnecting.
There are sensors mounted on the crusher that can be damaged by electrical fields commonly generated by
welding. JCI recommends that these sensors be removed when welding on the crusher or its support
structure. Most of the sensors are mounted on the upper assembly. Generally speaking there is some
welding associated with any liner change, but the upper assembly is removed during this operation so the
removal of those sensors is automatically accomplished. But there is frequently welding on or near the
crusher during installation of the crusher, and protecting these sensors could be easily overlooked. Therefore
during crusher installation be aware of these sensors and take appropriate precautions.
Follow the minimum recommended precautions whenever welding on the crusher or its support structure. If
welding near any sensors extra care is required. Removal of the sensor(s) is always 100% effective protec-
tion.

General Precautions
lifted.
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Wire Rope

Chains
ranges.
lifting hooks.
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BOWL SUPPORT THREAD REMOVAL PROCEDURE
Bowl Support Thread Removal Procedure

• Feeler gauge
• Hydraulic rams
• Hammer
• Straight edge
• Pry bar
• File
• Torch
• Grinder

4. Remove bowl assembly.
5. Remove bowl clamp assembly, if desired.
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BOWL SUPPORT THREAD REMOVAL PROCEDURE
6. Use a grinder and remove the thread stop that is closest to the thread that needs to be changed.
WARNING: The bowl support assembly is extremely heavy. Use a lifting device and
rigging rated for the weight of the bowl support. Do not reach under the bowl support
as it is being raised from the crusher. Do not allow anyone under or near the bowl
support as it is being lifted. Serious injury or death could occur if the lift failed and a
person was under the bowl support.
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BOWL SUPPORT THREAD INSTALLATION PROCEDURE
7. Remove the threads as needed.
RELATED LINKS:
Bowl Support Thread Installation Procedure

• Feeler gauge
• Hydraulic rams
• Hammer
• Straight edge
• Pry bar
• File
• Torch
• Grinder
1. Clean and remove any burrs from the bowl support as needed.
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2. If replacing one of the top or bottom threads, use a straight edge to locate the starting point of the thread.
The starting point of the threads is where the top edge of the brass insert is slightly below that of the
horizontal surface of the bowl support.
3. Remove any burrs from the end of the brass threads.
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4. Position the bowl support thread.
WARNING: When removing the threads, watch your fingers. The threads, by design,
are bigger than the bowl support. As you remove the thread it can spring back against
you.
5. Place thread in desired location. A pry bar may be used to assist the installation of the thread.
6. Make sure the brass threads are pressed up next to each other.
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7. Weld in temporary bottom wedge stop.
8. Install hydraulic ram.
9. Weld in a temporary wedge stop on top and install hydraulic ram.
10. Set pressure of hydraulic ram to 3000 psi this will help spread and seat the threads.
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11. Use a hammer to help seat the brass threads into the grooves of the bowl support.
12. Once the threads are seated, check for gaps with a ten-thousandths feeler gage. If there are gaps,
continue seating the threads and adjusting ram pressure to 3000 psi.
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13. When there are no gaps, weld in the top and bottom thread stops.
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14. Remove the wedge stops.
15. Clean up the welds and threads.
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BOWL CLAMP THREAD REMOVAL PROCEDURE
Bowl Clamp Thread Removal Procedure

• Feeler gauge
• Hydraulic rams
• Hammer
• Straight edge
• File
• Welder
• Grinder
• Lifting device rated for the bowl clamp assembly

3. Remove upper assembly.
4. Remove bowl assembly.
5. Remove bowl clamp assembly, if desired.
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6. Use a grinder and remove the thread stop.
are bigger than the bowl clamp. As you remove the thread it can spring back against
you.
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7. Remove the threads as needed.
RELATED LINKS:
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BOWL CLAMP THREAD INSTALLATION PROCEDURE
Bowl Clamp Thread Installation Procedure

• Feeler gauge
• Hydraulic rams
• Hammer
• Straight edge
• File
• Welder
• Grinder
• Lifting device rated for the bowl clamp assembly
1. Clean and remove any burrs from the bowl clamp.
2. Use a straight edge to locate the starting point of the thread. The starting point of the thread is where
the top edge of the brass insert is slightly below that of the horizontal surface of the bowl clamp.
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3. Remove any burrs from the end of the brass threads.
4. Position the bowl clamp thread.
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are bigger than the bowl clamp. As you remove the thread it can spring back against
you.
5. Use a pry bar to assist the installation of the thread.
6. Make sure the brass threads are pressed up next to each other.
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7. Weld in the bottom thread stop if removed.
8. Weld in a temporary wedge stop for hydraulic ram to push off.
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9. Install the hydraulic ram and set pressure to 3000 psi; this will seat the threads.
10. Use a hammer to help seat the brass threads into the grooves of the bowl clamp.
11. Once the threads are seated, check for gaps with a ten-thousandths feeler gage. If there are gaps,
continue seating the threads and adjusting ram pressure to 3000 psi.
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12. When there are no gaps, weld in the top thread stop.
13. Remove the wedge stop.
14. Clean up the welds and threads.
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BOWL CLAMP PISTON SEAL REMOVAL PROCEDURE
Bowl Clamp Piston Seal Removal Procedure

• Lifting eye (JCI p/n 090933) 1-8 UNC x 1x2 1/2
• Lifting device rated for the bowl clamp
• Air nozzle
• Lubriplate No 105 grease
• Dead blow mallet
• 4 clamps

3. Remove upper assembly.
4. Remove the bowl assembly.
5. Remove the hydraulic line to the bowl clamp.
6. Attach the hoist to the bowl clamp.
7. Remove the hose.
8. Remove the bowl clamp assembly.
WARNING: The bowl clamp assembly is extremely heavy. Use a lifting device and
rigging rated for the weight of the hopper. Do not reach under the hopper as it is being
raised from the crusher. Do not allow anyone under or near the bowl clamp as it is
being lifted. Serious injury or death could occur if the lift failed and a person was under
the hopper.
9. Remove the drive ring seal components.
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BOWL CLAMP PISTON SEAL REMOVAL PROCEDURE
10. Remove the bowl position proximity sensor and bracket.

11. Use a strap to turn the bowl clamp over.
12. Remove the hydraulic fitting.
13. Use air pressure and apply it to the bowl clamp; this will push out the white rod and piston seal.
14. Once air pressure is applied the piston seal and the white rod will blow out in one place, from this point
it can be pried out.
NOTE: Use only a blunt instrument to work the white rod and piston seal out of the bowl clamp.
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BOWL CLAMP PISTON SEAL INSTALLATION PROCEDURE
15. Remove the piston seal.

16. Clean the groove in the bowl clamp.
RELATED LINKS:
Bowl Clamp Piston Seal Installation Procedure

• Lifting eye (JCI p/n 090933) 1-8 UNC x 1x2 1/2
• Air nozzle
• Lubriplate No 105 grease
• Dead blow mallet
• 4 clamps
1. Make sure the piston seal groove is clean.
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2. Apply lubricant no. 105 to both sides of the groove.
3. Clean the piston seal.

4. Position the piston seal on the bowl clamp with the o-ring down.
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5. Use a clamp to start the piston seal into the groove.
NOTE: When installing the seal, it will want to twist; make sure the seal is vertical when installing it into the
groove.
6. Continue installing the piston seal in several places around the bowl clamp.
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7. Once the piston seal is started in several places, use a mallet to seat the seal all the way around in the
groove.
8. Use a non-metallic dowel to tap down and seat the seal in the bottom of the groove.
NOTE: A small piece of the white rod is the ideal tool to install the seal.
9. Install the plastic rods.
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10. Due to the curve of the bowl clamp, slight trimming of the plastic rods may be necessary to make sure
there is no gap between the rod ends.
11. Tap each piece to make sure there is no gap between the rods.
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12. When installing the last rod, cut it 1/8 inch (3 mm) too long.
13. For the last rod, install both ends of the rod and then tap the middle of the rod down. This will make sure
the rods are a tight fit.
NOTE: Use only a blunt instrument to work the white rod and piston seal out of the bowl clamp.
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14. Make sure the plastic rods are tapped all the way down against the piston seal.
15. Turn the bowl clamp over and install the hydraulic fitting.
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CONE LIFTING EYE AND CONE LIFTING EYE ASSEMBLY
Cone Lifting Eye and Cone Lifting Eye Assembly

This section provides instructions for using the two different cone lifting eyes. Each is used for a different lifting
application. For quick identification, note that one of the lifting eyes is one piece and the other is a two-piece
assembly.The cone lifting eyes are designed specifically for lifting certain cone assemblies made by JCI. The
load rating shown on the lifting eye should be sufficient for lifting any JCI cone assembly that has a thread
matching that particular lifting eye. Nonetheless, if you are unsure of the weight of a particular cone assembly,
it is imperative that you verify that the weight of the cone assembly to be lifted is within the load rating specified
on the lifting eye.
WARNING: If the cone becomes hung up during the removal or installation and it is
necessary to dislodge the cone by lifting with the crane, then it is assumed the
capacity of the lifting eye has been exceeded and the lifting eye must be visually and
magnaflux inspected.
Cone Lifting Eye (one-piece)
WARNING: Offset lifting eyes are not allowed for turning the cone assembly or
subcomponents over. Injury or death may result from improper use of this device.
The one-piece, cone lifting eye is for straight up and down loading only. For installation, with the mantle bolt
cap installed, screw the lifting eye into the top of the cone as far as it will go.
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The part numbers for the cone lifting eye:
CONE LIFTING EYE (ONE-PIECE)
K200+/K300+ 456531
K400+ 546849
Cone Lifting Eye Assembly (two-piece)

The two-piece cone lifting eye assembly is for lifting and turning the cone over when the mantle bolt cap has
been removed.
The part numbers for the cone lifting eye assembly:
CONE LIFTING EYE ASSEMBLY (TWO-PIECE)
K200+/K300+ 456532
K400+ 546852
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Cone Lifting Eye Assembly Installation Procedure
1. Remove the one-piece lifting eye.
2. Remove the mantle bolt cap.
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3. Apply anti-seize and install the base of the cone lifting eye assembly and tighten to refusal.
4. Apply anti-seize and install the lifting eye weldment and torque the four bolts to 80 ft/lbs (108 N-m).
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CONE REMOVAL PROCEDURE
Cone Removal Procedure

• Cone lifting eye
• Sila Tech Silicone Sealant
• Torch
• Lifting device rated for the cone assembly

3. Remove hopper assembly.
5. Remove the bolt that holds the mantle bolt cap.
6. Visually inspect the lifting eye prior to every use. Remove the lifting eye from service if there is any
evidence of bending or permanent deformation and/or cracks are found.
WARNING: Do not turn the cone assembly over for disassembly with the one-piece
cone lifting eye.
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CONE REMOVAL PROCEDURE
7. Install the lifting eye all the way into the cone.
8. Verify the cone turns freely and rotate the cone so the lifting eyes on the cone are aligned with the “high
side” of the wedgeplate.
NOTE: If in doubt about the correct orientation, be sure to have someone familiar with this process verify that
you have both the cone and the lifting eye properly oriented.
9. Align the offset hole in the lifting eye toward the “high side” of the wedgeplate (The side of the cone that
is closest to the tub).
WARNING: The cone is extremely heavy and will cause serious injury or death if not
handled properly. Use appropriately rated lifting devices and tools when moving heavy
items. Keep all bystanders away from the lifting area. Never place any part of your
body under the item being hoisted.
10. Attach hoist.

11. Make sure the hoist is directly over the cone.
CAUTION: The upper thrust bearing upper race and floating plate my stick to the
bottom of the cone. Use caution as it typically drops off a few moments after the cone
assembly is lifted.
12. Slowly raise the cone about an inch and stop while moving the cone side to side to prevent the bearings
from binding.
13. Verify the upper thrust bearing upper race is free of the cone and in place on top of the bearings.
14. Lift the cone assembly free of the wedgeplate and hold suspended above the wedgeplate while you
verify if the floating plate is stuck to the cone.
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CONE INSTALLATION PROCEDURE
CAUTION: Do not reach underneath the cone assembly to dislodge the floating plate if
it is stuck. Do not attempt to remove but use caution when lifting and moving as it
could drop off. Keep all personnel away from the cone assembly.
15. Attach a guide line if needed to assist in moving the cone.

16. Place the cone assembly on suitable blocking.
RELATED LINKS:
Cone Lifting Eye Assembly Installation Procedure
Cone Installation Procedure

• Cone lifting eye
• Sila Tech Silicone Sealant
• Torch
• Lifting device rated for the cone assembly
1. Verify the offset hole in the lifting eye is aligned with the two cast lifting ears on the cone.
2. Affix a tag line to the lifting ear to help guide the cone if desired.
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3. Align the floating plate so the slot is aligned with the lifting eye.
WARNING: The cone is extremely heavy and will cause serious injury or death if not
handled properly. Use appropriately rated lifting devices and tools when moving heavy
items. Keep all bystanders away from the lifting area. Never place any part of your
body under the item being hoisted.
4. Lift the cone and align with the wedgeplate over the crusher.
CAUTION: Prior to lowering the cone, make sure the cone stem is centered directly
over the bore of the wedgeplate and the offset lifting hole on the lifting eye is oriented
toward the “high side” of the wedgeplate.
5. As the cone is lowered, rotate the cone back and forth to avoid binding and damaging the bearing.
NOTE: If the wedgeplate becomes slightly misaligned, the cone may tip one side. If this happens, raise the
cone slightly, adjust the crane position, and slowly lower the cone.
WARNING: Do not reach into the gap between the seal rings.
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6. As the cone nears the bottom (2 in/5 cm) make sure the torque bar will engage the slot of the floating
plate.
7. Lower the cone until it is in place.
8. Verify the torque bar and floating plate are aligned by turning the cone clockwise slightly. If the cone is
installed correctly it should turn easily. If not, lift slightly, realign, and lower until the cone turns easily.
NOTE: On older crushers with a friction cone brake the cone may turn the cone may turn both ways easily.
9. Remove Hoist.
10. Remove the cone lifting eye.
11. Install the bolt to the mantle bolt cap and tighten until refusal.
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TIR RELIEF CYLINDER REMOVAL PROCEDURE
12. Fill in the recess of the mantle bolt cap with Sila Tech Silicone sealant (or equivalent).
TIR Relief Cylinder Removal Procedure

• Clean rags
• Leather gloves
• Wrench set
• Lifting device rated for the TIR cylinder
• Parker Super Lube (for o-ring lubrication)
WARNING: The following instructions show how to replace components that require
working around energized electrical and hydraulic circuits. Follow all local safety
regulations with respect to working around electrical hydraulic equipment. Familiarize
yourself with how these circuits operate before working on them. Never disconnect
any hose until you are certain that it is de-pressurized. Serious injury or death can
occur from exposure to high pressure oil.
1. Energize the HPU and press CLEAR until all the TIR cylinders begin to extend. Release the CLEAR
button before the upper assembly begins to move.
2. As soon as all the TIR cylinder rods are in contact with the underside of the bowl support, press ESTOP
to de-energize the HPU and hold the TIR cylinder rods in their partially extended position.
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5. Remove the keeper from the TIR cylinder rod that will be removed.
6. Remove the two-piece split collar from the TIR cylinder rod end. It may be necessary to use a small pry
bar to extend the TIR cylinder rod just enough to remove the split collar, but if the TIR hydraulic circuit
was de-energized as described earlier, the cylinder should extend easily.
7. Remove the spherical washer from the TIR cylinder.
8. Energize the HPU and engage the hydraulics until the TIR cylinder rod end retracts.
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9. Remove the bolt that holds the TIR clevis pin.
10. Clean the area around the TIR cylinder where the hydraulic lines connect to the cylinder.
11. Remove the four hydraulic hoses from the TIR cylinder, two on each side. Install caps and plugs on the
cylinder and the hydraulic lines to prevent contamination.
12. Attach a lifting device, take up slack and remove the clevis pin.
13. Guide the rod end out of the upper assembly and remove the TIR cylinder.
RELATED LINKS:
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TIR RELIEF CYLINDER INSTALLATION PROCEDURE
TIR Relief Cylinder Installation Procedure

• Clean rags
• Leather gloves
• Wrench set
• Lifting device rated for the TIR cylinder
• Parker Super Lube (for o-ring lubrication)
any hose until you are certain that it is de-pressurized. Serious injury or death can
1. Attach a lifting device and align the TIR cylinder with the crusher.
NOTE: Make sure the rod end is aligned with the hole in the upper support assembly.
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2. Install the clevis pin.
3. Align the tab with the hole and install the bolt.
4. Remove caps and apply o-ring lube to the fittings on the TIR cylinder.
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5. Remove the plugs from the hydraulic lines and install to the TIR cylinder.
6. Energize the HPU and press CLEAR until all the TIR cylinders are fully extended. Release the CLEAR
button until the TIR system is pressurized again. Repeat this process three or four times.
NOTE: This process will purge the air out of the hydraulic system and refill the installed cylinder with hydraulic
fluid.
7. Once all the air is purged out of the hydraulic system, press CLEAR until the TIR rod end is above the
upper assembly.
8. Install the spherical washer.
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REPLACING V-SEAT LINERS
9. Install the split collar.
10. Install the keeper.
11. Energize the HPU and contract the TIR cylinder.
Replacing V-Seat Liners

Kodiak plus crushers are equipped with bronze V-seat liners that reduce the probability of damage to the
baseframe and bowl support in the event of bowl float. The material used is UNS C61400 Aluminum Bronze
x 0.250” (6.4mm) thick.The liners are field replaceable. They are installed in groups of 4 and should be
replaced as a group. Replacing individual sections is not recommended. Three methods for welding the
replacement liners are described. JCI has subjected all three methods to tensile testing and found that they
are generally equivalent in terms of weld soundness when correctly implemented.
Method 1:
When bronze V-seat liners are installed at the factory they are attached using Aufhauser Aluminum Bronze
A2 solid wire x 0.045” diameter and 100% Argon shielding gas at 30-40 cu.ft/min at 23-26V and 275-350
in/min wire speed. Generally, the baseframe has been indoors long enough that little or no preheat is neces-
sary to drive out any moisture. When this option is available it is by far the easiest and fastest method.
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REPLACING V-SEAT LINERS
Method 2:
Generally wire welding will not be an option for field repairs. One method that can be used to make the field
welding a little easier is to apply Inconel (a nickel alloy) to the edges of the liner where it will be attached to
the V-seat. Liners prepped in this fashion can be field welded using E7018 stick electrodes. The prep work
can be done ahead of time with stick, wire or TIG, although TIG is the preferred process. Customers inter-
ested in this option should contact the factory for more detailed instructions.
Method 3:
Welding with stick electrodes is the most readily available process for most field service trucks. Welding with
non-ferrous electrodes will be a new experience for some and practicing on some scrap is recommended if
possible.Choice of electrode will be limited to availability of local welding supply sources. The electrode used
successfully by JCI is Bohler Thyssen UTP 34N aluminum bronze x 1/8” [3.2mm] diameter. This is a DC+
electrode requiring 70-80A. (AWS A5.6: ECuMnNiAl). For more information on this electrode contact: Bohler
Thyssen Welding USA inc.Houston Texas 281 499 1212
Setup:
When replacing liners, it is important to thoroughly remove all traces of the previous liner and the welds to
create a smooth bump-free surface. Take a moment and mark the vertical position of the liner on the V-seat
to reduce layout time when installing the replacement. Note the spacing between the liners and attempt to
maintain similar spacing between the replacements. The vertical position varies somewhat by model. Try to
reposition at the same height as before. The space between the liners will tend to be between 0.56”[14mm]
and 0.63”[16mm].
Preheat considerations:
The welding surfaces should be preheated to drive out any moisture. (The exact temperature is not critical.)
If the baseframe and liners have been indoors for a substantial period of time, little or no preheat will be
required. Warm up as much of the V-seat as practical and then preheat the weld area for the next liner
between 150-300F[66C-132C]. Warm up the V-seat liner prior to clamping in place. Clamp firmly to draw the
entire surface into tight contact with the V-seat. Work from one end to the other to work out any bulges. After
tack welding in place, do not apply heat directly to the liner or it can tend to bulge between the clamps/tack
welds. Once warmed up and tacked in place, weld each liner right away before moving on to the next.
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V-SEAT LINER REMOVAL PROCEDURE
V-Seat Liner Removal Procedure

4. Prior to removing the old V-seat liners, mark the location of each liner on both ends. This can help locate
the new liner.
5. Grind off all the welds from the V-seat liners. Make sure to support the V-seat when grinding the last
weld.
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V-SEAT LINER REMOVAL PROCEDURE
NOTE: Depending on your model of crusher there may be more welds that need to be ground off to remove
the V-seat.
6. Once all welds are ground off, remove the V-seat liner.
7. Throughly remove all traces of the previous liner and welds and clean to create a smooth bump-free
surface.
RELATED LINKS:
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V-SEAT LINER INSTALLATION PROCEDURE
V-Seat Liner Installation Procedure
1. Make sure all traces of the previous liner and welds have been removed to create a smooth and
bump-free surface.
NOTE: The welding surfaces should be preheated to drive out any moisture. The exact temperature is not
critical. If the base frame and liners have been indoors for a period of time little or no preheat is needed.
2. Preheat the weld area 150-300°F (66°C-132°C).
3. Warm the V-seat liner prior to clamping in place.
4. Locate the top edge of the V-seat 3/4 inch from top edge of base frame.
5. Clamp the V-seat firmly to the baseframe, make sure it is in tight contact with the baseframe.
NOTE: Use one of the welding methods described in the introduction. Do not apply heat directly to the liner
as it can bulge between the clamps or tack welds. Do not weld the lower edge of the liner. Work on one liner
at a time.
6. When welding the V-seat liner, work from one end to the other to prevent any bulging.
7. Tack weld V-seat liner in place. Tack liner where the welds will be placed.
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PINION ASSEMBLY REMOVAL PROCEDURE
1 1” (2.5cm)
2 2” (5cm), 3 places
3 18” (46cm), 2 places
4 1” (2.5cm)
5 Weld completely around hole, 3 places
6 Do not weld bottom edge
8. Weld the V-seat liner as shown in the diagram above.
Pinion Assembly Removal Procedure

• Leather gloves
• Clean rags
• Bucket
• Socket set
• Lifting device rated for pinion assembly
• Impact wrench
• Air source

3. Remove any rocks and debris from around the crusher pinion assembly.
4. Remove belt guard.
5. Remove belt.
NOTE: The Kodiak+ models have an external oil reservoir. When draining the oil you will collect about 1/2
gallon of oil.
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6. Drain crusher oil into a clean bucket.
NOTE: Provide yourself 30 to 36 inches minimum to remove the pinion assembly.

NOTE: If possible, leave sheave on pinion assembly. This will help balance the assembly. If sheave is
removed from the pinion assembly, it will be extremely gear heavy.
7. Remove the bolts attaching pinion assembly to the crusher.
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8. Remove the two set screws and install pusher bolts to the flange of the pinion assembly.
9. Tighten the pusher bolts evenly to “push” the pinion assembly apart from the crusher body enough to
remove the shims.
NOTE: When removing the shims take not of the placement they must be replaced the way they were
removed.
10. Remove the shims and place to be installed later.
11. Remove pinion assembly enough to install a lifting device.
12. Attach hoist.
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NOTE: The sheave can be left installed to help balance the pinion assembly when being removed. If the
sheave is removed install a section of pipe over the pinion shaft to help balance the assembly as it is being
removed.
WARNING: The pinion housing assembly is heavy. Use appropriately rated hoist when
lifting and proper lifting techniques.
WARNING: Be careful when removing the pinion assembly, depending on

configuration the assembly will be unbalanced when removed. Remove slowly so you
can keep pinion assembly under control.
13. Slowly remove the pinion assembly, keeping it balanced to prevent damage to gears and tunnel.
NOTE: There are two holes on the pinion housing, the larger of the two is the oil inlet which should be put at
the 12 o’clock position when installed.
14. Make sure the oil inlet hole is at the 12 o’clock position Mark an “X” on top of the pinion flange. This will
help with alignment when reinstalling.
RELATED LINKS:
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PINION ASSEMBLY INSTALLATION PROCEDURE
Pinion Assembly Installation Procedure

• Leather gloves
• Clean rags
• Socket set
• Lifting device rated for pinion assembly
• Impact wrench
• Air source
NOTE: There are two holes on the pinion housing, the larger of the two is the oil inlet which should be put at
the 12 o’clock position when installed.
1. You should have marked an “X” on the top of the pinion housing flange indicating the oil inlet hole is at
the 12 o’clock position when the pinion assembly was removed. If not, do so now.
2. Make sure the pinion tunnel on the lower assembly is clean and use emery cloth to burnish any nicks,
dings and burrs.
3. Apply anti seize to the bores.
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PINION ASSEMBLY INSTALLATION PROCEDURE
4. Install the pinion assembly into the lower assembly.
5. A long pipe can be used to balance the pinion when installing.
6. Install the shims that were previously used.

7. Once installed set the pinion measurement as defined in the table. The measurement is from the end
of the pinion to the vertical edge of the dam truss on the lower assembly.
NOTE: The below measurement is a general measurement. The pinion assembly will be adjusted during the
setting of the backlash when installing the wedgeplate.
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BACKLASH SETTING PROCEDURE
K200+ 7.7 / 19cm
K300+ 7.7in / 19cm
K400+ 9.2in / 23cm
K500+ 11.in / 28cm
8. Set backlash.
RELATED LINKS:
Backlash Setting Procedure
Backlash Setting Procedure

• Adjustable wrench
• Two (2) dial calipers
• Pinion shaft tool
NOTE: The backlash is determined by the manufacturer when the gears are made. This measurement can
be found engraved on the back of the pinion gear as shown in the figure below (B/L 0.025).
NOTE: Setting the backlash between the pinion gear and the ring gear determines the gear teeth pattern
which is important in the way the gears wear over time.
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1 Indicates travel of pinion assembly in or out.
2 Pinion assembly adjustment bolt in.
3 Indicates clearance between pinion and ring gear teeth.
4 Pinion assembly adjustment bolt out.
1. Install the dial caliper (3) X.XX inches from the edge of the shaft as shown above. See chart below.
DISTANCE FROM OD SHAFT TO

CRUSHER PITCH RADIUS PITCH RADIUS
K200+ 4.17 2.7 in (6.8 cm)
K300+ 4.17 2.42 in (6.1 cm)
K400+ 5.4 3.15 in (8 cm)
K500+
2. Gently rotate pinion shaft back and forth to determine the current backlash measurement on dial (3).
Record the measurement.
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3. If measurement is greater, turn the adjustment bolt (2) clockwise; this will draw the pinion assembly in.
4. Check the measurement and adjust until the desired measurement is met.
5. If the reading is less than desired, turn the adjustment bolt (2) counterclockwise to loosen.
6. Turn the adjustment bolt (4) clockwise; this will draw the pinion assembly out.
7. Check the measurement and adjust until the desired measurement is met.
8. Once the measurement is met snug down both adjustment bolts (2) and (4) to lock pinion assembly in
place.
9. Remove dial indicators.
10. Turn the pinion shaft back and forth several times, this will transfer the pinion gear markings to the ring
gear on the wedgeplate.
11. Remove the thrust plate.
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12. Lift the wedgeplate and inspect the pinion gear teeth pattern on the ring gear.
NOTE: The marks on the above photo indicate good alignment of the pinion gear and ring gear.
13. Install wedgeplate.
14. Apply anti-seize to thrust plate bolts and install thrust plate and torque to 520 ft lb./705 Nm.
15. Measure gap between pinion assembly and crusher to determine correct shims.
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16. Install shims and bolts.
17. Spray crusher oil on top of thrust plate and brake shaft.
18. Install the cone brake plate bar.
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19. Apply crusher oil to the top of the cone brake plate.
NOTE: For ease of installation of the cone note the orientation of the groove in the floating plate. This will aid
in alignment of the torque bar on the cone.
20. Install the floating plate and slide it back and forth to make sure there is no grinding or binding.
21. Cover and protect from contamination until you are ready to install the cone.
22. If you are installing the cone, see the cone installation section of this manual.
RELATED LINKS:
Pinion Assembly Installation Procedure
Cone Installation Procedure
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SETTING GAP BETWEEN THRUSTPLATE AND WEDGEPLATE PROCEDURE
Setting Gap Between Thrustplate and Wedgeplate Procedure

NOTE: The purpose of the gap is to make sure the thrustplate does not contact the wedgeplate and it allows
for the correct amount of oil for lubrication.
1. Install magnetic dial indicator on the inside surface of the outer radial bearing race.
2. Position dial indicator on thrust plate surface and set to zero.
3. Gently lift the wedgeplate up until it contacts the thrust plate to measure the clearance between the
wedge plate and thrust plate. The desired measurement should be between 0.025 to 0.035 thou-
sandths.
1 .025 to .035
2 Thrustplate
3 .025 to .035
4 Wedgeplate
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SETTING GAP BETWEEN THRUSTPLATE AND WEDGEPLATE PROCEDURE
4. If 0.025 to 0.035 thousandths measurement is not met the thrust plate needs to be machined.
1 Thrustplate
2 Wedgeplate
3 To increase gap, machine here
4 .025 to .035
5 To decrease gap, machine here
5. Once the 0.025 to 0.035 thousandths is met, record measurement.
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PIN CLUTCH REMOVAL PROCEDURE
Pin Clutch Removal Procedure

• Clean rags
• Socket set
• Pry bar
• Bucket
• Sealant

2. Lockout/tagout the crusher and power supply. Follow all local procedures and guidelines.
3. Clean the area under and around the brake housing cover in preparation for removing the clutch.
4. Place a bucket under the brake housing cover drain plug and remove the drain plug.
5. Allow the oil to drain and remove some of the bolts to the brake housing cover.
NOTE: When some of the bolts are removed it is a good idea to install a bolt that is longer than those being
removed. This will allow the access plate to be kept up off the ground and rotated out of the way.
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6. Use the set screws to separate the brake housing cover from the bottom of the crusher and remove the
rest of the bolts.
7. Rotate the brake housing cover out of the way.
WARNING: When removing the bolts to the guide ring it is possible for the guide ring,
clutch and cone brake shaft to fall from the crusher, Support the guide ring as you
remove the last bolt. Do not allow anyone directly under the guide ring assembly.
Serious injury could occur if these items fall.
8. Remove the allen bolts that attach the guide ring. Support the guide ring when removing the last bolt to
prevent it from falling.
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1 Guide Ring
2 Shear Bolts
9. Remove the guide ring, clutch and cone brake shaft.
RELATED LINKS:
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PIN CLUTCH INSTALLATION PROCEDURE
Pin Clutch Installation Procedure

• Clean rags
• Socket set
• Pry bar
• Bucket
• Sealant
1. Make sure the area in the spindle where the clutch will be mounted is clean and free of debris.
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2. Place the clutch onto guide ring.
3. Install shear bolts to attach clutch assembly to guide ring.

4. Install the cone brake shaft into the cone. Make sure the key aligns with the cone brake plate.
NOTE: Depending on the work being performed, the cone brake shaft can be installed from the topside if the
cone is removed.
5. Install the guide ring and clutch assembly so it aligns to the cone brake shaft.
6. Install the guide ring to the crusher with the four Allen bolts (no anti-seize).
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7. Tighten the four bolts.
1 Guide Ring
2 Shear Bolts
8. Apply a bead of sealant to the bottom of the crusher before installing the brake housing cover.
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9. Install brake housing cover.
10. Install drain plug to access panel.

11. Install all bolts and tighten.
12. Add lube oil.
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DRIVE RING SEAL INSTALLATION PROCEDURE
Drive Ring Seal Installation Procedure

• Anti-seize
• Socket set
1. Apply anti-seize to the bolts and install the drive ring seal upper retainer.
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DRIVE RING SEAL INSTALLATION PROCEDURE
2. Put the drive ring seal lower retainer in place around the bowl clamp assembly.
3. Lay out the drive ring seal rubber in place around the bowl clamp with the lower retainer.
NOTE: Make sure the rubber seals over lap.
4. Apply anti-seize to the bolts and install the drive ring seal lower retainer with the seal rubber.
NOTE: The rubber and lower retainer go under the upper retainer
5. Tighten until the lock washer flattens. If the bolts are over tightened: the upper will bulge and the lower
retainer will bend.
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HPU MOTOR REMOVAL PROCEDURE
HPU Motor Removal Procedure

• Wrench set
• Socket set
• Screw driver straight slot
• Lifting device rated for the HPU motor

3. Gain access to the electric motor in the crusher HPU by removing the bolts to the top of the hydraulic
panel unit. There are six bolts on each side, four on the front and three on the back.
4. Remove the cover to the electrical connections.
NOTE: Have a qualified electrician disconnect the wiring.
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5. Disconnect the wires.
6. Remove the cover to the pump adapter.
7. Measure the distance from the end of the coupler to the motor. This measurement will be used when
installing that half of the coupler on the new motor.
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8. Remove the four bolts to the pump adapter.
9. Remove the four bolts to the motor, two in front and two in back.
10. Separate the motor from the pump adapter.

NOTE: The objective is to not have to remove the hydraulic lines from the pump to limit the possibility of
contamination.
WARNING: The motor is 165lbs/75Kg. Use an appropriately rated hoist when

removing the motor.
11. Remove the motor from the hydraulic power unit.
RELATED LINKS:
HPU Pump Coupler Removal Procedure
Hydraulic Pump Removal Procedure
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HPU MOTOR INSTALLATION PROCEDURE
HPU Motor Installation Procedure

• Wrench set
• Socket set
• Lifting device rated for the HPU motor
1. Check the shaft of the new motor for burrs or rough edges if necessary.
2. Clean and install the key to the shaft of the motor.
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3. Install the coupler that was removed earlier from the old motor. Use the measurement from earlier and
tighten the set screw to the new shaft.
WARNING: The motor is 165lbs/75Kg. Use an appropriately rated hoist when

removing the motor.
4. Install the new motor into hydraulic power unit, align the coupler halves and put the motor in place
bringing the coupler together.
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5. Install the four bolts to the motor, two in front and two in back.
6. Install pump adapter onto the motor with the four bolts.
7. Install pump adapter cover.
NOTE: Have a qualified electrician connect the wiring.
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8. Connect the wiring and install the motor cover.
9. Install the top of the hydraulic power unit.
RELATED LINKS:
Hydraulic Pump Installation Procedure
HPU Pump Coupler Installation Procedure
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HYDRAULIC PUMP REMOVAL PROCEDURE
Hydraulic Pump Removal Procedure

• Set Allen wrenches
• Socket set
• Clean rags
• Gloves
• Thread tape or thread sealant

3. Clean the area around the hydraulic pump.
5. Loosen the set screw on the coupler inside the hydraulic pump adapter.
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HYDRAULIC PUMP REMOVAL PROCEDURE
6. Remove the two hydraulic lines from the pump and plug. Install caps and plugs on the pump and lines.
7. Remove the two bolts to the hydraulic pump.
8. Remove the pump.

9. Clean any spilled hydraulic fluid.
RELATED LINKS:
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HYDRAULIC PUMP INSTALLATION PROCEDURE
Hydraulic Pump Installation Procedure

• Socket set
• Clean rags
• Gloves
NOTE: Thread tape or thread sealant can be used, but it is very important to prevent contamination of the
hydraulic system.
1. When installing the hydraulic pump make sure the shaft of the pump slides into the coupler and the key
on the shaft aligns with the set screw on the coupler.
2. Hold the pump in place and install the two bolts.
3. Remove the caps and plugs and install the hydraulic lines on the front and back of the pump.
NOTE: The set screw should align with the middle of the key on the hydraulic pump shaft.
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HPU PUMP COUPLER REMOVAL PROCEDURE
4. Tighten the set screw on the pump side of the coupler.
5. Replace the cover of the pump adapter with three screws.
HPU Pump Coupler Removal Procedure

• Wrench set
• Allen set
• Straight slot screw driver
• Clean rags

3. Clean the area around the hydraulic pump.
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5. Loosen the set screw on the coupler inside the hydraulic pump adapter.
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6. Remove the two hydraulic lines from the pump and plug. Install caps on the fittings of the pump.
7. Remove the two bolts to the hydraulic pump and remove the pump.
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8. Remove the pump adapter.
9. Before removing the coupler, measure the distance from the motor face to the edge of the coupler (as
shown below). This measurement will be used when installing the new coupler.
10. Loosen the set screw on the motor side of the coupler and remove the coupler.
11. Clean any spilled hydraulic fluid.
RELATED LINKS:
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HPU PUMP COUPLER INSTALLATION PROCEDURE
HPU Pump Coupler Installation Procedure

• Wrench set
• Allen set
• Straight slot screw driver
• Clean rags
1. Make sure motor shaft is clean and free from burrs.
2. Install new coupler onto the motor to the measurement taken earlier. Make sure the set screw will be in
the middle of the key when tightened.
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3. Install the pump adapter and make sure the coupler is not in contact with the adapter. Tighten the set
screw on the motor side of the coupler.
4. When installing the hydraulic pump make sure the shaft of the pump slides into the coupler and the key
on the shaft aligns with the set screw on the coupler.
5. Hold the pump in place and install the two bolts.
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6. Remove the caps and plugs and install the hydraulic lines on the front and back of the pump.
NOTE: The set screw should align with the middle of the key on the hydraulic pump shaft.
7. Tighten the set screw on the pump side of the coupler.
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HYDRAULIC MANIFOLD RELIEF VALVE REMOVAL PROCEDURE
8. Replace the cover of the pump adapter with three screws.
NOTE: When starting, it may be necessary to prime the pump.

Hydraulic Manifold Relief Valve Removal Procedure

• Clean rags
• Wrench
any hose until you are certain that it is depressurized. Serious injury or death can

3. Clean the area around the manifold valve and the relief valve.
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HYDRAULIC MANIFOLD RELIEF VALVE REMOVAL PROCEDURE
4. Remove the relief valve from the underside of the hydraulic manifold.
5. With the relief valve removed, inspect the relief valve opening for contamination.
6. Inspect the relief valve for contamination and general condition and wear of o-rings and washers.
Replace as necessary.
RELATED LINKS:
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HYDRAULIC MANIFOLD RELIEF VALVE INSTALLATION PROCEDURE
Hydraulic Manifold Relief Valve Installation Procedure

Tools and supplies
• Clean rags
• Wrench
1. Install the relief valve.
NOTE: If installing a new system relief valve, skip back to the procedure for setting the system pressure now.
2. Close needle valves NV1 and NV2.
3. Remove the lockout/tagout to the power.
4. Energize hydraulic power and verify pressure.
5. Check for leaks around the relief valve.
RELATED LINKS:
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HYDRAULIC MOTOR REMOVAL PROCEDURE
Hydraulic Motor Removal Procedure

• Clean Rags
• Lifting device rated for hydraulic motor and gearbox

3. Remove the quick disconnect hydraulic lines from hydraulic motor.
4. Remove the two bolts.
5. Remove the hydraulic motor.
RELATED LINKS:
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GEAR BOX REMOVAL PROCEDURE
Gear Box Removal Procedure

• Clean Rags

3. Remove the hydraulic motor.
4. Remove the gearbox guard.
5. Remove the drive gear guard.
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GEAR BOX REMOVAL PROCEDURE
6. Remove the proximity sensor element.
7. Disconnect the electrical and remove the J-box if needed.

8. Remove the drive gear and attach the lifting eye.
9. Remove the bolts that hold the adjustment plates. Do not remove the square adjustment bolts.
10. Remove the adjustment plate with the reduction gearbox from the motor base.
11. Remove the adjustment plate from the gear box.
RELATED LINKS:
Hydraulic Motor Removal Procedure
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HYDRAULIC MOTOR AND GEAR BOX INSTALLATION PROCEDURE
Hydraulic Motor and Gear Box Installation Procedure

• Feeler gauge
• Thread tape
• Pipe sealant
• Anti-seize
• Crusher Lube oil
• Mobil grease CM-S
• Set of allen wrenches
• Clean Rags
• Lubriplate No. 105 lubricant
1. Install the motor base.
2. Apply anti-seize and install the four motor mount base bolts.
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3. Install adjustment bolts.
4. Apply o-ring lube and install o-ring.
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5. Clean the gearbox and remove the plastic cap.
6. Install the hydraulic pump onto the gear box.
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7. Install the bolts and tighten.
8. Primer and paint the reduction gearbox and hydraulic motor if needed.
9. Once paint is dry, turn over and apply anti-seize to gear reducer flange.
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10. Install motor mounting plate.
11. Install the proximity sensor mount bracket.
12. Install the bolts and tighten down.
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13. Remove the gearbox oil fill plug.
14. Fill the gear box with 0.33 gallons of 629 lube oil or until it seeps out of the hole.
15. Apply thread seal tape and/or pipe sealant to the plug and install.
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16. Remove the pan head screw next to the grease fitting on the reduction gearbox.
17. Fill the grease box with Mobil Grease CM-S until grease begins to come out of the overflow hole.
18. Install pan head screw and clean fitting from extra grease.
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19. Install the gearbox assembly into the motor base.
20. Install the nuts and washers, two on each side. Do not tighten; this will be done after adjusting the
distance between the drive gear and driven gear.
21. Remove the plugs from the hydraulic motor.
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22. Install the fitting into M2.
23. Install the fitting into M1.
24. Install the hydraulic quick disconnect fittings.
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25. Install the drive gear.
26. Install the close side setting sensor.
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27. Install the drive gear guard.
28. Install the gearbox guard.
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HYDRAULIC PRESSURE TRANSDUCER REMOVAL PROCEDURE
Hydraulic Pressure Transducer Removal Procedure

3. Remove the electrical connector to the transducer.
4. Remove transducer from the hydraulic manifold.
RELATED LINKS:
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HYDRAULIC PRESSURE TRANSDUCER INSTALLATION PROCEDURE
Hydraulic Pressure Transducer Installation Procedure
1. Loosen the locknut on the pressure transducer sensor to allow adjustment of the swivel base.
NOTE: Do not separate the upper and lower sections of the pressure transducer. There is an o-ring between
the upper and lower sections. This will prevent the o-ring from dislodging and becoming contaminated.
2. Install the pressure transducer on to the hydraulic manifold.
3. Position transducer for ease of reading the display and tighten jam nut.
4. Install the electrical connector to the transducer.
5. Close the NV1 and NV2 needle valves.

6. Energize the hydraulic system.
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HYDRAULIC PRESSURE TRANSDUCER INSTALLATION PROCEDURE
1 Mode Button
2 Enter Button
3 Set Button
NOTE: Typically the display will default to the BAR setting on a new transducer. To change the display to PSI:
7. Press the “MODE” button until “UNI” is displayed.
8. Press the “SET” button until “PSI” is displayed.
9. Hold the “SET” button until “PSI stops flashing.
10. Use a small point such as the end of a paper clip to press the recessed enter button.
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LOW LUBRICATION OIL LEVEL SHUTOFF SWITCH REMOVAL PROCEDURE
Low Lubrication Oil Level Shutoff Switch Removal Procedure

• Clean rags
• Wrench set
• Six (6) clean five-gallon buckets

3. Remove the drain plug on the lube tank to drain the oil below the level of the low level shutoff switch. If
the lube oil is to be changed, completely drain the lube oil.
NOTE: When replacing the low level shutoff switch, this may be a good time to change the lube oil. If the lube
oil is clean and free from contamination the lube oil may be reused.
4. Locate the low level shutoff switch.
5. Disconnect the electrical connector.
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LOW LUBRICATION OIL LEVEL SHUTOFF SWITCH INSTALLATION PROCEDURE
6. Remove the low level shutoff switch.
7. Install the drain plug.

RELATED LINKS:
Low Lubrication Oil Level Shutoff Switch Installation Proce-

dure
• Clean rags
• Wrench set
1. Make sure the drain plug is installed; if not, install it.

NOTE: It is acceptable to use thread tape or thread sealant on the threads of the switch and drain plug.
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LOW LUBRICATION OIL LEVEL SHUTOFF SWITCH INSTALLATION PROCEDURE
2. Install the new lube low level shutoff switch. Make sure the switch is oriented correctly when tightened.
3. Connect the electrical plug.
4. Fill the lube oil tank with appropriate lube oil.

NOTE: If the lube oil is clean and free from contamination the lube oil may be reused.
5. Perform a leak check around the low level shutoff switch and drain plugs.
RELATED LINKS:
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LUBE COOLER BYPASS VALVE REMOVAL PROCEDURE
Lube Cooler Bypass Valve Removal Procedure

• Clean rags
• Wrench set

NOTE: When removing the bypass valve, make a note of the directions of the fittings on the bypass valve if
you are going to install the fittings on the new valve. Protect nearby equipment to prevent oil from dripping on
it.
3. Disconnect the oil inlet line and install a cap and plug on the line and valve.
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4. Disconnect the hose on the top right of the valve and install a cap and plug on the line and valve.
5. Disconnect the two (2) hoses from the bottom right of the valve and install caps and plugs on the valve
and lines.
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6. Remove the two (2) nuts and bolts securing the valve.

8. Take note of alignment of fittings if installing them on the new valve.
RELATED LINKS:
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LUBE COOLER BYPASS VALVE INSTALL PROCEDURE
Lube Cooler Bypass Valve Install Procedure

• Clean rags
• Wrench set
1. Position lube cooler bypass valve in place and install two (2) bolts and nuts.
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LUBE COOLER BYPASS VALVE INSTALL PROCEDURE
2. Remove the caps and plugs and connect the two (2) hoses to the bottom right of the valve.
3. Remove the cap and plug and connect the hose to the top right of the valve.
4. Remove the cap and plug and connect the oil inlet line to the valve.
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LUBE FLOW ENCODER REMOVAL PROCEDURE
Lube Flow Encoder Removal Procedure

• Clean rags
• Wrench set

3. Locate the lube flow encoder near the filter element on the back side of the lube pump.
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4. Remove the nut and plastic washer securing the flow encoder to the pump.
5. Remove the tie wrap and disconnect the electrical connector to the flow encoder.
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6. Loosen the Allen screw on the collar of the flow encoder.
7. Remove the flow encoder.
RELATED LINKS:
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LUBE FLOW ENCODER INSTALLATION PROCEDURE
Lube Flow Encoder Installation Procedure

• Clean rags
• Wrench set
1. Install the flow encoder.
2. Install the plastic washer and nut to secure the flow encoder.
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LUBE FLOW ENCODER INSTALLATION PROCEDURE
3. Tighten the Allen screw on the collar of the flow encoder.
4. Connect the electrical connector and tie wrap in place.
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LUBRICATION MOTOR REMOVAL PROCEDURE
Lubrication Motor Removal Procedure

• Wrench set
• Socket set
• Lifting device rated for the lube motor

3. Gain access to the electric motor on the crusher lube panel.
4. Remove the cover to the electrical connections.
NOTE: Have a qualified electrician disconnect the wiring.
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5. Disconnect the wires.
7. If possible measure the distance from the end of the coupler to the motor.
NOTE: This measurement will be used when installing the coupler on the new motor.
8. Loosen the Allen screws on the coupler.
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9. Remove the four bolts to the pump adapter.
10. Remove the four bolts to the motor base, two in front and two in back.
NOTE: The objective is to not have to remove the lines to the oil pump to limit the possibility of contamination.
11. Separate the motor from the pump adapter and pump/motor coupler.
WARNING: The motor is 165lbs/75kg. Use an appropriately rated hoist when

removing the motor.
12. Remove the motor from the lube panel.
RELATED LINKS:
Lube Pump Removal Procedure
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LUBRICATION MOTOR INSTALLATION PROCEDURE
Lubrication Motor Installation Procedure

• Wrench set
• Socket set
• Lifting device rated for the lube motor
1. Check the shaft of the new motor for burrs or rough edges if necessary.
2. Clean and install the key to the shaft of the motor.
3. Install the part of the coupler that was removed earlier from the old motor.
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WARNING: The motor is 165lbs/75kg. Use an appropriately rated hoist when

removing the motor.
4. Install the new motor into the lubrication panel, align the coupler halves and put the motor in place
bringing the coupler halves together.
NOTE: It may be necessary to adjust the coupler slightly, one way or the other, to prevent binding or rubbing
of the coupler on the motor or pump adapter.
NOTE: Make sure when installing the coupler the Allen screws line up over the middle of the key on the motor
shaft and the over middle of the key on the pump shaft.
5. When the coupler is in position, rotate the coupler to make sure it does not bind.
6. Tighten Allen screws.
7. Install the four bolts to the motor, two in front and two in back.
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8. Install pump adapter onto the motor with the four bolts.
9. Install pump adapter cover.
NOTE: Have a qualified electrician connect the wiring.

10. Connect the wiring and install the motor cover.
RELATED LINKS:
Lube Pump Installation Procedure
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LUBE PUMP REMOVAL PROCEDURE
Lube Pump Removal Procedure

• Socket set
• Clean rags
• Gloves

NOTE: It is very important to prevent contamination of the lube oil system.
3. Clean the area around the oil pump.
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LUBE PUMP REMOVAL PROCEDURE
5. Loosen the set screw to the oil pump on the coupler inside the oil pump adapter.
6. Remove the two oil lines from the pump and install caps and plugs on the pump and lines.
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LUBE PUMP INSTALLATION PROCEDURE
7. Remove the four bolts to the hydraulic pump.
8. Remove the pump.

9. Clean any spilled lube oil.
RELATED LINKS:
Lube Pump Installation Procedure

• Socket set
• Clean rags
• Gloves
NOTE: Thread tape or thread sealant can be used, but it is very important to prevent contamination of the lube
oil system.
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1. When installing the lube oil pump make sure the shaft of the pump slides into the coupler and the set
screw aligns with the middle of the key.
2. Hold the pump in place and install the four bolts.
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3. Remove the caps and plugs and install the oil lines on the front and back of the pump.
4. Tighten the set screw on the pump side of the coupler and rotate the coupler to make sure it does not
rub on the adapter.
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LUBE OIL HEATER REMOVAL PROCEDURE
5. Replace the cover of the pump adapter with two screws.
Lube Oil Heater Removal Procedure

• Clean rags
• Adjustable wrench to 4 1/2 plus (11.4cm plus)

3. Remove the drain plug on the lube tank to drain the oil below the level of the oil heater that is being
replaced. If the lube oil is to be changed, completely drain the lube oil.
NOTE: When replacing the lube oil heater, this may be a good time to change it. if the lube oil is clean and
free from contamination it may be reused.
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LUBE OIL HEATER REMOVAL PROCEDURE
4. Locate the lube oil heaters on the side of the lube panel.
5. Have a certified electrician disconnect the electrical connections to the heater.
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LUBE OIL HEATER INSTALLATION PROCEDURE
6. Remove the oil heater once oil level is below the oil heater opening.

RELATED LINKS:
Lube Oil Heater Installation Procedure

• Clean rags
• Adjustable wrench to 4 1/2 plus (11.4cm plus)

NOTE: It is acceptable to use thread tape or thread sealant on the threads of the drain plug.
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LUBE OIL HEATER INSTALLATION PROCEDURE
2. Install the new lube oil heater. When tightening, make sure the holes for the electrical connections are
level.
NOTE: It is acceptable to use thread tape or thread sealant on the threads of the oil heater.
3. Have a certified electrician connect the electrical connections to the heater.

NOTE: If the lube oil is clean and free from contamination the lube oil may be reused.
5. Perform a leak check around the oil heater and drain plugs.
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LUBE TEMPERATURE TRANSDUCER REMOVAL PROCEDURE
Lube Temperature Transducer Removal Procedure

• Clean rags
• Wrench set
NOTE: There are two (2) lube temperature transducers in the lube system. These instructions will work for
either transducer.

3. Remove the drain plug on the lube tank to drain the oil below the level of the transducer being changed.
If the lube oil is to be changed, completely drain the lube oil.
NOTE: When replacing the lube temperature transducer, this may be a good time to change the lube oil. If the
lube oil is clean and free from contamination it may be reused.
4. Locate the lube temperature transducers.
5. One transducer is located on the upper right of the lube panel.
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LUBE TEMPERATURE TRANSDUCER REMOVAL PROCEDURE
6. The other transducer is located on the lower right the of the lube panel.
7. Disconnect the electrical plug from the transducer.
8. Remove the transducer.

RELATED LINKS:
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LUBE TEMPERATURE TRANSDUCER INSTALLATION PROCEDURE
Lube Temperature Transducer Installation Procedure

• Clean rags
• Wrench set

NOTE: It is acceptable to use thread tape or thread sealant on the threads on the drain plug.
2. Install the new transducer.
3. Connect the electrical plug to the transducer.

5. Perform a leak check around the lube temp transducer.
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REPLACING COMMUNICATION MODULE
Replacing Communication Module

The RS485 Communication Module is a replaceable component located in the lower left-hand corner of both
the Master and Slave PLCs . The two (2) PLCs are connected by a hybrid cable that contains conductors for
24VDC power, ground, and ESTOP and separate conductors for transferring modbus serial data. The data
conductors terminate at the RS485 Communication Module.
In the event of a communication failure, the first steps should be:

1) Attempt to determine the source of any possible interference (nearby radio towers, lightening, welding,
etc) and take steps to avoid future interference if possible.
2) Verify that the wiring has no intermittent connections.
a) Disconnect the two wires from each PLC (keep track of wire colors).
b) At one end, twist the conductors together.
c) Using an ohm meter at the other end verify continuity.
d) Have a second person wiggle the various connection points along the way.
e) If a broken or intermittent connection is detected or suspected, troubleshoot this using normal
continuity checking procedures.
If it has been determined that the communication problem is in the PLC, the RS485 Communication Module
can be replaced separately. If a PLC is being replaced, a new RS485 communication module will also be
installed with it at the factory.
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To replace:
1. Remove the access cover from the bottom of the PLC.
2. Remove the two small wires from the module terminals A and B (keep track of the wire colors).
3. While holding the RS485 Communication Module through the access hole, pry gently at the three (3)
plastic clips that secure the module in place.The easiest way to do this would be to start with the left
side, then the top, and finally the right.
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4. When ready to install the RS485 Communication Module, note the connector on the underside of the
module and the three (3) sets of locking tabs. Find the mating connectors and locking clips in the PLC
in order to become familiar with how the parts fit together.
5. Reinstall the new RS485 Communication Module in the opposite order. Verify that it is snapped securely
into position and down all the way. The access cover is installed with the embossed dot toward the
bottom. If the access cover does not snap easily into place, the RS485 Communication Module is not
fully engaged in its mating receptacle. When properly installed, the access cover will snap into place
easily.
Underside of the RS485 Communication Module showing electrical connection receptacle and the three (3)
locking tabs.
1 Locking Tabs
2 Receptacle
6. Re-install the two (2) small wires into terminals A and B.
RELATED LINKS:
Communication Fault
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KODIAK PLUS CRUSHER CONTROL SYSTEM (MILO) SOFTWARE UPDATE
Kodiak Plus Crusher Control System (MILO) Software Update

There are three (3) memory devices associated with this upgrade: two (2) EEPROM memory modules for the
MASTER and SLAVE PLCs, and one compact flash (CF) memory card for the HMI display.
Update Display Module (HMI) Procedure
1. Follow all procedures to lockout/tagout the crusher. Locking out the crusher includes the following
components:
• Crusher motor
• Lube motor
• Hydraulic motor
• Cooler motor
• 120V control power to the HPU
2. Insert CF card into G306MS CF card slot as shown.
3. With card inserted, restore 120V power to the HPU.

4. Observe on the display screen during boot-up the new program is being read from CF card.
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5. Leave the CF card in the HMI.

6. Access the System Configuration screen to update the operational parameters for your crusher (using
Tab and Scroll), and verify that the correct version of the code is installed.
NOTE: The information for each of the three (3) memory devices will be displayed as you update them. Until
you update the PLC1 and PLC2, their values will blank.
7. Verify the description on the screen matches the description printed on the removable media sent with
the update kit.
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Update the Master PLC Procedure
This PLC is located in the same enclosure as the HMI display.
components:
• Crusher motor
• Lube motor
• Hydraulic motor
• Cooler motor
2. Remove the memory module port cover located in the remote control panel.
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1 Top of Master Memory Module
2 Connector Pins at Bottom of Module
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3. Plug in the Master Memory Module with the pins oriented towards the bottom and the text on the back
of the chip right-side-up as shown.
4. Restore 120V power to the hydraulic power unit (HPU).
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1 PWR (green)
2 RUN (green)
3 ERR (red)
4 STAT (green)
5. Observe that initially:

• Green PWR LED is on
• Green RUN LED is blinking
• Red ERR LED is blinking
• Green STAT LED is blinking
6. Wait for about 15 seconds, then observe:
• Green PWR LED remains on
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NOTE: After you restore power to the HPU in step 4, the lights will immediately start to flash in sequence as
described in step 5. After about 15 seconds, the PWR and RUN lights will come on as described in step 6.
Only then proceed to step 7.
7. Lockout/tagout 120V power to the HPU.
8. Remove the master memory module.
9. Replace the master memory module port cover.
10. Access the System Configuration screen to verify that the correct version of the code is installed for
PLC1.
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Update the Slave PLC Procedure
components:
• Crusher motor
• Lube motor
• Hydraulic motor
• Cooler motor
2. Remove the memory module port cover located in the HPU control panel.
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1 Top of Master Memory Module
2 Connector Pins at Bottom of Module
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3. Plug in the slave memory module with the pins oriented towards the bottom and the text on the back of
the chip right-side-up, as shown.
4. Restore 120V power to the HPU.
1 PWR (green)
2 RUN (green)
3 ERR (red)
4 STAT (green)
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5. Observe that initially:

• Green PWR LED is on
• Red ERR LED is blinking
• Green STAT LED is blinking
6. Wait for about 15 seconds, then observe:
• Green PWR LED remains on
NOTE: After you restore power to the HPU in step 4, the lights will immediately start to flash in sequence as
described in step 5. After about 15 seconds the PWR and RUN lights will come on as described in step 6.
Only then proceed to step 7.
7. Lockout/tagout 120V power to the HPU.
8. Remove the slave memory module.
9. Replace the slave memory module port cover.
10. Access the System Configuration screen to verify that the correct version of the code is installed for
PLC2.
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Post Kodiak Plus Crusher Control System Software Update

Verify the following before you start the crusher:
• 120V power is restored to the HPU
• The system is configured to your crusher model parameters.
• The correct version of the MILO operating code is installed.
WARNING: Follow all lockout/tagout procedures set by your site safety rules and
regulations prior to re-energizing locked out equipment.
Re-energize the following components:

• Crusher motor
• Lube motor
• Hydraulic motor
• Cooler motor
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REFERENCE INFORMATION
AVAILABLE LINER CONFIGURATIONS
Reference Information
Available Liner Configurations
K300+ Coarse Chamber
Item Part Number Chamber Weight
Mantle 456394SX 1600 lbs (726 kg)
Liner 456262SX 1743 lbs (791 kg)
Reduction Ratio: 4:1 to 8:1 max. (Based on no bowl float. If bowl float occurs, then you have gone beyond the allowable reduction ratio).
See Upper Assembly in parts book for liner hardware.
A B C
9 1/4” (234.9mm) 10 1/8” (257.1mm) 3/4” (19mm)
9 3/8” (238.1mm) 10 1/4” (260.3mm) 7/8” (22.2mm)
9 1/2” (241.3mm) 10 3/8” (263.5mm) 1” (25.4mm)
9 5/8” (244.4mm) 10 1/2” (266.7mm) 1 1/4” (31.7mm)
9 3/4” (274.6mm) 10 3/4” (273mm) 1 1/2” (38.1mm)
10” (254mm) 11” (279.4mm) 1 3/4” (44.4mm)
10 1/4” (260.3mm) 11 1/4” (285.8mm) 2” (50.8mm)
Approximate Backing Material
(P/N 090037B Domestic; P/N 090804B International Shipments)
Liner Mantle Chamber
Buckets (22 lb each) 3 3 6
Weight 66 lbs (29.9 kg) 66 lbs (29.9 kg) 132 lbs (59.9 kg)
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K300+ Medium Coarse Chamber
Mantle 456262SX 1600 lbs (726 kg)
Liner 456495SX 1868 lbs (847 kg)
Reduction Ratio: 4:1 to 8:1 max. (Based on no bowl float. If bowl float occurs, then you have gone beyond
the allowable reduction ratio).
A B C
7 3/4” (196.8mm) 8 3/4” (222.2mm) 3/4” (19mm)
7 3/4” (196.8mm) 9” (228.6mm) 7/8” (22.2mm)
8” (203.2mm) 9” (228.6mm) 1” (25.4mm)
8 1/4” (209.5mm) 9 3/8” (238.1mm) 1 1/4” (31.7mm)
8 1/2” (215.9mm) 9 5/8” (244.4mm) 1 1/2” (38.1mm)
8 3/4” (222.2mm) 9 7/8” (250.8mm) 1 3/4” (44.4mm)
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K300+ Medium Chamber
Mantle 456262SX 1600 lbs (726 kg)
Liner 456395SX 1862 lbs (845 kg)
A B C
6 1/2” (165.1mm) 7 5/8” (193.7mm) 5/8” (15.9mm)
6 5/8” (168.2mm) 7 3/4” (196.8mm) 3/4” (19mm)
6 3/4” (171.4mm) 7 7/8” (200mm) 7/8” (22.2mm)
6 7/8” (174.6mm) 8” (203.2mm) 1” (25.4mm)
7 1/8” (180.9mm) 8 1/4” (209.5mm) 1 1/4” (31.7mm)
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K300+ Medium Chamber with Feed Slots
Mantle 456262SX 1600 lbs (726 kg)
Liner 456396SX 1871 lbs (849 kg)
A B C
7 7/8” (200mm) 8 7/8” (225.4mm) 5/8” (15.9mm)
8” (203.2mm) 9” (228.6mm) 3/4” (19mm)
8 1/8” (206.4mm) 9 1/8” (231.8mm) 7/8” (22.2mm)
8 1/4” (209.5mm) 9 1/4” (234.9mm) 1” (25.4mm)
8 1/2” (215.9mm) 9 1/2” (241.3mm) 1 1/4” (31.9mm)
Weight 88 lbs (39.9 kg) 44 lbs (20 kg) 154 lbs (69.9 kg)
436
K300+ Medium Fine Chamber
Mantle 456262SX 1843 lbs (836 kg)
Liner 456397SX 1600 lbs (726 kg)
A B C
3 5/8” (92mm) 5 1/8” (130.2mm) 1/2” (12.7mm)
3 3/4” (95.5mm) 5 1/4” (133.3mm) 5/8” (15.9mm)
3 7/8” (98.4mm) 5 3/8” (136.5mm) 3/4” (19mm)
4” (101.6mm) 5 1/2” (139.7mm) 7/8” (22.2mm)
4 1/8” (104.8mm) 5 5/8” (142.9mm) 1” (25.4mm)
437
K300+ Fine Chamber
Mantle 456322SX 1604 lbs (728 kg)
Liner 456398SX 1657 lbs (752 kg)
A B C
2 3/4” (69.8mm) 4 3/8” (111.1mm) 1/4” (6.4mm)
2 7/8” (73mm) 4 1/2” (114.3mm) 3/8” (9.5mm)
3” (76.2) 4 5/8” (117.5mm) 1/2” (12.7mm)
3 1/8” (79.4mm) 4 3/4” (120.7mm) 5/8” (15.9mm)
3 1/4” (82.5mm) 4 7/8” (123.8mm) 3/4” (19mm)
3 3/8” (85.7mm) 5” (127mm) 7/8” (22.2mm)
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CRUSHING APPLICATION GUIDELINES
Crushing Application Guidelines

Some terms that will be used in this section:
Closed Side Setting (CSS): The smallest distance between the bowl liner and cone mantle. The CSS is
approximately similar to the largest desired particle size.
Choke feed: The condition where the chamber is consistently filled with feed material to a level significantly
above the top of the cone. The column of rock above the cone can be quite high without causing a problem.
Conversely, all sorts of problems result from failure to choke feed.
Chamber: Mantle/liner pairs that create specifically shaped cavities designed for reducing rock size between
certain maximum and minimum limits.
Reduction ratio: The product resulting by dividing the largest particle size in the feed material by the CSS.
Open circuit: An application where the feed material entering the crushing chamber passes through once
and none of the discharge material is allowed to return for further crushing.
Closed circuit: An application where material discharged from the crusher passes over a screen and any
particles that fail to pass through certain wirecloth is returned to the crusher until it does pass.
Product size: The largest particle size in the discharge stream for a specific crusher. The product stream
consists of particles this size or smaller.
Top size: The largest particle size in the feed material.
Feed gradation: The distribution of particle size fractions within the feed.
Feed opening: The opening for accepting rock in the uppermost portion of the crushing chamber. The size
of this opening varies from the closed side to the open side of the chamber.
Getting a particular crusher to produce a desired product size, shape, and quantity is controlled by decisions
and adjustments that are made prior to putting the crusher into service. The application definition begins with
a desired product size. A given crusher will discharge aggregate of some maximum size and some distribution
of particles smaller than that size. That maximum size is controlled by manipulating the closed side setting
(CSS) of the chamber. Manipulating the CSS alone is not enough to assure the desired product but that is
the only adjustment available at the crusher itself. Consequently, all other parameters must be controlled
ahead of time.
Things that cannot be controlled include:
• Rock abrasiveness
• Rock compressive strength
• Rock work index
Things that can be controlled include:
• Chamber geometry
• Closed Side Setting (CSS)
• Speed
• Feed gradation and general condition
Most applications involve setting the CSS to a value equal to or slightly larger than the desired product size.
Some notable exceptions will be discussed later. An open circuit crusher will generally operate with a reduc-
tion ratio somewhere between 6:1 and 8:1. Some applications may go as high as 10:1 if the rock is soft and/or
439
friable enough. A closed circuit crusher is more likely to see a reduction ratio of 4:1 to 6:1 and some fine appli-
cations may go as low as 3:1.
When choosing a chamber, consider the following guidelines.
1) Assume the maximum feed size should be less than or equal to the average of the open and closed
side feed opening.
2) The average feed opening should be equal to or slightly larger than the maximum feed size.
3) The feed should be graded such that approximately half the feed passes a sieve size equal to the
average of the open side feed opening and the CSS.
Example: A Medium Chamber Set at CSS = .75” (19.1 mm)
1 Open side feed opening = 6.250” (158.75 mm)
2 Closed side feed opening = 4.5” (114.3 mm)
3 Average = [6.25” + 4.5”] / 2 = 5.375” or [158.75 mm + 114.3 mm] / 2 = 136.5 mm
Midway between closed side feed opening and CSS. Less than 50% of feed should be smaller than this
4
size. [4.5” -.75”] / 2 = 2.625 or [114.3 mm - 19.05 mm] / 2 = 47.625 mm
5 CSS = .75” (19.1 mm). Less than 10% of feed should be smaller than this size.
Maximum feed to this chamber should not exceed 5.375” (136.5 mm). Note that there is still plenty of
6 room for the occasional oversize or oddly shaped rock, but feed equipment (grizzly, jaw, screens, etc.)
should be adjusted to produce 80% or more passing 5.375 (136.5 mm).
For most applications, the following guidelines will help maximize throughput, optimize product gradation, and
minimize wear and tear on the crusher.
• Keep the chamber choke fed. First and foremost keep the chamber full. It is virtually impossible to main-
tain control over gradation and throughput is always substandard whenever the chamber is not choke
440
fed (aka trickle fed). Failure to choke feed increases sliding contact against the mantle and liner
resulting in uneven and/or premature wear and more impact loading on the bearings. Choke feeding
maintains downward pressure on the feed in the crushing chamber, which promotes rock on rock
crushing and urges the feed downward and through the chamber.
• Maximum feed size must not exceed the average of the closed side and open side feed openings. The
largest rock that will enter the crusher is almost always larger than the largest rock that was planned for.
This is especially true in slabby material. When that rock arrives it is highly likely to bridge across the
feed opening. Liners with feed slots and mantle caps with extensions can be installed to help tip slabs
over and get them aimed into the opening, but these are not intended to permit excessive reduction
ratios.
• Feed gradation should have approximately 50% passing a sieve size equal to the average of the closed
side feed opening and the CSS.
a) As the percentage increases beyond 50% (surplus fines), the power required increases and the
throughput tends to decrease. In severe cases, chronic bowl float will develop. Early wear on the
lower end of the chamber is also a symptom.
b) As the percentage decreases below 50% (course fed) the throughput may increase slightly but
particle shape tends to suffer and wear of the upper portions of the chamber is common.
• Keep reduction ratio within reasonable limits. The maximum reduction ratio in any application is
exceeded whenever there is bowl float. Some general guidelines may be used when planning a new
application. Open circuit cone crushers tend to be in primary or secondary positions making generally
larger products and may see reduction ratios of 6:1 to 8:1. As the product size increases, reduction
ratios of 10:1 may be tolerated but are the exception to the rule. Closed circuit crushers tend to be in
applications making smaller products and tend to run in the 4:1 to 6:1 range. As the product gets
smaller, 3:1 may be tolerated, but bowl float is more likely to be a problem in these very small reduction
ratios. These tend to be more specialized applications requiring more specialized solutions.
• Less than 10% of the feed should pass a sieve size smaller than the CSS. This condition tends to retard
flow through the discharge area and promote premature wear in the lower portions of the chamber.
Feed with more than 10% passing CSS is typically a symptom that the feed is too fine in general. As
the voids between particles in the chamber are filled with fine material, there is insufficient room for parti-
cles to expand when crushed. The result is bowl float.
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A Feed Gradation
B Percent Passing
C Sieve Size in Inches (MM)
1 Closed Side Feed Opening
2 Midpoint Size
3 CSS
The desired product size will typically dictate the CSS. Although there are exceptions to the rule, generally
speaking, the CSS will be approximately equal to or slightly larger than the desired product size. Once the
CSS and a general description of the feed is known, the liner selection is usually narrowed to only one or two
choices in most cases. This will in turn dictate some limits on top size based on reduction ratio. Knowledge
gained from experience with the rock in a particular area is the best tool for narrowing the selection criteria
and should be sought whenever possible. The other components of the plant before and after the crusher
need to be configured to produce a feed gradation that complies with the guidelines outlined above.
When reducing CSS, the recommended procedure is to make the changes in small increments (smaller than
.063” [1.6mm]), allowing the entire circuit to react to the change and stabilize. There is seldom, if ever, any
reason to make sudden CSS reductions. The same can be said for increasing CSS to fine tune the circuit.
442
Make small adjustments and wait. When bowl float or high motor amperages occur, there is sometimes no
choice but to increase CSS suddenly, however. Prevention is preferable to reaction. Any sudden change in
CSS will typically have negative effects elsewhere in the circuit.
NOTE: Choosing the proper chamber and operating speed for a given crushing condition cannot be over-
stated. Refer to the references in this manual or call JCI for help in finding the chamber and operating speed
that will work best in your application.
RELATED LINKS:
Pinion Speed
Increasing Speed:
• Tends to decrease throughput, although not usually dramatically. Retards movement of feed through
the chamber, allowing rocks to be compressed more times.
• Tends to improve particle shape. Exposing rock particles to more frequent compression. The improved
particle shape can result in an increase in fines as well.
• Tends to reduce drive motor amperage. Horsepower is basically (torque X speed). Torque is related
directly to amp draw. Increasing speed generally reduces amps but should never increase amps.
• Reduces tendency for bowl float. This is directly related to the same (torque X speed) relationship. If
bowl float is detected, the only immediate cure is opening the CSS, which will generally have a negative
effect elsewhere. In such cases, speed changes may be a reasonable solution that will generally not
have any negative impacts downstream other than a possible increase in fines.
Decreasing Speed:
Has the opposite effects.
In general, unless the change is dramatic, speed changes fall into the category of fine tuning a circuit that is
basically working pretty good but has a specific area where some improvement is required. The best speed
is the slowest speed that keeps the motor amperage in the target range, and does not compromise output
gradation or promote bowl float.
Experience has shown that in the absence of any site or application specific date to the contrary, the Kodiak+
series will work well in a wide variety of applications with a pinion speed of 900 RPM.
• Portable plants must be able to handle a wider variety of applications and rock types. As such, they are
not the best candidates for speed tuning, but stationary plants can benefit by making adjustments.
• Open circuit applications tend to have less critical gradation requirements but downstream components
depend on maximizing output. These tend to be good candidates for slowing down below 900 RPM, if
amp draw suggests that there is power to spare and there is no current tendency for bowl float.
• Although there is no minimum limit on speed, Kodiak+ crushers seldom run slower than 800 RPM.
• Increasing speed beyond 900 RPM is seldom required but is sometimes used for applications with
particularly stubborn elongation problems, making products smaller than 3/8” (9.25 mm) and to a lesser
extent for particularly hard rock. Kodiak+ crushers run successfully up to 1000 RPM but these applica-
tions are rare.
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Choke Feeding
Assuming that the bowl and liner have been properly selected for the feed material and desired product, the
most important thing you can do to optimize the performance and life of the Kodiak+ crusher and wear parts
is to keep the crusher choke fed. Many factors affect how difficult it is to keep the crusher choke fed, including
hopper and surge bin sizes, feeder and belt speeds, and loader capacity. Of these, surge capacity is perhaps
the best way to ensure that choke feed conditions can be maintained.
Rock Characteristics
There are some variables that the operator can do nothing about and these variables are characteristics of
the rock itself.
Abrasiveness
Manganese gets harder when you pound on it but will wear rapidly when it is exposed to sliding abrasion.
When you are properly crushing rock, the crusher action is trapping the rock in the closed side and squeezing
it until it breaks apart small enough to fall through the closed side. As the rocks tumble inside the crushing
chamber, they are rubbing on the liner, causing it to wear. The more abrasive the rock, the more rapidly
manganese will be lost. If the feed material contains abrasive compounds such as silica dioxide, iron oxide,
aluminum oxide, magnesium carbonate, or calcium carbonate, the liner will wear more quickly.
In the case of abrasiveness, expect reduced liner wear. Given that prospect, the operator is under even more
pressure to make good choices to match the feed gradation and speed with the chosen CSS and chamber
so that the wear is as even as possible from top to bottom.
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Hardness
Hardness is basically the amount of pressure needed to break a rock. Kodiak crushers are designed to crush
rock with the compressive strength of 40,000psi or less. The following scale from ASTM C170 shows the
corresponding pressure classification:
PRESSURE STRENGTH
5,000 to 10,000 psi (344.7 to 689.5 bar) Soft
10,000 to 20,000 psi (689.5 to 1379 bar) Medium
20,000 to 30,000 psi (1379 to 2068.4 bar) Hard
30,000 to 40,000 psi (2068.4 to 2757.9 bar) Very Hard
over 45,000 psi (over 3102.6 bar) Extremely Hard
A simple test to do in the field to get a good idea of hardness is based on the Mohs Scale of Hardness. The
scale is hardness from 1 to 10 with diamonds rating 10. The following scale shows some common items you
can scratch a rock with:
ITEM RATING ON MOHS SCALE
Finger Nail 2
Copper Coin 3
Glass 5 1/2
Pocket Knife 5
Steel File 6 1/2
Contact JCI for more information on characteristics of feed material classification.

In the case of hardness, it takes more power to break the rock. For that reason, it becomes even more
important to avoid excessive reduction ratios, erring instead on the side of more conservative reduction ratios.
Avoid other mistakes that cause higher power draw such as excessive fines, etc. Avoid chambers with
enlarged feed slots on very hard materials. All things being equal, hard materials will be more prone to cause
bowl float. The only immediate short term solution to any bowl float is to open the CSS until more compre-
hensive solutions can be implemented.
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Fine Crushing
In some cases it is not practical or possible to continue to squeeze the CSS tighter and tighter to make smaller
and smaller products. If attempts to do so result in persistent bowl float but it is important to make that partic-
ular size product, it is sometimes possible to approach the problem entirely differently from that described so
far. To make very fine materials when other methods prove unsatisfactory, open the CSS and make adjust-
ments to the close circuiting screen to allow higher than normal recirculating loads. This will promote attrition
(rock on rock) crushing and can result in excellent particle shape in manufactured sand. Throughput is obvi-
ously compromised. This method is only practical where production of a specific product outweighs
throughput concerns.
K300+ Product Capacities

Open circuit capacities in tons-per-hour
OPEN CIRCUIT CAPACITIES IN TONS-PER-HOUR
1/2” 5/8” 3/4” 7/8” 1” 1-1/4” 1-1/2” 1-3/4” 2”

CSS (13mm) (16mm) (19mm) (22mm) (25mm) (32mm) (38mm) (44mm) (51mm)
170-210 190-240 215-270 240-300 270-330 310-385 330-415 350-440 370-460

K300+ Gross
(154-191 (172-218 (195-245 (218-272 (245-299 (281-350 (299-376 (318-399 (335-417
Thoughput
mtph) mtph) mtph) mtph) mtph) mtph) mtph) mtph) mtph)
CLOSED CIRCUIT CAPACITIES IN TONS-PER-HOUR
CSS 1/2” (13mm) 5/8” (16mm) 3/4” (19mm) 7/8” (22mm) 1” (25mm) 1-1/4” (32mm)
K300+ Net 145-179 162-204 178-224 192-240 213-261 223-277

Product (131-162 mtph) (147-185 mtph) (162-203 mtph) (174-218 mtph) (194-237 mtph) (202-251 mtph)
3/8” 1/2” 5/8” 3/4” 7/8” 1-1/4”

CSS (10mm) (13mm) (16mm) (19mm) (19mm) 1” (22mm) (32mm)
K300+
Recirculating 15% 15% 15% 17% 20% 21% 28%
Load
Minimum closed side setting is the closest setting possible that does not induce bowl float. Actual minimum
closed side setting and production numbers will vary from pit to pit and are influenced by such factors as
nature of feed material, ability to screen out fines, manganese condition, and low relief system pressure.
NOTICE: Estimated results may differ from published data due to variations in operating conditions and application
of crushing and screening equipment. This information does not constitute an expressed or implied warranty, but
shows estimated performance based on machine operation within recommended design parameters. Use this
information for estimating purposes only.
446
K300+ CSS Chart
DESIRED CHANGE IN CSS
INCHES INCHES MM 164/REV TEETH
1/32 0.03 0.8 4.71
1/16 0.06 1.6 9.42
1/8 0.13 3.2 18.84
3/8 0.38 9.5 56.52
1/2 0.50 12.7 75.36
5/8 0.63 15.9 94.20
3/4 0.75 19.1 113.04
7/8 0.88 22.2 131.89
1 1.00 25.4 159.73
1-1/8 1.13 28.6 169.57
1-1/4 1.25 31.8 189.41
1-3/8 1.38 34.9 207.25
1-1/2 1.50 38.1 226.09
447
K300+ Pressures and Statistics
Item Statistic US Statistic Metric
Crusher HP 300 hp 220.65 kW
TIR Operating Pressure 3000 psi 206.8 bar
TIR Relief Valve Pressure 3500 psi 241.2 bar
TIR Interlock Pressure 1500 psi 103.4 bar
Bowl Clamp Operating Pressure 3000 psi 206.8 bar
System Relief Pressure 3600 psi 248.2 bar
Accumulator N2 Pressure 1900 psi 131 bar
Bowl Position Counter Scaling Factor .6635 in 1.685 mm
Lubrication Unit Reservoir Volume 25 Gallons 94.6 Liters
Approximate Flow Rate 8 gpm 30.28 lpm
Lube Flow Interlock (Low Set Point) 5.5 gpm 20.82 lpm
Lube Pump HP 3 hp 2.21 (kW)
Hydraulic Power Unit (HPU) Reservoir Volume 25 Gallons 94.6 Liters
Approximate HP Flow Rate 5 gpm 18.97 lpm
Hydraulic Pump HP 15 hp 11.03 kW
Oil Cooler HP 1 hp .735 kW
448
Kodiak Plus Gradation Chart
CRUSHER CLOSED SIDE SETTING

PRODUCT
SIZE 5/16” 3/8” 7/16” 1/2” 5/8” 3/4” 7/8” 1” 1-1/4” 1-1/2” 1-3/4” 2”
4”
100
(101.6mm)
3-1/2”
100 96
(88.9 mm)
3”
100 95 90
(76.2mm)
2-3/4”
98 92 86
(69.8mm)
2-1/2”
100 95 88 81
(63.5mm)
2-1/4”
97 91 83 74
(57.1mm)
2”
100 94 86 76 65
(50.8mm)
1-3/4”
100 97 88 79 66 55
(44.5mm)
1-1/2”
100 96 91 80 68 56 45
(38.1mm)
1-1/4”
100 97 90 83 70 56 46 38
(31.7mm)
1”
100 99 90 82 72 58 45 36 29
(25.4mm)
7/8”
100 99 93 86 74 64 48 38 30 25
(22.2mm)
3/4”
100 97 94 87 80 65 54 40 32 26 21
(19mm)
5/8”
98 94 87 80 59 55 46 34 28 22 18
(15.9mm)
1/2”
100 95 88 80 69 58 47 39 28 23 19 16
(12.7mm)
3/8”
91 84 73 63 52 44 37 28 21 17 14 12
(9.8mm)
449
CRUSHER CLOSED SIDE SETTING

PRODUCT
SIZE 5/16” 3/8” 7/16” 1/2” 5/8” 3/4” 7/8” 1” 1-1/4” 1-1/2” 1-3/4” 2”
5/16”
85 74 63 54 46 37 31 25 19 15 13 10
(7.9mm)
1/4”
74 61 50 44 36 32 26 21 16 13 11 9
(6.4mm)
4M 58 48 42 35 32 26 21 18 14 11 9 7
5/32”
50 41 36 30 28 23 18 15 12 10 8 6
(3.9mm)
8M 40 35 30 26 24 20 16 12 9 7 5 4
10M 35 31 26 22 20 18 14 10 8 6 4 3
16M 28 24 21 17 15 13 10 8 6 4 3 2
30M 20 18 15 11 9 8 6 5 4 3 2 1.5
40M 18 15 14 10 8 7 5 4 3 2 1.5 1
50M 14 12 12 8 7 6 4 3 2 1.5 1 0.8
100M 11 9 9 7 6 5 4 3 1.5 1 0.5 0.5
200M 8 7 6 6 5 4 3 2 1 0.5 0.5 0.3
Estimated product gradation percentages at setting shown.
450
System Control Variables
Variable Unit K300+
TIR control pressure hi set point psi (bar) 3000 (206.8)
TIR control pressure lo set point psi (bar) 2700 (186.1)
TIR control pressure shutdown psi (bar) 1500 (103.4)
TIR relief valve bypass pressure psi (bar) 3500 (241.3)
TIR relief min reseat pressure psi (bar) 2975 (205.1)
Bowl clamp control pressure hi set point psi (bar) 3000 (206.8)
Bowl clamp control pressure lo set point psi (bar) 2700 (186.1)
Bowl clamp pressure alarm psi (bar) 1500 (103.4)
System relief valve pressure (operating mode) psi (bar) 3300 (227.5)
System relief valve pressure (temp set point) psi (bar) 3700 (255.1)
For temp use while adjusting the TIR relief valves
Hyd flow nominal (60hz) gpm (lpm) 6 (22)
Hyd flow nominal (50hz) gpm (lpm) 5 (19)
Lube flow nominal (60hz) gpm (lpm) 8 (30)
Lube flow nominal (50hz) gpm (lpm) 9.5 (35)
Lube flow warning gpm (lpm) 6 (22)
Lube flow shutdown gpm (lpm) 5.5 (21)
Heater thermostat hi °F (°C) 100 (38)
Heater thermostat lo °F (°C) 80 (27)
Lube reservoir temp min recommended °F (°C) 60 (15.5)
Lube reservoir temp cooler fan enable °F (°C) 130 (55)
Lube reservoir temp warn °F (°C) 190 (88)
Lube reservoir temp shutdown °F (°C) 220 (102)
Hyd temp warn °F (°C) 165 (74)
CSS change per tooth in 0.00665
CSS change per tooth mm 0.16891
Teeth per rev 164
451
Codes for Integrating into an External System
TWIDO VARIABLE (& TWIDO CONSOLIDATED DESTINATION ADDRESS

VARIABLE DESCRIPTION SCALING) ADDRESS TO HOST AND SCALING AT HOST
MOTOR 1 CURRENT (A) (MW301 * 0.9158) - 187.739 %MW331 (400332 * 0.9158) - 187.739
MOTOR 2 CURRENT (A) MW306 * 0.9158) - 187.739 %MW332 (400333 * 0.9158) - 187.739
WARNING - HYDRAULIC
MW226:1 %MW333.0 40334 bit 1
TEMP > 190F
WARNING - HYDRAULIC
MW226:3 %MW333.1 40334 bit 2
TEMP > 80C
FAILURE - LUBE MOTOR MW230:1 %MW333.2 40334 bit 3
FAILURE - CRUSHER
MW230:2 %MW333.3 40334 bit 4
MOTOR
FAILURE - HYDRAULIC
MW230:3 %MW333.4 40334 bit 5
PUMP MOTOR
WARNING - LUBE TEMP >

MW231:1 %MW333.5 40334 bit 6
190F

MW231:2 %MW333.6 40334 bit 7
220C
WARNING - LUBE TEMP

MW231:3 %MW333.7 40334 bit 8
>88C

MW231:4 %MW333.8 40334 bit 9
104C
SHUTDOWN - HIGH LUBE

MW231:5 %MW333.9 40334 bit 10
TEMP
WARNING - LOW TIR

MW232:1 %MW333.10 40334 bit 11
PRESSURE
SHUTDOWN - LOW TIR

MW232:2 %MW333.11 40334 bit 12
PRESSURE
WARNING - LOW LUBE

MW233:1 %MW333.12 40334 bit 13
FLOW
SHUTDOWN - LOW LUBE

MW233:2 %MW333.13 40334 bit 14
FLOW
COMMUNICATION FAILURE
MW276:1 %MW333.14 40334 bit 15
DETECTION
SHUTDOWN -
MW276:2 %MW333.15 40334 bit 16
COMMUNICATION FAILURE
452

ESTOP SHUTDOWN MW220:1 %MW334.0 400335 bit 1
BOWL UPPER LIMIT

MW202:11 %MW334.1 400335 bit 2
WARNING
LOW LUBE LEVEL

M31 %MW334.2 400335 bit 3
WARNING
LUBE FILTER BYPASS

M200 %MW334.3 400335 bit 4
WARNING
BOWL POSITION WARNING MW112 %MW335 400336
MW152 * (0.000001 * 400337 * (0.000001 *

CLOSED SIDE SETTING (“) %MW336
MW112) MW112)
CLOSED SIDE SETTING MW152 * ((0.000001 * 400337 * ((0.000001 *

%MW336
(MM) MW112) * 25.4) MW112) * 25.4)
HYDRUALIC PUMP
(MW139 * 7.08) -1451.4 %MW337 (400338 * 7.08) - 1451.4
PRESSURE (PSI)
HYDRAULIC PUMP ((MW139 * 7.08) -1451.4) / ((400338 * 7.08) - 1451.4) /

%MW337
PRESSURE (BAR) 14.5038 14.5038
BOWL CLAMP PRESSURE

(MW132 * 7.08) - 1451.4 %MW338 (400339 * 7.08) - 1451.4
(PSI)
BOWL CLAMP PRESSURE ((MW132 * 7.08) - 1451.4) / ((400339 * 7.08) - 1451.4) /

%MW338
(BAR) 14.5038 14.5038
TRAMP IRON RELIEF

((MW133 * 7.08) - 1451.4 %MW339 (400340 * 7.08) - 1451.4
PRESSURE (PSI)
TRAMP IRON RELIEF ((MW133 * 7.08) - 1451.4) / ((400340 * 7.08) - 1451.4) /

%MW339
PRESSURE (BAR) 14.5038 14.5038
CONE BRAKE PRESSURE

(MW140* 7.08) - 1451.4 %MW340 (400341 * 7.08) - 1451.4
(PSI)
CONE BRAKE PRESSURE ((MW140 * 7.08) - 1451.4) / ((400341 * 7.08) - 1451.4) /

%MW340
(BAR) 14.5038 14.5038
LUBE RESERVOIR
(MW137 * 0.3662) - 75.071 %MW341 (400342 * 0.3662) - 75.071
TEMPERATURE (F)
LUBE RESERVOIR ((((MW137 / 0.3662) - 75.071) ((((400342 * 0.3662) - 75.071)

%MW341
TEMPERATURE (C) - 32) * 5) / 9 - 32) * 5) / 9
LUBE RETURN
(MW138 * 0.3662) - 75.071 %MW342 (400343 * 0.3662) -75.071
TEMPERATURE (F)
LUBE RETURN ((((MW138 / 0.3662) - 75.071) ((((400343 * 0.3662) - 75.071)

%MW342
TEMPERATURE (C) - 32) * 5) / 9 - 32) * 5) / 9
453
PRODUCT SPECIFICATION TROUBLESHOOTING

LUBE FLOW (GPM) MW148 * 0.0537 %MW343 400344 * 0.0537
LUBE FLOW (LPM) MW148 * 0.2019 %MW343 400344 * 0.2019
Product Specification Troubleshooting
Not choke fed.
Hook in manganese.
Loose liner or mantle.
Segregated feed.
Feed material not centered.
CSS cchanges due to bowl clamp malfunction.

Product won’t hold spec.
Excessive fine material in feed.
Excessive moisture in feed material.
Up-stream screen blinded over.
Change in up-stream crusher CSS.
Reduction ratio too large.
Wrong crusher speed or chamber for application.
454
Causes of Bowl Float

Below you will find a listing of some of the most common causes of bowl float. There are more, and if you
cannot find the cause in your situation, call your dealer or JCI at 800-314-4656.
Reduction Ratio Too High

If the reduction ratio is too high, the crushing forces within the crushing chamber can exceed the design limit
for the machine. This overload pushes the upper assembly up and causes bowl float similar to tramp iron.
The maximum reduction ratio capability depends on the material compressive strength, friability, moisture
content, percentage of mud or clay, compaction index, or gradation. Because of the variety of factors, the
maximum reduction ratio will be unique for each site.
DESIRED CRUSHING REDUCTION RATIO CLOSED SIDE SETTING
Fine 3:1 to 6:1 3/8” to 5/8” (9.5 mm - 15.9 mm)
Medium 3:1 to 6:1 5/8” to 1” (15.9 mm - 25.4 mm)
Coarse 4:1 to 8:1 1” to 2” (25.4 mm - 50.8 mm)
Crusher Not Choke Fed

Not choke feeding the crusher will produce larger than normal reduction to the rock with each cycle. These
localized high reduction loads will result in bowl float. When the crusher is not choke fed, the material falls
faster than normal through the chamber and each crushing cycle has less rock on rock crushing. This
produces a very coarse and inconsistent gradation, and long term feeding of the crusher in this manner will
cause uneven wear to the bowl liner.
Excessive Near Size Material

Feeding unscreened material or excessive near size material fed into the crusher will cause bowl float. The
smaller material will fill the voids between the larger rocks, thus producing a near solid mat of material in the
crushing chamber. This dense mat of material generates high localized pressure, which overloads the
crusher. This same effect can happen if the feed material is segregated with near size material entering one
side of the crusher and larger rock entering the opposite side of the chamber.
Too Much Clay, Mud, or High Moisture Content

Combinations of clay or mud, soft rock like soft limestone or shale, with more than 5% moisture content and
sand will cause the material to compact into a composite solid form nicknamed “pancakes.”
TIR Pressure Too Low

If the TIR pressure is below the design setting, the feed material may overcome the TIR system and cause
bowl float. The possible causes of low TIR pressure are improper settings or a malfunction in the HPU.
Frequently check your system pressure and follow the daily inspection checklist as outlined in the Mainte-
nance section.
455
Air in the Relief System

Air in the TIR system can cause it to have less hold down force. This can allow the feed material to overcome
the system and lead to bowl float.
Rock Material Backing Up into the Crushing Discharge Area

Never allow the crushed material to build up inside the crusher discharge area. Follow the daily inspection
checklist outlined in the Maintenance section. Check the discharge area of your crusher periodically during
your shift to make sure that debris is clear and the out-feed system is functioning properly.
Feed Related Problems

If the feed is overly coarse (significantly less than 50% passing midpoint) for a given chamber:
• Upper end of chamber wears prematurely.
• Product gradation is too coarse.
• Elongation can be a problem.
• Lower power draw.
• Lowered production rate.
If the feed is overly fine (significantly more than 50% passing midpoint) for a given chamber:
• Lower end of chamber wears prematurely. Feed opening pinches off.
• Lowered production rate.
• High power draw.
• Persistent bowl float.
Feed that is too fine is the more frequent problem. Whenever possible it is always advantageous to find a way
to modify the feed rather than the chamber. This is usually possible to control by changing wire cloth and other
relatively low cost modifications. Oddly enough, most operators tend to resist these types of changes opting
instead for concentrating entirely on the chamber, which is significantly more expensive and time consuming.
If the decision is made to make chamber changes based on unsatisfactory results and it has been decided
that nothing can be done to improve the feed gradation, then use the guidelines above to evaluate the old
chamber and the new candidate. To assist in your decision, use the following questions:
1) Will the existing feed improve the percentage passing this new midpoint?
2) Will the existing top size fit through the new feed opening? If not, then can the top size be reduced
somehow?
3) Is the new chamber really designed for this particular CSS? Most chambers have an ideal CSS where
the bottom end of the liner and mantle line up across from each other. If the chamber is too fine for the
CSS, a hook will tend to form on the liner. If the chamber is too coarse for the CSS, a hok will tend to
form on the mantle. There is almost always a tendency to form a depression in the crushing zone of the
mantle but hooking is characterized by a definite unused portion of one wear part caused by its lowest
portion hanging out beyond the mating part.
456
A Chamber too coarse for CSS
B Chamber Optimized for CSS
C Chamber too fine for CSS
1 Hook will form on liner
2 Liner and mantle line up
3 Hook will form on mantle
457
CRUSHER LUBRICATION OIL SPECIFICATIONS
Crusher Lubrication Oil Specifications

Recommended Oil Type
The oil installed at the factory is Mobilgear 600XP 150, a premium grade ISO 150 gear oil with extreme pres-
sure additives specially formulated to minimize pitting. JCI requires use of Mobilgear 600XP or Mobilgear
SHC150 synthetic oil throughout the warranty period. Refer to the official warranty policy documentation for
details. These oils are available from Exxon/Mobil jobbers throughout the world.
JCI does not monitor developments with oil suppliers other than Exxon/Mobil. Consequently, JCI does not
provide recommendations regarding alternate oil suppliers.
JCI discourages the use of thinner oils in cold climates because it is seldom possible to keep the operating
temperature low enough to prevent these oils from becoming too thin.
The Kodiak+ crusher lube system is equipped with two (2) 1500 w heaters and has a relatively small volume
(25 gal [95L]). Consequently, the oil can be warmed quickly even in extremely cold climates. For particularly
frigid environments it may be necessary to take extra measures such as:
1) Wrapping the lube assembly and/or hoses with insulation.
2) Covering the feed opening with an insulated cover overnight to retain heat in the crusher.
3) Covering the discharge opening overnight to retain heat in the crusher.
If there is no electrical power available at night then energize the HPU and lube assembly immediately upon
arrival at the job site in the morning. This will start the heaters. If the weather is so cold that lube temperature
is an issue, there will be other cold weather related issues in other parts of the plant as well. By the time they
are all attended to, the oil in the lube assembly should be warm enough that ISO150 oil will be thin enough
to use in even the coldest ambient temperatures.
For extremely hot environments, heavier oil may be used, but in these hot environments, the oil temperature
may exceed the recommended 180°F (82°C) and continued operation at elevated temperature can cause
thermal breakdown of the oil. The heavier viscosity will cause the oil to be thicker at the higher temperature
but will not prevent this thermal breakdown. JCI has larger oil coolers available for these applications. But any
time oils are used at temperatures higher than 180°F (82°C) oil sampling frequency should be increased and
analysis should focus on breakdown of EP additives in particular.
Synthetic Oil
Synthetic lubricants may be used in the Kodiak+ lubrication system. The viscosity of synthetic oil does not
vary with temperature as drastically as mineral oil based lubricants. Consequently, they will flow more easily
at cold temperatures and have a higher viscosity at elevated temperatures than a mineral based equivalent.
They will also tolerate high temperatures with less thermal breakdown allowing more time between oil
changes. These attributes may make synthetic lubricants an attractive option in extreme climates. Synthetic
lubricants are not immune to thermal breakdown, however. If operating at oil temperatures consistently higher
than 180°F (82°C), oil sampling and replacements are more critical.
An acceptable synthetic substitute for Mobilgear 600XP is Mobilgear SHC 150.
RELATED LINKS:
Lube Circulation Procedure
458
Lube Oil Analysis

JCI recommends sending samples in to be analyzed every 250 hours to monitor the condition of the lubricant
and the effects of wear over time.
The results of a single sample, although useful, are not nearly as valuable as the cumulative effect of several
samples over time. Comparing samples over time can uncover trends or detect the sudden presence or
increase of a contaminant or wear product that indicates something new is happening with the crusher or its
surroundings.
An oil sample should include at a minimum:
• Viscosity
• Detect the presence of water in the oil
• Concentrations of contaminants and wear materials
• Size distribution of particles detected
The chart below lists the maximum allowable limits (measured in parts per million) for some of the most
commonly encountered contaminant and wear particle types:
NORMAL LEVEL (PARTS PER

METAL MILLION) *MAXIMUM (PARTS PER MILLION)
Copper 15-30 100
Nickel 0-5 10
Chrome 0-5 10
Lead 15-30 100
Iron 50-75 150
Silicon (dirt) 50-75 150
A typical oil sample report will include values for a variety of elements but there are a few that are of particular
interest because they are the key measure of contamination and/or wear:
• Silica. In a rock crusher, this translates as dirt. For the most part, any increase in silica indicates
increased infiltration of dirt from the outside or may indicate failure to change filter elements when they
become overloaded. The oil sampling port on the Kodiak+ lube panel captures oil before it enters the
filter so it represents the state of the oil in the reservoir. If the oil filter is maintained regularly, the oil
being delivered to the bearings will have a lower silica content than the value on the report.
• Iron. This is the primary wear byproduct and represents wear in any of the sliding or rolling parts of the
crusher interior. Although some iron will always be present in the oil sample, the main value of periodic
sampling is the ability to detect changes over time.
• Copper. The main sources of copper as a wear element are the bearing cages. As in the case of iron,
there will always be some copper present, but increases over time should be monitored. Copper content
will be higher than normal during the initial break in period but should level off. Increases after this
leveling off period should be monitored.
459
• Water. This will typically be reported as YES or NO. A YES reading on the report indicates that water
(measured in percent of sample volume) exceeded a threshold limit. YES typically means great than
1%, but you should check with the lab performing the test to verify what their threshold value is. Anything
other than NO is too much. There should be no appreciable amount of water entrained in the oil as a
contaminant. A small amount that might come out when the drain plug is removed for an oil change can
be overlooked, but if significant amounts of oil are being emulsified (oil appears milky), the source of the
leak needs to be determined and corrected.
It is normal for oil to break down over time due to thermal effects. The rate at which this occurs can be very
site specific and is primarily sensitive to operating temperature. This is another reason why periodic sampling
is useful. Synthetic oils are significantly more resistant but not immune to thermal breakdown.
• Viscosity. This is the most important indicator of oil condition. This will be reported as a viscosity
number with units of SSU (Saybolt Universal Seconds) or CSt (Centistokes) at a particular temperature.
When comparing against the baseline (new oil) viscosity, be sure that the baseline data is measure in
same viscosity units and at the same temperature. The oil should be changed before the viscosity
changes by 20%. The viscosity can decrease or increase over time, but in rock crusher applications, an
increase is more common.
Most oil tests will contain data on elements not listed in the contaminants chart above. Some of these
elements are constituents of the EP (extreme pressure) additives, but the primary elements found in EP addi-
tives are phosphorous and sulfur. Phosphorus is commonly reported but sulfur requires special testing and
is not commonly reported. A reduction in phosphorus indicates a deterioration of the EP additives. The oil
should be changed before the additive constituents drop by 50%. Some testing labs will flag changes in
elements that indicate breakdown of the oil of its additives.
Particle size count measures the size of the particles entering the lube oil. Recall that the test port on the lube
panel is sampling oil before it enters the filter. If the filter is maintained, the oil delivered to the bearings should
be removing most of the larger particle sizes. If a sudden change is noted in this part of the analysis data it
may indicate a new or enlarged path for external contaminants has opened up, or an accelerated wear of an
internal component is occurring. Evaluate a change in particle size reported with any changes in the amount
of silica, iron, or copper to get a clue on the source of the change. Any increase in the particle count should
also impact the filters. Therefore your first indication that a change is occurring in the size and/or number of
particles in the lube system may come from increased consumption of oil filters. This is another good reason
to be vigilant about watching the bypass indicator for you lube filter. Determining the particle count in the oil
delivered to the crusher bearings would require a separate test downstream of the oil filter. A second test port
is provided just below the cooler bypass valve.
460
ISO Rating
This value is a measure of the fluid contamination. It is a calculated value based on the number of particles
per ml between 5 micron and 15 micron. Somewhere in the same area of the report that contains the particle
count there will be a value labeled ISO and expressed as two numbers separated by a slash such as 22/16,
18/13, etc. As with most other values described so far, the main thing to watch for are changes that occur
over time. The actual value of the ISO rating is mainly of interest in hydraulic applications. As the numbers
increase, it indicates an increase in dirt or wear particles.
Oil Filter Element Beta Ratings

Filter elements are currently classified by a Beta rating system. A particular filter element may have several
Beta ratings (typically 3 are listed), each corresponding to a specific particle size. Beta ratings are a measure
of capture efficiency, and represent the ratio of the number of particles of a given size or greater upstream of
the filter to the number of particles of the same size downstream.
BETA RATING EFFICIENCY
Beta 2 50%
Beta 5 80%
Beta 10 90%
Beta 20 95%
Beta 75 98.7%
Beta 100 99%
Beta 200 99.5%
Beta 1000 99.9%
Previously, the terms “nominal” and “absolute” were used to describe filter efficiency. Terms such as “10
micron absolute” were meant to imply that the filter would capture all particles greater than or equal to 10
micron. Strictly speaking this was not true, and the Beta system is more precise. Few, if any, filter manufac-
turers use “absolute” anymore but it persists among end users. There is no industry-wide agreement on what
Beta rating corresponds to “nominal” or “absolute.” Assuming that Beta 2 (50%) translates roughly to
“nominal” and Beta 20 (98.7%) translates roughly to “absolute” is a reasonable rule of thumb.
The standard filter elements used on Kodiak+ crushers are:
• Beta5 2 (50% of 5 micron+ particles captured)
461

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JCI Crusher Operation &

Maintenance ................................................................................................. 153

Crusher Service............................................................................................ 273

Reference Information ................................................................................. 433

Address For Notices

Johnson Crushers International, Inc.

86470 Franklin Blvd.

Eugene, Oregon 97405

Office: 541-736-1400 / Fax: 541-988-9401

Toll Free: 800-314-4656

Service Department: (866) 875-4058

Parts Sales Department: (888) 474-0115

Kodiak+ Series Crusher Overview

1 Tramp Iron Relief (TIR) Cylinder

2 Hydraulic Bowl Clamp

5 Bowl Liner Retention System

7 Hydraulic Bowl Rotation Motor

9 Crusher Base Frame Assembly

11 Pin Clutch Assembly

17 Hydraulic Power Unit (HPU)

18 Remote Control Panel

Kodiak+ Series Crusher Theory of Operation

Crusher Upper Assembly

1 Bowl Rotation Assembly

2 Bowl Position Proximity Sensor

5 Upper Dust Seal Assembly

8 Liner Retention Components

9 Manganese Bowl Liner

10 Lower Dust Seal Assembly

12 Bowl Clamp Hydraulic Oil Supply Hose

Hazard and Advisory Statements

Hazard Warning Symbol

Arc Flash Safety

Who Must Use Lockout/Tagout?

When Must Lockout/Tagout Occur?

When Can Lockout/Tagout Devices be Removed?

Additional Lockout/Tagout Requirements

1 Multiple User Lockout Device

2 Do Not Operate Tag

OSHA has identified the following step-by-step lockout/ tagout procedure:

Miscellaneous Safety Tips

Know Your Machinery

Be Prepared for Emergencies

Wear Personal Protective Equipment (PPE)

Observe Personal Safety Precautions

Help Prevent Accidents

Avoid Alcohol and Other Drugs

Be Aware of Your Surroundings

Practice Good Housekeeping

Inspect And Maintain Machinery

WARNING: DO NOT EXCEED 55 MPH! — When towing the

WARNING: HAZARDOUS VOLTAGE — The electrical

WARNING: CRUSH HAZARD — The trailer can roll

WARNING: CRUSH HAZARD — This equipment drive poses

WARNING: LOUD NOISE HAZARD — This equipment’s

WARNING: PINCH POINT — This equipment poses a pinch

CAUTION: SLIP HAZARD — The walkways around this

WARNING: FALLING LOAD — This equipment is extremely

WARNING: FALL HAZARD — This equipment is mounted on

WARNING: AVOID INJURY — This equipment poses a severe

WARNING: FALLING MATERIAL HAZARD — Operation

WARNING: AVOID INJURY — Performing service on this