C100609 Operation and Services Manual and Parts CONO NUEVO (3o) [PDF]

Zitiervorschau

Crusher Operation and Service Manual and Parts Book

1200LS Crusher S/N C100609 86470 Franklin Blvd, Eugene, OR 97405 • 800-314-4656 • 541-736-1400 • Fax 541-988-9401 24/7 Parts Number 888-474-0115

JCI LS CRUSHERS

1200LS Crusher Parts Book Serial Number: C100609

JCI 24/7 Parts Number 888-474-0115 © 2010 JCI

JCI LS CRUSHERS New Parts and Equipment Warranty 1. Johnson Crushers International, Inc. (JCI) Warranty: JCI warrants to the Distributor and Distributor’s customers on resale with respect to JCI products sold that the new equipment will be free from defect in material and workmanship under normal use for a period of one (1) year after the date of start-up or 2,000 hours of operation, whichever first occurs. JCI further warrants to the Distributor and Distributor’s customers on resale that any and all parts supplied by JCI will be free from defect in material and workmanship under normal use (excluding ordinary wear) for a period of six (6) months after installation. The sole and exclusive remedy for any breach of warranty, breach of contract, or any claim in tort (including, but not limited to, strict liability and negligence) shall be the repair or replacement (at JCI’s option) of any defective part, parts or equipment at JCI’s manufacturing plant in Lane County, Oregon. Any part(s) and/or equipment claimed to be defective shall be returned, freight prepaid, to JCI’s manufacturing plant in Lane County, Oregon, following the receipt of JCI’s Returned Goods Authorization. Written notice of any claimed defect must be provided to JCI within sixty (60) days of the discovery of any claimed defect(s). 2. Disclaimer/Limitation of Warranties: The expressed warranty described above is expressly in lieu of other warranties, expressed or implied AND ANY AND ALL IMPLIED WARRANTIES, INCLUDING, BUT NOT LIMITED TO, ANY AND ALL IMPLIED WARRANTIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY EXPRESSLY DISCLAIMED AND EXCLUDED. NO PERSON(S), INCLUDING, BUT NOT LIMITED TO, EMPLOYEES AND AGENTS OF JCI AND/OR ITS DISTRIBUTORS ARE AUTHORIZED TO MAKE ANY REPRESENTATION OR WARRANTY CONCERNING JCI PRODUCTS THAT ARE IN ANY WAY INCONSISTENT WITH THE FOREGOING WARRANTY. JCI MAKES NO WARRANTY OR WARRANTIES, EXPRESSED OR IMPLIED, WITH RESPECT TO ANY ACCESSORIES, COMPONENTS OR PARTS NOT MANUFACTURED BY JCI, AND THE INSTALLATION OF ANY PARTS OR COMPONENTS NOT MANUFACTURED OR SUPPLIED BY JCI, AND ANY ALTERATION OF EQUIPMENT OR PARTS SUPPLIED BY JCI WITHOUT JCI’S EXPRESSED WRITTEN CONSENT SHALL VOID THE WARRANTY GRANTED HEREBY. UNDER NO CIRCUMSTANCES SHALL JCI BE RESPONSIBLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, INCLUDING, BUT NOT LIMITED TO, LOST PROFITS OR LOSS OF USE. 3. Address for Notices: Any and all inquiries and/or warranty claims should be reduced to writing and submitted to JCI at the following address: Johnson Crushers International, Inc., 86470 Franklin Blvd, Eugene OR 97405. 24/7 Parts Number: 888-474-0115

JCI 24/7 Parts Number 888-474-0115 © 2010 JCI

JCI LS CRUSHERS JCI Parts Ordering Information

The JCI Parts Department is open from 7 AM to 5 PM Pacific Time. You can contact us in the following ways:

• *24/7 Phone (24 Hours- 7 Days a week): 1-888-474-0115 (Even holidays!) • Fax: 541-988-9487 • Email: [email protected]

Model No. Serial No.

The Serial Number Plate for your screen is usually located on the right-hand side feedbox end of your screen. 1. Follow the steps to safely lock out/tag out the power source to your crusher. (Lockout/Tagout Kit # 090011) 2. Find the model number and serial number of your crusher from the Serial Number Plate. Located on the opposite side of the drive side of the crusher. 3. Locate the parts to be replaced by using the parts lists and drawings in this catalog. 4. Call your JCI dealer or use the JCI Parts contact information provided to order your parts. Be sure to include model number and serial number when ordering. Information Needed To Order Parts 1. **Serial number of the equipment. (ex. 99C04D1400LS for a crusher or 99LP05G32 for a screen) 2. Model of the equipment. (ex. 1400LS, JCI6203-32LP) 3. Part number(s) and quantity. 4. Shipping information. 5. Priority. (Next day air, ground, truck, etc…) 6. Purchase order number. JCI also accepts Visa and MasterCard. Orders may also be sent COD. *There is a $100 call in charge for emergency orders shipped outside of normal business hours. **JCI can also supply you with parts for your Cedarapids/ElJay® Rollercone™ Crusher and 3-shaft screens.

JCI 24/7 Parts Number 888-474-0115 © 2010 JCI

JCI LS CRUSHERS Important Safety Precautions

WARNING: Failure to adhere to the following safety precautions may result in serious injury or death.

• Perform a complete inspection before starting the crusher. Be sure that the crushing chamber is clear. Make sure the cone blocking is removed. • Be sure that all guards and other safety devices are correctly installed and tightly secured before starting the crusher. Stay clear of rotating or moving parts during crusher operation. • Do not allow personnel to be on or near the crusher during operation. The crusher will shake violently should tramp iron be feed into the machine. Stay clear of feed and discharge areas to prevent being injured or killed by flying or falling rock. • Rock projected upwards through the feed opening can injure or kill. Do not look directly into the feed opening while the crusher is operating. Use mirrors or closed-circuit cameras if close observation of the feed arrangement is necessary for troubleshooting or evaluation purposes. • Never attempt to clear jammed material from the crushing chamber while the crusher is operating. Serious injury or death could result if you are pulled into, or fall inside, the crushing chamber. • Never attempt to manually clear jammed material from the crushing chamber while the upper frame is in the lowered (clamping) position. Any material lodged in the chamber could release without warning, and may be propelled upward through the feed opening. Serious injury or death could result. • Do not tamper with crusher alarm components. Never attempt to defeat electrical interlocks or to disable crusher protective devices. • Never place hands on cylinder rods. Stay clear of pinch-point area between the upper and main frames. • Never stand on hydraulic hoses or use them as steps. If hoses rupture, serious injury or death could result. As required, use a safety harness during servicing. • Always lockout/tagout power to the crusher drive motor, crusher oil lubrication system and crusher hydraulic system before performing any inspection, adjustment, lubrication, maintenance or repair procedures. Also lockout power to all crusher feed and discharge equipment. Be sure pressure is fully relieved before servicing the hydraulic system. • If the crusher is powered by a diesel engine, always disconnect batteries and shut-off fuel supply before performing any inspection, adjustment, lubrication, maintenance or repair procedures. Lockout/tagout engine controls to prevent the engine from being accidentally started while the crusher is being serviced. • Support the crusher upper frame with hardwood blocking or steel safety spacers before entering the JCI 24/7 Parts Number 888-474-0115 © 2010 JCI

JCI LS CRUSHERS crushing chamber for service work. Never rely on hydraulic pressure to keep the upper frame raised. You could be crushed and killed if the upper frame lowers unexpectedly. • Always stop the crusher immediately if any gauges show abnormal readings, or if there is a sudden obvious change in operation. Be alert for noises that might indicate trouble. • Inspect, lubricate, maintain and repair the crusher in accordance with the instructions contained in this manual and any additional manuals or documentation provided with the crusher. • Inspect all warning signs and caution decals. If they become torn or not readable contact your local dealer or Johnson Crushers International for replacement. • On portable plants be sure that the trailer is properly blocked and level. All blocking must be suitable to support the trailer dead load weight plus the crusher impact live loading. • Before starting the crusher visually check the tramp iron and clamp cylinder pressure gauges on the hydraulic manifold. Both pressures should range from 2700 psi to 3000 psi. Occasionally check the system pressure gauge with the hydraulic pump motor running. This pressure shall not exceed 3000 psi. • Avoid stopping the crusher with material inside the crushing chamber. In the event that the crushing chamber is full of rock use the hydraulic clearing feature. Always inspect the crushing chamber and U-seat after a clear for loose or jammed rock. • Do not adjust the close side setting smaller than the recommended minimum setting for your mantle and bowl liner combination. • An oil flow meter has been provided as a safety device to protect the crusher components in the event of a lubrication system failure. Should the flow meter detect a flow of oil less than its preset value, the electrical panel will activate the warning horn alerting crusher operators that the machine needs to be shut down immediately to prevent permanent damage to crusher components. In addition, it is strongly suggested that the control circuit be wired such that, when the warning system is activated, the feed device feeding the crusher is shut down. The crusher should be shut down immediately after the rock has cleared the crushing chamber (less than 10 seconds).Wear your hard hat at all times. • Stop the crusher, lock out power, and tag controls: 1.Before performing any lubrication, maintenance, adjustments, or repairs. 2.Before removing any spilled materials. 3.Before clearing jams or working on the crusher. 4.Whenever any unusual noises or sudden changes in operation are noticed. • Refer to the JCI Operation Manual for screen safety information. If your copy of the manual is missing, please contact your local JCI dealer or the JCI Parts Department for a replacement copy.Read your Operation Manual for your screen. Be sure that you fully understand all phases of screen operation. A careful and well-trained operator is the best insurance against an accident. Additional Counterweights available to purchase: JCI 24/7 Parts Number 888-474-0115 © 2010 JCI

JCI LS CRUSHERS Factory Installed 1200LS Manganese Configuration

1

2

ITEM

QTY

1 2 3

1 1 198

PART NUMBER 450128 450177 090037

DESCRIPTION MANTLE LINER MANGANESE BACKING MATERIAL

JCI 24/7 Parts Number 888-474-0115 © 2010 JCI

COMMENTS

JCI LS CRUSHERS Factory Installed 1200LS Counter Weight Configuration

ITEM 1 2 3 4 5 6 7 8 9 10 11 12

QTY 1 1 1 1 1 1 1 1 1 1 1 1

PART NUMBER 450034 450035 450035 450035 450035 450035 450035 450035 450035 450035 450035 450035

DESCRIPTION CWT LEADING CWT LIGHT CWT LIGHT CWT LIGHT CWT LIGHT CWT LIGHT CWT LIGHT CWT LIGHT CWT LIGHT CWT LIGHT CWT LIGHT CWT LIGHT

PART NUMBER

COUNTER WEIGHT

450034

CWT LEADING

450035

CWT LIGHT

450088

SHIM CWT 1/8

450089

SHIM CWT 1/4

JCI 24/7 Parts Number 888-474-0115 © 2010 JCI

COMMENTS

JCI LS CRUSHERS Kits and Additional Spare Parts Accumulator Kits ITEM

QTY

1 2 3 4 5 6 7 8

1 1 1 1 1 1 1

PART NUMBER 450010 450014 450178 450179 450024 450020 450266 450015

DESCRIPTION

COMMENTS

ACCUMULATOR KIT ACCUMULATOR KIT ACCUMULATOR KIT ACCUMULATOR KIT ACCUMULATOR BAG ACCUMULATOR BAG NITROGEN PRESSURE GAUGE ACCUMULATOR CHARGE KIT

2-1/2 OR 5 GALLON BAG 1 GALLON BAG 2-1/2 OR 5 GALLON BAG (W/O NUTS) 1 GALLON BAG (W/O NUTS) 1 GALLON 5 GALLON

Seal Kits ITEM 1 2 3 4

QTY 1 1 1 1

PART NUMBER 450079 450004 450013 540053

DESCRIPTION SEAL KIT SEAL KIT SEAL KIT SEAL KIT

COMMENTS CLAMP CYLINDER ASSY WITH BRASS ADJUSTING JACK RELIEF CYLINDER

Hose Kits 1

1

450495

HOSE KIT

Repair Kits ITEM 1 2 3

QTY 1 1 1

PART NUMBER 540053 450004 450079

DESCRIPTION RELIEF CYLINDER REPAIR KIT CLAMP CYLINDER REPAIR KIT CLAMP CYLINDER REPAIR KIT

JCI 24/7 Parts Number 888-474-0115 © 2010 JCI

COMMENTS With Brass WITHOUT BRASS

Table of Contents Crusher Components ............................................................................................. 1 Upper Assembly 1200LS/SS ................................................................................. 6 Clamp Cylinder Assembly ...................................................................................... 11 Adjusting Jack Assembly ....................................................................................... 12 Relief Cylinder Assembly 1200LS .......................................................................... 13 Lower Assembly 1200LS ....................................................................................... 14 Wedgeplate Assembly 1200LS .............................................................................. 19 Cone Assembly 1200LS/SS ................................................................................... 20 Pinion Assembly 1200LS ....................................................................................... 23 Floating Plate Assembly ........................................................................................ 24 Pin Clutch Assembly .............................................................................................. 25 Heater Assembly 2000W 120V .............................................................................. 27 Baseframe Machining ............................................................................................ 29 Dipstick .................................................................................................................. 31 Lube Assembly Hose Kit ........................................................................................ 32 Shim Guard ............................................................................................................ 34 Shim Stack Kit ....................................................................................................... 35 Cone Lifting Eye Assembly .................................................................................... 36 External Lube Panel Assembly 1200LS ................................................................. 37 External Lubrication Panel Housing Assembly ...................................................... 43 Horn Assembly ....................................................................................................... 44 Lube Panel J-Box Assembly .................................................................................. 45 Hose Kit 1200LS & 1400LS ................................................................................... 46

JCI 24/7 Parts Number 888-474-0115 © 2010 JCI

11/11/10

REF#

450246

Crusher Components

Rev. O

1

11/11/10

REF#

450246

Crusher Components

Rev. O

2

11/11/10

REF#

450246

Crusher Components

Rev. O

3

11/11/10

REF#

450246

Crusher Components ITEM

QTY

1 2 3 4 5 6 7 8 9 10 12 15 17 18 21 22 23 24 25 26 27 29 30 31 32

1 1 1 2 1 8 8 8 8 8 8 1 1 1 1 1 1 1 2 2 1 2 1 2 1

PART NUMBER 450241 450242 450141 540130 450076 450148 450358 084001 084065 450162 450184 090034 450030 450132 090497 090486 090485 090518 090090 090508 090490 090499 090498 090069 090504

33 34 35 45 46 47 48

2 1 1 1 4 1 1

090506 090056 090556 085001 546338 456531 456532

Rev. O

DESCRIPTION ASSY UPPER 1200LS /SS LOWER ASSY 1200LS GUARD SHIM LEG SHIM GUARD SEAL SHIM GUARD (NO DRAWING) CPLR BOLT ADJ 2 SPLITS WASHER ALIGNING CLAMP CYL O-RING 6227-30 O-RING PARK 2-329 2.375 OD WASHER BOLT ADJ KIT SHIM STACK 8.563 WRENCH ALLEN 7/8 WRENCH CLAMP CYL WRENCH MANTLE NUT STD ISO6202 DECAL EYE PROT DECAL ISO6202/6115/6041 HRG/EP DECAL ISO1014/6011 CRSH/LOTO DECAL ISO3005 DGR HARD HAT DECAL JCI 1200 LS DECAL ISO1040 WRNG HIGHPRESS ISO5018 DECAL FALL HZD ISO1017 DECAL PINCH PT ISO6126 DECAL READ OPS MAN DECAL NON FLAMABLE GAS DECAL ARROW CLOCKWISE ROTATION DECAL KPI/JCI 22.00 X 5.00 DECAL BUILT IN USA SMALL PL SERIAL NUMBER LS ELEMENT FILTER DONALDSON SHIM 16 GA BASEFRAME MNTG CONE LIFTING EYE CONE LIFTING EYE ASSY

COMMENTS

Not Shown Not Shown

4

11/11/10

REF#

450246

Crusher Components

ITEM

QTY

1 2 3

1 1 6

Rev. O

PART NUMBER 060039 060005 060199

DESCRIPTION SHEAVE 8V 6GR 24.8 OD 24.6 PD BUSHING QD M 2-15/16 V-BELT 8V 1400

COMMENTS

NOT SHOWN

5

11/11/10

REF#

450241

Upper Assembly 1200LS/SS

Rev. G

6

11/11/10

REF#

450241

Upper Assembly 1200LS/SS

Rev. G

7

11/11/10

REF#

450241

Upper Assembly 1200LS/SS

Rev. G

8

11/11/10

REF#

450241

Upper Assembly 1200LS/SS ITEM

QTY

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

1 1 8 3 4 4 8 32 1 1 8 4 1 2 2 4 8 3 3 168 4 4 8 2 1 8 2 12 2 8 8 2 2 1 6 4 2 8 32

Rev. G

PART NUMBER 450042 450221 450055 087001 450130 076011 450006 080007 450065 540166 450109 450116 082012 083019 083018 083017 450044 083038 083051 081001 450218 450217 450216 540168 450638 450215 540157 540173 450222 070180 078030 083022 083023 083078 083055 083124 540203 084016 070107

DESCRIPTION

COMMENTS

BONNET MACH SUPT BONNET MACHINING 1200 ROD PRESSURE VALVE RELIEF 3/8 WEDGE BOWL CASTING NUT JAM ADJUSTING JACK CONNECTOR FLUID O-RING 2-012 BLOCK MANIFOLD ACCUM 1GAL 1.25NPT ASSY CLAMP CYL ASSY ADJUSTING JACK HOSE 1/4X 12IN - 04MB X 04MC 4-JBU-S (PARKER) 4-4-FBU-S (PARKER) 4-4-CBU-S (PARKER) CVR DUST CYL RELIEF CPLR DISC QUICK PVV-14-F TMP-14 TUBE .250 X .049 HYD PIN ROTATION STOP 1200 ROTATION STOP LOWER (BOLT ON) BOLT PRESS RING SOLID MANIFOLD ACCUM 5GAL SPLIT FLANGE 3000 RING BEAM RELIEF CYLINDER ASSY CYL RELIEF1200 BRKT ACCUM 5GAL 180DEG BRKT ACCUMULATOR BLOCK BRKT M ACCUM MOUNT CAPSCREW HEX 1 8NC X 5 G8 ZIN WASHER HT 1 YELLOW ZINC B7405X4 7129X4 5406-P-20 CLIP MNTG 1/4 TUBE FLANGE SPLIT 51H32 BRKT ACCUMULATOR 1GAL O-RING 6230-12 CAPSCREW HEX 3/4 10NC X 4-1/2

9

11/11/10

REF#

450241

Upper Assembly 1200LS/SS ITEM

QTY

40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64

2 10 4 38 16 6 2 4 32 2 8 20 4 2 2 4 6 4 2 8 8 20 1 4 4

Rev. G

PART NUMBER 070086 070134 070014 076001 076040 070055 070080 540507 078026 090063 540236 078000 540303 450301 540304 070151 078022 450302 084069 070194 078025 070158 450520 070016 076005

DESCRIPTION

COMMENTS

CAPSCREW HEX 5/8 11NC X 5 G5 CAPSCREW HEX 5/8 11NC X 6 G5 CAPSCREW HEX 5/8 11NC X 2-1/2 NUT NYLOCK 5/8-11 NC NUT HEAVY HEX JAM 2-1/4 X 4-1/ CAPSCREW HEX 1/4 20NC X 3/4 CAPSCREW HEX 5/8 11NC X 3-1/2 STOP WEDGE LOWER WASHER LOCK 3/4 OAKUM DARK ANGLE CLIP 2X2X3/8 WASHER HT 5/8 YELLOW ZINC BRKT ACCUM HD BOLT CLAMP BRKT ACCUM BRKT ACCUM 5GAL BOTTOM SETSCREW SOC 1/2 13NC X 3/4 WASHER LOCK 1/4 CAP ROT PLG STOP CCF2 1/2-8-12 O-RING 2-228 32 SPLIT FLANGE CAPSCREW HEX 1/2 13NC X 4-1/2 WASHER LOCK 1/2 CAPSCREW HEX 5/8 11NC X 2-1/4 HOPPER 1200LS CAPSCREW HEX 1/2 13NC X 1-1/2 NUT NYLOCK 1/2 13NC

10

11/11/10

REF#

450109

Clamp Cylinder Assembly

ITEM

QTY

1 2 3 4 5 6 7 8 9 10

1 1 1 1 1 1 1 1 1 1

Rev. 0

PART NUMBER 450343 450359 080009 079004 079005 080010 450000 450479 450480 080011

DESCRIPTION

COMMENTS

CLAMP CYLINDER INSERT CLAMP CYLINDER SEAL U-CUP CLAMP CYL 1870-2 RETAINING RING BRG INC-UR262 RETAINING RING SMALLEY-BS-437 SEAL ANCHOR PK CLAMP CY 1870-4 CLAMP CYLINDER PISTON SLEEVE, BRASS, CLAMP CYLINDER THREADED COVER CLAMP CYLINDER SEAL DUST CLAMP CYL 18939H

11

11/11/10

REF#

450116

Adjusting Jack Assembly

ITEM

QTY

1 2 3 4 5 6 7

1 1 1 1 1 1 1

Rev. 0

PART NUMBER 450114 450003 450110 450113 080013 079006 070029

DESCRIPTION

COMMENTS

RAM, ADJUSTING JACK CYL WELDMENT, ADJ JACK GUIDE, OUTER, ADJ JACK CYL GUIDE, INNER ADJ. JACK CYL SEAL ADJ JACK POLY, 2500-1 SNAP RING SH100STPA (5100-100) RETAINING RING, WH162

12

11/11/10

REF#

450215

Relief Cylinder Assembly 1200LS

ITEM 1 2 3 4 5 6

Rev. 0

QTY 1 1 1 1 1 2

PART NUMBER 450214 540158 079002 080046 080041 080042

DESCRIPTION RELIEF CYLINDER - 1200 PISTON CORE SNAP RING, 5100-450 SEAL, RELIEF CYLINDER SEAL, RELIEF CYLINDER RCII SEAL, SPLIT, RELIEF CYL, RCII

COMMENTS

13

11/11/10

REF#

450242

Lower Assembly 1200LS

Rev. R

14

11/11/10

REF#

450242

Lower Assembly 1200LS

Rev. R

15

11/11/10

REF#

450242

Lower Assembly 1200LS

Rev. R

16

11/11/10

REF#

450242

Lower Assembly 1200LS ITEM

QTY

1 2 3 4 5 6 7 8 9 11 12 14 15 16 17 18 19 22 25 26 27 28 29 30 31 32 33 34 35 36 39 40 41 42 43 45 46 47 48

1 1 1 1 4 4 1 1 1 1 1 1 1 3 8 1 1 2 4 4 6 20 2 8 8 8 8 3 8 4 1 1 1 1 1 32 8 1 1

Rev. R

PART NUMBER 450243 450244 450268 450043 450068 084009 450497 406087 546840 450166 406109 546844 450227 540129 450069 450485 450603 406110 070130 070203 070152 070027 070141 450148 070010 540226 450126 070016 084065 540222 083033 083032 540243 540191 450157 078025 078014 083061 083082

DESCRIPTION

COMMENTS

ASSY PL WEDGE 1200 LS ASSY CONE 1200 LS/SS ASSY PINION 1200LS RING SEAL BASEFRAME PIN PUSH BASEFRAME O-RING 6227-27 FLOATING PLATE W/ INSERTS SHAFT CONE BRAKE PIN CLUTCH ASSEMBLY 10 PIN THRUST PLATE CONE BRAKE PLATE CLUTCH GUIDE RING 10 PIN CVR BRAKE HOUSING 1200 ROLLER SHIM GUARD BOLT ADJ CONNECT QUICK ASSY HEATER 2000W 120V BASEFRAME MACH (SEE TEXT) BRAKE SHAFT KEY CAPSCREW HEX 5/16 24NF X 3/4 CAPSCREW SOC 5/16-18NC X 1-1/2 CAPSCREW HEX 1 14NF X 3 CAPSCREW HEX 1/2 13NC X 1-1/4 SETSCREW SOC 5/8 11NC X 5/8 CPLR BOLT ADJ 2 SPLITS CAPSCREW HEX 5/8 11NC X 1-3/4 RETAINER ADJ BOLT WASHER BOLT ADJ CAPSCREW HEX 1/2 13NC X 1-1/2 O-RING PARK 2-329 2.375 OD BASEFRAME STRUT GUARD PIPE SCH 40 1-1/4 X 26 NPT ELBOW SCH 40 1-1/4 NPT 90 BRKT FILL PIPE DIPSTICK KEY DRIVE SHEAVE WASHER LOCK 1/2 WASHER LOCK 5/8 5503-08-08 1404-08-08

17

11/11/10

REF#

450242

Lower Assembly 1200LS ITEM

QTY

49 50 51 53 55 56 60 61 62 63

1 2 1 1 1 1 1 1 1 12

Rev. R

PART NUMBER 082013 083079 083035 083515 083496 546685 079124 080032 450628 070048

DESCRIPTION

COMMENTS

HOSE 939B 27.5 SS WIRE CON TFE CLAMP TUBE 3/4-PARK #3075 PIPE SCH 40 1-1/4 X 4 NPT FS2501-12-08 FS2501-16-16 KIT HOSE LUBE RET RING SMALLEY WHM-162 PLUG MAGNETIC 1 SPACER CLUTCH CVR 10-PIN CAPSCREW HEX 1/2-13NC X 2 G5

18

11/11/10

REF#

450243

Wedgeplate Assembly 1200LS

ITEM

QTY

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

1 1 1 1 1 3 1 1 11 1 4 4 8 6 12 12 1

Rev. C

PART NUMBER 450634 450059 450007 450008 456156 450228 406017 450023 450035 450034 450088 450089 070025 070027 070083 078034 450134

DESCRIPTION

COMMENTS

WEDGE PLATE, 1200LS GEAR, RING (SPIRAL) SEAL RING - UPPER WEDGE PLATE SEAL RING - LOWER WEDGE PLATE BEARING, RADIAL UPPER RADIAL RETAINER BEARING, UPPER THRUST BEARING, LOWER THRUST COUNTERWEIGHT, LIGHT COUNTERWEIGHT, LEADING SHIM, COUNTERWEIGHT, 1/8 SHIM, COUNTERWEIGHT, 1/4 CAPSCREW HEX 3/4 16NF X 2-1/2 CAP SCREW HEX 1/2 13NC X1-1/4 CAP SCREW HEX 7/8-9NC X2-1/2 WASHER, LOCK, 7/8 WEAR BAND WEDGE PL SEAL RG

19

11/11/10

REF#

450244

Cone Assembly 1200LS/SS

Rev. E

20

11/11/10

REF#

450244

Cone Assembly 1200LS/SS

ITEM

QTY

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1 1 1 1 1 1 1 1 1 1 2 4 1 1 1 1

Rev. E

PART NUMBER 450247 450151 450057 450053 450056 450018 450052 456156 450501 450257 070189 070032 070105 450258 084041 084050

DESCRIPTION

COMMENTS

CONE WITH STEM - 45 MANTLE BOLT MANTLE NUT MANTLE NUT CAP - 45 INCH MANTLE WASHER SEAL RING - CONE RETAINER, CONE RADIAL BEARING BEARING, RADIAL TORQUE BAR, UNHARDENED PIN, .500 X 1.000 CAP SCREW SOC 7/8 9NC X 1-3/4 CAP SCREW HEX 3/8 16NC X1-1/4 CAP SCREW SOC 1-1/4 7NC X2-1/2 PIN, .875 X 2.000 O-RING 6227-48 O-RING 6227-60

21

11/11/10

REF#

450244

Cone Assembly 1200LS/SS ITEM

QTY

17

1

Rev. E

PART NUMBER 540103

DESCRIPTION

COMMENTS

FOAM, 1

22

11/11/10

REF#

450268

Pinion Assembly 1200LS

ITEM

QTY

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 1 1 1 1 1 1 1 1 1 1 1 1 8 8 1 1 1 1

Rev. A

PART NUMBER 450267 450058 450033 450111 450117 450118 450119 450120 450156 450067 540140 450027 070142 070032 078024 070150 084055 450028 450029

DESCRIPTION

COMMENTS

PINION HOUSING GEAR, PINION (SPIRAL) PINION SHAFT NUT LOCK, PINION BEARING BEARING, PINION, CUP, OUTER BEARING, PINION, CONE, OUTER BEARING, PINION, CUP, INNER BEARING, PINION, CONE, INNER KEY, PINION GEAR LOCKNUT, PINION SHAFT KEY, LOCK RING COVER PLATE SETSCREW 3/8 X 3/8 NC SOC HD CAP SCREW HEX 3/8 16NC X1-1/4 WASHER, LOCK, 3/8 SETSCREW 1/4-20NC X 1/2 SOC HD O-RING 6227-74 FLINGER - INNER FLINGER - OUTER

23

11/11/10

REF#

450497

Floating Plate Assembly

ITEM

QTY

1 2 3 4 5

1 2 2 16 2

Rev. C

PART NUMBER 450168 450312 450313 070039 450498

DESCRIPTION

COMMENTS

FLOATING PLATE FLOATING PLATE UPPER INSERT FLOATING PLATE LOWER INSERT CAP SCREW SOC 3/8 16NC X 3/4 FLOATING PLATE UPPER INSERT

24

11/11/10

REF#

546840

Pin Clutch Assembly

Rev. 0

25

11/11/10

REF#

546840

Pin Clutch Assembly ITEM

QTY

1 2 3 4 5 6 7

1 1 10 1 10 10 1

Rev. 0

PART NUMBER 546841 546842 546641 546460 090442 070540 079052

DESCRIPTION

COMMNETS

BLOCK DRIVE 10-PIN BLOCK RATCHET 10-PIN PIN DRIVE WASHER THRUST SPRG COMPRES C0600-0490-1750 CAPSCREW BUTTON 1/2-13NCX1 RING RET SMALLEY WS-250

26

11/11/10

REF#

450485

Heater Assembly 2000W 120V

Rev. A

27

11/11/10

REF#

450485

Heater Assembly 2000W 120V ITEM

QTY

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

1 1 1 1 2 4 2 1 1 2 2 192 2 2 2 196 196 196 196 196 1 1 4 2 2 1

Rev. A

PART NUMBER 450254 540533 540294 020026 540254 070032 070008 076042 070056 020036 020037 020033 020041 020042 020043 020028 020029 020030 020031 020032 076046 078037 078024 020018 020019 080032

DESCRIPTION

COMMENTS

HEATER COVER WELDMENT HEATER MACHINED,2000W,220V HEATER ELECTRICAL BOX COVER THERMO ON 60 DEG OFF 80 DEG. GASKET, HEATER CAP SCREW HEX 3/8 16NC X1-1/4 CAP SCREW HEX 3/8 16NC X1G5 NUT 1-1/2-6NC MACH SCREW RD HD #8-32NC X 3/4 LUG, T & B C-10-8 CONNECTOR 3/4X90 FITS 3/4 FLEX CONDUIT, 3/4 FLEX, NON-METALLI DISCONNECT FEM 10-12 GA, NYLON DISCONNECT FEM 14-16 GA, NYLON DISCONNECT MALE 14-16GA NYLON WIRE, 10 GA THHN, WHITE WIRE, 10 GA, THHN RED WIRE, 16 GA MTW BLACK WIRE, 16 GA MTW BLUE WIRE, 16 GA MTW GREEN NUT, #8-32NC WASHER, LOCK, #8 WASHER, LOCK, 3/8 SEALING RING 5263 LOCKNUT, RID METAL CON, 3/4 T PLUG, MAGNETIC 1

28

11/11/10

REF#

450603

Baseframe Machining

Rev. D

29

11/11/10

REF#

450603

Baseframe Machining

ITEM

QTY

1 2 3 4 5 6 7 8 9

1 1 3 12 5 1 1 1 1

Rev. D

PART NUMBER 450604 456116 456344 540242 070103 456061 450249 456125 450159

DESCRIPTION

COMMENTS

BASEFRAME WELDMENT CENTER SECT STRAIGHT BORE PLUG 1.625 DIA X 0.500 CLAMP RING PAD GUSSET CAPSCREW SOC 1-1/2 6NC X 4 SPINDLE BASEFRAME - 1040 NUT AN-44 PL WEAR PINION TUNNEL REMOTE RING CLAMP

30

11/11/10

REF#

540191

Dipstick

ITEM 1 2 3

Rev. B

QTY 1 1 1

PART NUMBER 083036 051046 076148

DESCRIPTION CAP, BLACK PIPE, 1-1/4 DIP STICK SHAFT 24.75" NUT 1/2-13NC PLAIN

COMMENTS

31

11/11/10

REF#

546685

Lube Assembly Hose Kit

Rev. A

32

11/11/10

REF#

546685

Lube Assembly Hose Kit ITEM

QTY

1 2 3 4 5 6 7 9

72 72 1 1 1 1 1 1

Rev. A

PART NUMBER 088051 088013 088124 088134 088123 088133 083508 083350

DESCRIPTION

COMMENTS

HOSE 16GMV HOSE 12G2 16G-16MFFOR 16G-16FFORX 12G-12MFFOR 12G-12FFORX FS0304-C-12 FS0304-C-16

33

11/11/10

REF#

450141

Shim Guard

ITEM 1 2 5 8 9

Rev. A

QTY 1 1 1 3 1

PART NUMBER 450140 540130 090039 620134 076043

DESCRIPTION RING, SHIM GUARD LEG, SHIM GUARD TOGGLE, SHIM GUARD HANDLE NUT, 5/8-18NF

COMMENTS

34

11/11/10

REF#

450184

Shim Stack Kit

No Graphic Available

ITEM 1 2 3 4 5 6 7 8 9 10 11 12

Rev. 0

QTY 1 5 1 1 1 1 1 1 1 1 1 2

PART NUMBER 450090 450091 450092 450093 450094 450095 450096 450097 450098 450099 450100 450101

DESCRIPTION SHIM ADJUSTING .062 Lt Green SHIM ADJUSTING .125, WHITE SHIM ADJUSTING .188, YELLOW SHIM ADJUSTING .250, BLACK SHIM ADJUSTING .313, RED SHIM ADJUSTING .375, BLUE SHIM ADJUSTING .500, ORANGE SHIM ADJUSTING .625, BROWN SHIM ADJUSTING .750, PURPLE SHIM ADJUSTING .875, GREY SHIM ADJUSTING 1.000, GREEN SHIM ADJUSTING 1.500, WHITE

COMMENTS

35

11/11/10

REF#

456532

Cone Lifting Eye Assembly

ITEM

QTY

1 2 3 4 5 6

1 1 1 1 4 4

Rev. 0

PART NUMBER 456533 078056 070548 456534 078004 070486

DESCRIPTION

COMMENTS

CONE LIFTING EYE BASE WASHER HT 1 1/4 CAPSCREW SOC 1-1/4 7NC X 4-1/2 CONE LIFTING EYE WELDMENT WASHER HT 1/2 CAPSCREW HEX 1/2-13 X 1-3/4 G8

36

11/11/10

REF#

450197

External Lube Panel Assembly 1200LS

Rev. M

37

11/11/10

REF#

450197

External Lube Panel Assembly 1200LS

Rev. M

38

11/11/10

REF#

450197

External Lube Panel Assembly 1200LS

Rev. M

39

11/11/10

REF#

450197

External Lube Panel Assembly 1200LS

Rev. M

40

11/11/10

REF#

450197

External Lube Panel Assembly 1200LS ITEM

QTY

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

1 1 1 1 1 1 1 1 1 1 2 1 2 1 1 1 1 1 1 1 1 1 4 4 4 4 4 4 2 8 4 6 6 6 2 2 1 40 1

Rev. M

PART NUMBER 060539 080024 089093 080030 085004 456154 080027 450187 456169 450620 083527 083030 083191 080034 083026 083016 090114 083515 083346 080043 083074 020027 070224 076022 078023 070066 076027 070009 070056 078024 070008 070062 076026 078015 020019 020018 083471 020034 020138

DESCRIPTION

COMMENTS

MTR 3HP 182TC PUMP LUBE .761 CU IN/REV COUPLING LO95 .500x1.125 PUMP ADAPTOR (FIL-4AA) FILTER ASSY DONALDSON HAK05 LUBE PANEL EXT FLOW SWITCH 54 HORN ASSY 120V NO PROJECTOR J BOX 110V/60HZ 8.0 X 6.0 KIT HOSE LUBE 5406-24-12 5404-12-08 5605-12-12-12 5406-12-04 5502-04-02 SAMPLER PLUG THERM 40-240F, 5' CAPILLARY FS2501-12-08 FS2501-16-12 COVER PLATE PUMP ADAPTOR NEEDLE OIL SAMPLER W/TUBING "CONN 3/4"" X 90 T&B 2272 " CAPSCREW SOC 5/16 18NC X 1-1/4 NUT 5/16 18NC WASHER LOCK 5/16 CAPSCREW HEX 5/16-18NC X3/4 NUT NYLOCK 5/16-18NC CAPSCREW HEX 3/8 16NC X 3/4 G5 MACH SCREW RD HD #8-32NC X 3/4 WASHER LOCK 3/8 CAPSCREW HEX 3/8 16NC X1G5 CAPSCREW HEX 1/4 20NC X 1 G5 NUT NYLOCK 1/4-20NC WASHER FLAT 1/4 "RIGID 3/4"" LOCKNUT T&B 142 " "SEALING RING 3/4"" T&B 5263 " FS2501-08-12 CORD 16/4 SO RCPT CVR FLIP LID PELWR81C

41

11/11/10

REF#

450197

External Lube Panel Assembly 1200LS ITEM

QTY

41 42 43 48 49 50 51 52 53 54 55 56 57 59 60 61 62 63 65 66

1 1 1 3 3 3 2 1 2 1 3 1 4 1 1 1 1 4 1 1

Rev. M

PART NUMBER 020139 020422 083192 020014 020038 020039 020147 083193 083160 020199 020016 406218 070470 090089 090311 090551 090194 078016 083508 083350

DESCRIPTION RCPT BOX SINGLE GANG T&B T11 RCPT DUPLEX 250V 15A HBL5662I NIPPLE 3/4 NPT X 5 BLK "CORD GRIP 1/2"" .38-.50 CGB194 " SEALING RING T&B 5262 "RIGID 1/2"" LOCKNUT T&B 141 " "KNOCKOUT SEAL 3/4"" 90052 " 5404-12-12 5406-12-08 "CORD GRIP 1/2"" .38-.50 CGE194 " TERM VINYL LOCKING FORK ADAPTER PLATE CAPSCREW SOC 1/2-13 X 1-1/4 DECAL NOTICE RUN LUB DECAL DANGER HIGH VOLTAGE DECAL ISO 110V YELLOW DECAL ROTATION ARROW WASHER FLAT 5/16 FS0304-C-12 FS0305-C-16

COMMENTS

NOT SHOWN NOT SHOWN

42

11/11/10

REF#

456154

External Lubrication Panel Housing Assembly

ITEM

QTY

1 2 3 4 5 6 7 8 9 10

1 1 1 1 1 5 10 5 5 1

Rev. C

PART NUMBER 456152 456153 540011 456167 456461 070016 078019 078025 076024 620128

DESCRIPTION

COMMENTS

EXT LUBE PANEL SIDES,FORMED EXT LUBE PANEL BASE,FORMED OIL FILTER BRACKET, DONALDSON MTG BRACKET,BY-PASS VALVE MOTOR BASE CAP SCREW HEX 1/2 13NC X1-1/2 WASHER, FLAT, 1/2 WASHER, LOCK, 1/2 NUT, 1/2-13NC LIFTING EAR

43

11/11/10

REF#

450187

Horn Assembly

ITEM

QTY

1 2

1 1

Rev. B

PART NUMBER 020001 020421

DESCRIPTION

COMMENTS

HORN BASE HORN FED SIGNAL 350-240-30

44

11/11/10

REF#

456169

Lube Panel J-Box Assembly

ITEM

QTY

1 2 3 4 5 6 7 8 9 10 11

1 1 12 2 4.75 2 0.5 1 0.1 2 2

Rev. F

PART NUMBER 020136 020137 020500 020512 020182 020510 020103 020505 020513 070341 076072

DESCRIPTION

COMMENTS

ENCL 8X6X3.5 NEMA4/12/13 ENCL PNL 8X6 A8P6 TERM BLOCK (J4) AB1492-J4 TERM BLOCK END STOP DIN MOUNTING RAIL DIN #3 TERM BLOCK END PLATE GROUND BAR KIT 14 POS GB14 TERM BLOCK CENTER JUMPER 2P J4 MARKER TERM 6CMX12CM MACHSCREW RD HD 10-24 x .500 NUT 10-24 NC

45

11/11/10

REF#

450499

Hose Kit 1200LS & 1400LS

Rev. 0

46

11/11/10

REF#

450499

Hose Kit 1200LS & 1400LS ITEM

QTY

1 2 3 4 5 6

72 88 2 2 1 1

Rev. 0

PART NUMBER 088014 088013 088133 088134 083579 083580

DESCRIPTION

COMMENTS

HOSE 16G2 HOSE 12G2 12G-12FFORX 16G-16FFORX FS2408-12 FS2408-16

47