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: parts@jcieug.com

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

JCI 24/7 Parts Number 888-474-0115

© 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 suit-
able to support the trailer dead load weight plus the crusher impact live loading.
• Before starting the crusher visually check the tramp iron and clamp cylinder pressure gauges on the
hydraulic manifold. Both pressures should range from 2700 psi to 3000 psi. Occasionally check the
system pressure gauge with the hydraulic pump motor running. This pressure shall not exceed 3000
psi.
• Avoid stopping the crusher with material inside the crushing chamber. In the event that the crushing
chamber is full of rock use the hydraulic clearing feature. Always inspect the crushing chamber and
U-seat after a clear for loose or jammed rock.
• Do not adjust the close side setting smaller than the recommended minimum setting for your mantle
and bowl liner combination.
• An oil flow meter has been provided as a safety device to protect the crusher components in the
event of a lubrication system failure. Should the flow meter detect a flow of oil less than its preset
value, the electrical panel will activate the warning horn alerting crusher operators that the machine
needs to be shut down immediately to prevent permanent damage to crusher components. In addi-
tion, it is strongly suggested that the control circuit be wired such that, when the warning system is
activated, the feed device feeding the crusher is shut down. The crusher should be shut down imme-
diately after the rock has cleared the crushing chamber (less than 10 seconds).Wear your hard hat at
all times.
• Stop the crusher, lock out power, and tag controls:
1.Before performing any lubrication, maintenance, adjustments, or repairs.
2.Before removing any spilled materials.
3.Before clearing jams or working on the crusher.
4.Whenever any unusual noises or sudden changes in operation are noticed.
• Refer to the JCI Operation Manual for screen safety information. If your copy of the manual is miss-
ing, please contact your local JCI dealer or the JCI Parts Department for a replacement copy.Read
your Operation Manual for your screen. Be sure that you fully understand all phases of screen opera-
tion. A careful and well-trained operator is the best insurance against an accident.
Additional Counterweights available to purchase:

JCI 24/7 Parts Number 888-474-0115

© 2010 JCI
 JCI LS CRUSHERS
Factory Installed 1200LS Manganese Configuration

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 450128 MANTLE
2 1 450177 LINER
3 198 090037 MANGANESE BACKING MATERIAL

JCI 24/7 Parts Number 888-474-0115

© 2010 JCI
 JCI LS CRUSHERS
Factory Installed 1200LS Counter Weight Configuration

ITEM QTY PART NUMBER DESCRIPTION COMMENTS

1 1 450034 CWT LEADING
2 1 450035 CWT LIGHT
3 1 450035 CWT LIGHT
4 1 450035 CWT LIGHT
5 1 450035 CWT LIGHT
6 1 450035 CWT LIGHT
7 1 450035 CWT LIGHT
8 1 450035 CWT LIGHT
9 1 450035 CWT LIGHT
10 1 450035 CWT LIGHT
11 1 450035 CWT LIGHT
12 1 450035 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
 JCI LS CRUSHERS
Kits and Additional Spare Parts
Accumulator Kits
PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 450010 ACCUMULATOR KIT 2-1/2 OR 5 GALLON BAG
2 1 450014 ACCUMULATOR KIT 1 GALLON BAG
3 1 450178 ACCUMULATOR KIT 2-1/2 OR 5 GALLON BAG (W/O NUTS)
4 1 450179 ACCUMULATOR KIT 1 GALLON BAG (W/O NUTS)
5 1 450024 ACCUMULATOR BAG 1 GALLON
6 1 450020 ACCUMULATOR BAG 5 GALLON
7 450266 NITROGEN PRESSURE GAUGE
8 1 450015 ACCUMULATOR CHARGE KIT
Seal Kits
ITEM QTY PART NUMBER DESCRIPTION COMMENTS
1 1 450079 SEAL KIT CLAMP CYLINDER ASSY
2 1 450004 SEAL KIT WITH BRASS
3 1 450013 SEAL KIT ADJUSTING JACK
4 1 540053 SEAL KIT RELIEF CYLINDER
Hose Kits
1 1 450495 HOSE KIT
Repair Kits
ITEM QTY PART NUMBER DESCRIPTION COMMENTS
1 1 540053 RELIEF CYLINDER REPAIR KIT
2 1 450004 CLAMP CYLINDER REPAIR KIT With Brass
3 1 450079 CLAMP CYLINDER REPAIR KIT WITHOUT BRASS

JCI 24/7 Parts Number 888-474-0115

© 2010 JCI
 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
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REF# 450246

Crusher Components

Rev. O 2
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REF# 450246

Crusher Components

Rev. O 3
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REF# 450246

Crusher Components
PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 450241 ASSY UPPER 1200LS /SS
2 1 450242 LOWER ASSY 1200LS
3 1 450141 GUARD SHIM
4 2 540130 LEG SHIM GUARD
5 1 450076 SEAL SHIM GUARD (NO DRAWING)
6 8 450148 CPLR BOLT ADJ 2 SPLITS
7 8 450358 WASHER ALIGNING CLAMP CYL
8 8 084001 O-RING 6227-30
9 8 084065 O-RING PARK 2-329 2.375 OD
10 8 450162 WASHER BOLT ADJ
12 8 450184 KIT SHIM STACK 8.563
15 1 090034 WRENCH ALLEN 7/8
17 1 450030 WRENCH CLAMP CYL
18 1 450132 WRENCH MANTLE NUT STD
21 1 090497 ISO6202 DECAL EYE PROT
22 1 090486 DECAL ISO6202/6115/6041 HRG/EP
23 1 090485 DECAL ISO1014/6011 CRSH/LOTO
24 1 090518 DECAL ISO3005 DGR HARD HAT
25 2 090090 DECAL JCI 1200 LS
26 2 090508 DECAL ISO1040 WRNG HIGHPRESS
27 1 090490 ISO5018 DECAL FALL HZD
29 2 090499 ISO1017 DECAL PINCH PT
30 1 090498 ISO6126 DECAL READ OPS MAN
31 2 090069 DECAL NON FLAMABLE GAS
32 1 090504 DECAL ARROW CLOCKWISE
ROTATION
33 2 090506 DECAL KPI/JCI 22.00 X 5.00
34 1 090056 DECAL BUILT IN USA SMALL
35 1 090556 PL SERIAL NUMBER LS
45 1 085001 ELEMENT FILTER DONALDSON
46 4 546338 SHIM 16 GA BASEFRAME MNTG
47 1 456531 CONE LIFTING EYE Not Shown
48 1 456532 CONE LIFTING EYE ASSY Not Shown

Rev. O 4
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REF# 450246

Crusher Components

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 060039 SHEAVE 8V 6GR 24.8 OD 24.6 PD
2 1 060005 BUSHING QD M 2-15/16
3 6 060199 V-BELT 8V 1400 NOT SHOWN

Rev. O 5
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REF# 450241

Upper Assembly 1200LS/SS

Rev. G 6
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REF# 450241

Upper Assembly 1200LS/SS

Rev. G 7
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REF# 450241

Upper Assembly 1200LS/SS

Rev. G 8
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REF# 450241

Upper Assembly 1200LS/SS

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 450042 BONNET MACH
2 1 450221 SUPT BONNET MACHINING 1200
3 8 450055 ROD PRESSURE
4 3 087001 VALVE RELIEF 3/8
5 4 450130 WEDGE BOWL CASTING
6 4 076011 NUT JAM ADJUSTING JACK
7 8 450006 CONNECTOR FLUID
8 32 080007 O-RING 2-012
9 1 450065 BLOCK MANIFOLD
10 1 540166 ACCUM 1GAL 1.25NPT
11 8 450109 ASSY CLAMP CYL
12 4 450116 ASSY ADJUSTING JACK
13 1 082012 HOSE 1/4X 12IN - 04MB X 04MC
14 2 083019 4-JBU-S (PARKER)
15 2 083018 4-4-FBU-S (PARKER)
16 4 083017 4-4-CBU-S (PARKER)
17 8 450044 CVR DUST CYL RELIEF
18 3 083038 CPLR DISC QUICK PVV-14-F
19 3 083051 TMP-14
20 168 081001 TUBE .250 X .049 HYD
21 4 450218 PIN ROTATION STOP 1200
22 4 450217 ROTATION STOP LOWER (BOLT ON)
23 8 450216 BOLT PRESS RING SOLID MANIFOLD
24 2 540168 ACCUM 5GAL SPLIT FLANGE 3000
25 1 450638 RING BEAM RELIEF CYLINDER
26 8 450215 ASSY CYL RELIEF1200
27 2 540157 BRKT ACCUM 5GAL 180DEG
28 12 540173 BRKT ACCUMULATOR BLOCK
29 2 450222 BRKT M ACCUM MOUNT
30 8 070180 CAPSCREW HEX 1 8NC X 5 G8 ZIN
31 8 078030 WASHER HT 1 YELLOW ZINC
32 2 083022 B7405X4
33 2 083023 7129X4
34 1 083078 5406-P-20
35 6 083055 CLIP MNTG 1/4 TUBE
36 4 083124 FLANGE SPLIT 51H32
37 2 540203 BRKT ACCUMULATOR 1GAL
38 8 084016 O-RING 6230-12
39 32 070107 CAPSCREW HEX 3/4 10NC X 4-1/2

Rev. G 9
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REF# 450241

Upper Assembly 1200LS/SS

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
40 2 070086 CAPSCREW HEX 5/8 11NC X 5 G5
41 10 070134 CAPSCREW HEX 5/8 11NC X 6 G5
42 4 070014 CAPSCREW HEX 5/8 11NC X 2-1/2
43 38 076001 NUT NYLOCK 5/8-11 NC
44 16 076040 NUT HEAVY HEX JAM 2-1/4 X 4-1/
45 6 070055 CAPSCREW HEX 1/4 20NC X 3/4
46 2 070080 CAPSCREW HEX 5/8 11NC X 3-1/2
47 4 540507 STOP WEDGE LOWER
48 32 078026 WASHER LOCK 3/4
49 2 090063 OAKUM DARK
50 8 540236 ANGLE CLIP 2X2X3/8
51 20 078000 WASHER HT 5/8 YELLOW ZINC
52 4 540303 BRKT ACCUM HD BOLT CLAMP
53 2 450301 BRKT ACCUM
54 2 540304 BRKT ACCUM 5GAL BOTTOM
55 4 070151 SETSCREW SOC 1/2 13NC X 3/4
56 6 078022 WASHER LOCK 1/4
57 4 450302 CAP ROT PLG STOP CCF2 1/2-8-12
58 2 084069 O-RING 2-228 32 SPLIT FLANGE
59 8 070194 CAPSCREW HEX 1/2 13NC X 4-1/2
60 8 078025 WASHER LOCK 1/2
61 20 070158 CAPSCREW HEX 5/8 11NC X 2-1/4
62 1 450520 HOPPER 1200LS
63 4 070016 CAPSCREW HEX 1/2 13NC X 1-1/2
64 4 076005 NUT NYLOCK 1/2 13NC

Rev. G 10
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REF# 450109

Clamp Cylinder Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 450343 CLAMP CYLINDER
2 1 450359 INSERT CLAMP CYLINDER
3 1 080009 SEAL U-CUP CLAMP CYL 1870-2
4 1 079004 RETAINING RING BRG INC-UR262
5 1 079005 RETAINING RING SMALLEY-BS-437
6 1 080010 SEAL ANCHOR PK CLAMP CY 1870-4
7 1 450000 CLAMP CYLINDER PISTON
8 1 450479 SLEEVE, BRASS, CLAMP CYLINDER
9 1 450480 THREADED COVER CLAMP CYLINDER
10 1 080011 SEAL DUST CLAMP CYL 18939H

Rev. 0 11
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REF# 450116

Adjusting Jack Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 450114 RAM, ADJUSTING JACK
2 1 450003 CYL WELDMENT, ADJ JACK
3 1 450110 GUIDE, OUTER, ADJ JACK CYL
4 1 450113 GUIDE, INNER ADJ. JACK CYL
5 1 080013 SEAL ADJ JACK POLY, 2500-1
6 1 079006 SNAP RING SH100STPA (5100-100)
7 1 070029 RETAINING RING, WH162

Rev. 0 12
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REF# 450215

Relief Cylinder Assembly 1200LS

ITEM QTY PART NUMBER DESCRIPTION COMMENTS

1 1 450214 RELIEF CYLINDER - 1200
2 1 540158 PISTON CORE
3 1 079002 SNAP RING, 5100-450
4 1 080046 SEAL, RELIEF CYLINDER
5 1 080041 SEAL, RELIEF CYLINDER RCII
6 2 080042 SEAL, SPLIT, RELIEF CYL, RCII

Rev. 0 13
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REF# 450242

Lower Assembly 1200LS

Rev. R 14
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REF# 450242

Lower Assembly 1200LS

Rev. R 15
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REF# 450242

Lower Assembly 1200LS

Rev. R 16
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REF# 450242

Lower Assembly 1200LS

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 450243 ASSY PL WEDGE 1200 LS
2 1 450244 ASSY CONE 1200 LS/SS
3 1 450268 ASSY PINION 1200LS
4 1 450043 RING SEAL BASEFRAME
5 4 450068 PIN PUSH BASEFRAME
6 4 084009 O-RING 6227-27
7 1 450497 FLOATING PLATE W/ INSERTS
8 1 406087 SHAFT CONE BRAKE
9 1 546840 PIN CLUTCH ASSEMBLY 10 PIN
11 1 450166 THRUST PLATE
12 1 406109 CONE BRAKE PLATE
14 1 546844 CLUTCH GUIDE RING 10 PIN
15 1 450227 CVR BRAKE HOUSING 1200
16 3 540129 ROLLER SHIM GUARD
17 8 450069 BOLT ADJ CONNECT QUICK
18 1 450485 ASSY HEATER 2000W 120V
19 1 450603 BASEFRAME MACH (SEE TEXT)
22 2 406110 BRAKE SHAFT KEY
25 4 070130 CAPSCREW HEX 5/16 24NF X 3/4
26 4 070203 CAPSCREW SOC 5/16-18NC X 1-1/2
27 6 070152 CAPSCREW HEX 1 14NF X 3
28 20 070027 CAPSCREW HEX 1/2 13NC X 1-1/4
29 2 070141 SETSCREW SOC 5/8 11NC X 5/8
30 8 450148 CPLR BOLT ADJ 2 SPLITS
31 8 070010 CAPSCREW HEX 5/8 11NC X 1-3/4
32 8 540226 RETAINER ADJ BOLT
33 8 450126 WASHER BOLT ADJ
34 3 070016 CAPSCREW HEX 1/2 13NC X 1-1/2
35 8 084065 O-RING PARK 2-329 2.375 OD
36 4 540222 BASEFRAME STRUT GUARD
39 1 083033 PIPE SCH 40 1-1/4 X 26 NPT
40 1 083032 ELBOW SCH 40 1-1/4 NPT 90
41 1 540243 BRKT FILL PIPE
42 1 540191 DIPSTICK
43 1 450157 KEY DRIVE SHEAVE
45 32 078025 WASHER LOCK 1/2
46 8 078014 WASHER LOCK 5/8
47 1 083061 5503-08-08
48 1 083082 1404-08-08

Rev. R 17
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REF# 450242

Lower Assembly 1200LS

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
49 1 082013 HOSE 939B 27.5 SS WIRE CON TFE
50 2 083079 CLAMP TUBE 3/4-PARK #3075
51 1 083035 PIPE SCH 40 1-1/4 X 4 NPT
53 1 083515 FS2501-12-08
55 1 083496 FS2501-16-16
56 1 546685 KIT HOSE LUBE
60 1 079124 RET RING SMALLEY WHM-162
61 1 080032 PLUG MAGNETIC 1
62 1 450628 SPACER CLUTCH CVR 10-PIN
63 12 070048 CAPSCREW HEX 1/2-13NC X 2 G5

Rev. R 18
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REF# 450243

Wedgeplate Assembly 1200LS

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 450634 WEDGE PLATE, 1200LS
2 1 450059 GEAR, RING (SPIRAL)
3 1 450007 SEAL RING - UPPER WEDGE PLATE
4 1 450008 SEAL RING - LOWER WEDGE PLATE
5 1 456156 BEARING, RADIAL
6 3 450228 UPPER RADIAL RETAINER
7 1 406017 BEARING, UPPER THRUST
8 1 450023 BEARING, LOWER THRUST
9 11 450035 COUNTERWEIGHT, LIGHT
10 1 450034 COUNTERWEIGHT, LEADING
11 4 450088 SHIM, COUNTERWEIGHT, 1/8
12 4 450089 SHIM, COUNTERWEIGHT, 1/4
13 8 070025 CAPSCREW HEX 3/4 16NF X 2-1/2
14 6 070027 CAP SCREW HEX 1/2 13NC X1-1/4
15 12 070083 CAP SCREW HEX 7/8-9NC X2-1/2
16 12 078034 WASHER, LOCK, 7/8
17 1 450134 WEAR BAND WEDGE PL SEAL RG

Rev. C 19
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REF# 450244

Cone Assembly 1200LS/SS

Rev. E 20
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REF# 450244

Cone Assembly 1200LS/SS

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 450247 CONE WITH STEM - 45
2 1 450151 MANTLE BOLT
3 1 450057 MANTLE NUT
4 1 450053 MANTLE NUT CAP - 45 INCH
5 1 450056 MANTLE WASHER
6 1 450018 SEAL RING - CONE
7 1 450052 RETAINER, CONE RADIAL BEARING
8 1 456156 BEARING, RADIAL
9 1 450501 TORQUE BAR, UNHARDENED
10 1 450257 PIN, .500 X 1.000
11 2 070189 CAP SCREW SOC 7/8 9NC X 1-3/4
12 4 070032 CAP SCREW HEX 3/8 16NC X1-1/4
13 1 070105 CAP SCREW SOC 1-1/4 7NC X2-1/2
14 1 450258 PIN, .875 X 2.000
15 1 084041 O-RING 6227-48
16 1 084050 O-RING 6227-60

Rev. E 21
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REF# 450244

Cone Assembly 1200LS/SS

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
17 1 540103 FOAM, 1

Rev. E 22
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REF# 450268

Pinion Assembly 1200LS

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 450267 PINION HOUSING
2 1 450058 GEAR, PINION (SPIRAL)
3 1 450033 PINION SHAFT
4 1 450111 NUT LOCK, PINION BEARING
5 1 450117 BEARING, PINION, CUP, OUTER
6 1 450118 BEARING, PINION, CONE, OUTER
7 1 450119 BEARING, PINION, CUP, INNER
8 1 450120 BEARING, PINION, CONE, INNER
9 1 450156 KEY, PINION GEAR
10 1 450067 LOCKNUT, PINION SHAFT
11 1 540140 KEY, LOCK RING
12 1 450027 COVER PLATE
13 1 070142 SETSCREW 3/8 X 3/8 NC SOC HD
14 8 070032 CAP SCREW HEX 3/8 16NC X1-1/4
15 8 078024 WASHER, LOCK, 3/8
16 1 070150 SETSCREW 1/4-20NC X 1/2 SOC HD
17 1 084055 O-RING 6227-74
18 1 450028 FLINGER - INNER
19 1 450029 FLINGER - OUTER

Rev. A 23
 11/11/10

REF# 450497

Floating Plate Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 450168 FLOATING PLATE
2 2 450312 FLOATING PLATE UPPER INSERT
3 2 450313 FLOATING PLATE LOWER INSERT
4 16 070039 CAP SCREW SOC 3/8 16NC X 3/4
5 2 450498 FLOATING PLATE UPPER INSERT

Rev. C 24
 11/11/10

REF# 546840

Pin Clutch Assembly

Rev. 0 25
 11/11/10

REF# 546840

Pin Clutch Assembly

PART
ITEM QTY DESCRIPTION COMMNETS
NUMBER
1 1 546841 BLOCK DRIVE 10-PIN
2 1 546842 BLOCK RATCHET 10-PIN
3 10 546641 PIN DRIVE
4 1 546460 WASHER THRUST
5 10 090442 SPRG COMPRES C0600-0490-1750
6 10 070540 CAPSCREW BUTTON 1/2-13NCX1
7 1 079052 RING RET SMALLEY WS-250

Rev. 0 26
 11/11/10

REF# 450485

Heater Assembly 2000W 120V

Rev. A 27
 11/11/10

REF# 450485

Heater Assembly 2000W 120V

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 450254 HEATER COVER WELDMENT
2 1 540533 HEATER MACHINED,2000W,220V
3 1 540294 HEATER ELECTRICAL BOX COVER
4 1 020026 THERMO ON 60 DEG OFF 80 DEG.
5 2 540254 GASKET, HEATER
6 4 070032 CAP SCREW HEX 3/8 16NC X1-1/4
7 2 070008 CAP SCREW HEX 3/8 16NC X1G5
8 1 076042 NUT 1-1/2-6NC
9 1 070056 MACH SCREW RD HD #8-32NC X 3/4
10 2 020036 LUG, T & B C-10-8
11 2 020037 CONNECTOR 3/4X90 FITS 3/4 FLEX
12 192 020033 CONDUIT, 3/4 FLEX, NON-METALLI
13 2 020041 DISCONNECT FEM 10-12 GA, NYLON
14 2 020042 DISCONNECT FEM 14-16 GA, NYLON
15 2 020043 DISCONNECT MALE 14-16GA NYLON
16 196 020028 WIRE, 10 GA THHN, WHITE
17 196 020029 WIRE, 10 GA, THHN RED
18 196 020030 WIRE, 16 GA MTW BLACK
19 196 020031 WIRE, 16 GA MTW BLUE
20 196 020032 WIRE, 16 GA MTW GREEN
21 1 076046 NUT, #8-32NC
22 1 078037 WASHER, LOCK, #8
23 4 078024 WASHER, LOCK, 3/8
24 2 020018 SEALING RING 5263
25 2 020019 LOCKNUT, RID METAL CON, 3/4 T
26 1 080032 PLUG, MAGNETIC 1

Rev. A 28
 11/11/10

REF# 450603

Baseframe Machining

Rev. D 29
 11/11/10

REF# 450603

Baseframe Machining

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 450604 BASEFRAME WELDMENT
2 1 456116 CENTER SECT STRAIGHT BORE
3 3 456344 PLUG 1.625 DIA X 0.500
4 12 540242 CLAMP RING PAD GUSSET
5 5 070103 CAPSCREW SOC 1-1/2 6NC X 4
6 1 456061 SPINDLE BASEFRAME - 1040
7 1 450249 NUT AN-44
8 1 456125 PL WEAR PINION TUNNEL REMOTE
9 1 450159 RING CLAMP

Rev. D 30
 11/11/10

REF# 540191

Dipstick

ITEM QTY PART NUMBER DESCRIPTION COMMENTS

1 1 083036 CAP, BLACK PIPE, 1-1/4
2 1 051046 DIP STICK SHAFT 24.75"
3 1 076148 NUT 1/2-13NC PLAIN

Rev. B 31
 11/11/10

REF# 546685

Lube Assembly Hose Kit

Rev. A 32
 11/11/10

REF# 546685

Lube Assembly Hose Kit

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 72 088051 HOSE 16GMV
2 72 088013 HOSE 12G2
3 1 088124 16G-16MFFOR
4 1 088134 16G-16FFORX
5 1 088123 12G-12MFFOR
6 1 088133 12G-12FFORX
7 1 083508 FS0304-C-12
9 1 083350 FS0304-C-16

Rev. A 33
 11/11/10

REF# 450141

Shim Guard

ITEM QTY PART NUMBER DESCRIPTION COMMENTS

1 1 450140 RING, SHIM GUARD
2 1 540130 LEG, SHIM GUARD
5 1 090039 TOGGLE, SHIM GUARD
8 3 620134 HANDLE
9 1 076043 NUT, 5/8-18NF

Rev. A 34
 11/11/10

REF# 450184

Shim Stack Kit

No Graphic Available

ITEM QTY PART NUMBER DESCRIPTION COMMENTS

1 1 450090 SHIM ADJUSTING .062 Lt Green
2 5 450091 SHIM ADJUSTING .125, WHITE
3 1 450092 SHIM ADJUSTING .188, YELLOW
4 1 450093 SHIM ADJUSTING .250, BLACK
5 1 450094 SHIM ADJUSTING .313, RED
6 1 450095 SHIM ADJUSTING .375, BLUE
7 1 450096 SHIM ADJUSTING .500, ORANGE
8 1 450097 SHIM ADJUSTING .625, BROWN
9 1 450098 SHIM ADJUSTING .750, PURPLE
10 1 450099 SHIM ADJUSTING .875, GREY
11 1 450100 SHIM ADJUSTING 1.000, GREEN
12 2 450101 SHIM ADJUSTING 1.500, WHITE

Rev. 0 35
 11/11/10

REF# 456532

Cone Lifting Eye Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 456533 CONE LIFTING EYE BASE
2 1 078056 WASHER HT 1 1/4
3 1 070548 CAPSCREW SOC 1-1/4 7NC X 4-1/2
4 1 456534 CONE LIFTING EYE WELDMENT
5 4 078004 WASHER HT 1/2
6 4 070486 CAPSCREW HEX 1/2-13 X 1-3/4 G8

Rev. 0 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

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 060539 MTR 3HP 182TC
2 1 080024 PUMP LUBE .761 CU IN/REV
3 1 089093 COUPLING LO95 .500x1.125
4 1 080030 PUMP ADAPTOR (FIL-4AA)
5 1 085004 FILTER ASSY DONALDSON HAK05
6 1 456154 LUBE PANEL EXT
7 1 080027 FLOW SWITCH 54
8 1 450187 HORN ASSY 120V NO PROJECTOR
9 1 456169 J BOX 110V/60HZ 8.0 X 6.0
10 1 450620 KIT HOSE LUBE
11 2 083527 5406-24-12
12 1 083030 5404-12-08
13 2 083191 5605-12-12-12
14 1 080034 5406-12-04
15 1 083026 5502-04-02
16 1 083016 SAMPLER PLUG
17 1 090114 THERM 40-240F, 5' CAPILLARY
18 1 083515 FS2501-12-08
19 1 083346 FS2501-16-12
21 1 080043 COVER PLATE PUMP ADAPTOR
22 1 083074 NEEDLE OIL SAMPLER W/TUBING
23 1 020027 "CONN 3/4"" X 90 T&B 2272 "
24 4 070224 CAPSCREW SOC 5/16 18NC X 1-1/4
25 4 076022 NUT 5/16 18NC
26 4 078023 WASHER LOCK 5/16
27 4 070066 CAPSCREW HEX 5/16-18NC X3/4
28 4 076027 NUT NYLOCK 5/16-18NC
29 4 070009 CAPSCREW HEX 3/8 16NC X 3/4 G5
30 2 070056 MACH SCREW RD HD #8-32NC X 3/4
31 8 078024 WASHER LOCK 3/8
32 4 070008 CAPSCREW HEX 3/8 16NC X1G5
33 6 070062 CAPSCREW HEX 1/4 20NC X 1 G5
34 6 076026 NUT NYLOCK 1/4-20NC
35 6 078015 WASHER FLAT 1/4
36 2 020019 "RIGID 3/4"" LOCKNUT T&B 142 "
37 2 020018 "SEALING RING 3/4"" T&B 5263 "
38 1 083471 FS2501-08-12
39 40 020034 CORD 16/4 SO
40 1 020138 RCPT CVR FLIP LID PELWR81C

Rev. M 41
 11/11/10

REF# 450197

External Lube Panel Assembly 1200LS

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
41 1 020139 RCPT BOX SINGLE GANG T&B T11
42 1 020422 RCPT DUPLEX 250V 15A HBL5662I
43 1 083192 NIPPLE 3/4 NPT X 5 BLK
48 3 020014 "CORD GRIP 1/2"" .38-.50 CGB194 "
49 3 020038 SEALING RING T&B 5262
50 3 020039 "RIGID 1/2"" LOCKNUT T&B 141 "
51 2 020147 "KNOCKOUT SEAL 3/4"" 90052 "
52 1 083193 5404-12-12
53 2 083160 5406-12-08
54 1 020199 "CORD GRIP 1/2"" .38-.50 CGE194 "
55 3 020016 TERM VINYL LOCKING FORK
56 1 406218 ADAPTER PLATE
57 4 070470 CAPSCREW SOC 1/2-13 X 1-1/4
59 1 090089 DECAL NOTICE RUN LUB
60 1 090311 DECAL DANGER HIGH VOLTAGE
61 1 090551 DECAL ISO 110V YELLOW
62 1 090194 DECAL ROTATION ARROW
63 4 078016 WASHER FLAT 5/16
65 1 083508 FS0304-C-12 NOT SHOWN
66 1 083350 FS0305-C-16 NOT SHOWN

Rev. M 42
 11/11/10

REF# 456154

External Lubrication Panel Housing Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 456152 EXT LUBE PANEL SIDES,FORMED
2 1 456153 EXT LUBE PANEL BASE,FORMED
3 1 540011 OIL FILTER BRACKET, DONALDSON
4 1 456167 MTG BRACKET,BY-PASS VALVE
5 1 456461 MOTOR BASE
6 5 070016 CAP SCREW HEX 1/2 13NC X1-1/2
7 10 078019 WASHER, FLAT, 1/2
8 5 078025 WASHER, LOCK, 1/2
9 5 076024 NUT, 1/2-13NC
10 1 620128 LIFTING EAR

Rev. C 43
 11/11/10

REF# 450187

Horn Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 020001 HORN BASE
2 1 020421 HORN FED SIGNAL 350-240-30

Rev. B 44
 11/11/10

REF# 456169

Lube Panel J-Box Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 020136 ENCL 8X6X3.5 NEMA4/12/13
2 1 020137 ENCL PNL 8X6 A8P6
3 12 020500 TERM BLOCK (J4) AB1492-J4
4 2 020512 TERM BLOCK END STOP
5 4.75 020182 DIN MOUNTING RAIL DIN #3
6 2 020510 TERM BLOCK END PLATE
7 0.5 020103 GROUND BAR KIT 14 POS GB14
8 1 020505 TERM BLOCK CENTER JUMPER 2P J4
9 0.1 020513 MARKER TERM 6CMX12CM
10 2 070341 MACHSCREW RD HD 10-24 x .500
11 2 076072 NUT 10-24 NC

Rev. F 45
 11/11/10

REF# 450499

Hose Kit 1200LS & 1400LS

Rev. 0 46
 11/11/10

REF# 450499

Hose Kit 1200LS & 1400LS

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 72 088014 HOSE 16G2
2 88 088013 HOSE 12G2
3 2 088133 12G-12FFORX
4 2 088134 16G-16FFORX
5 1 083579 FS2408-12
6 1 083580 FS2408-16

Rev. 0 47