an Astec Company

Crusher Operation and

Service Manual
and Parts Book

JCI LS Series Crusher

S/N C060396

86470 Franklin Blvd, Eugene, OR 97405 • 800-314-4656 • 541-736-1400 • Fax 541-988-9401

24/7 Parts Number 888-474-0115
 1200LS
Crusher Parts Book
Serial Number: C060396

JCI 24/7 Parts Number 888-474-0115

© 2006 JCI
 JCI Parts Ordering Information
The JCI Parts Department is open from 7 AM to 5 PM Pacific Time. You can contact us in the following
ways:

• *24/7 Phone (24 Hours- 7 Days a week): 1-888-474-0115 (Even holidays!)

• Fax: 541-988-9487
• Email: 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

© 2006 JCI
 Important Safety Precautions

WARNING: Failure to adhere to the following safety precautions may result in

serious injury or death.

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

JCI 24/7 Parts Number 888-474-0115

© 2006 JCI
crushing chamber for service work. Never rely on hydraulic pressure to keep the upper frame raised.
You could be crushed and killed if the upper frame lowers unexpectedly.
• Always stop the crusher immediately if any gauges show abnormal readings, or if there is a sudden
obvious change in operation. Be alert for noises that might indicate trouble.
• Inspect, lubricate, maintain and repair the crusher in accordance with the instructions contained in
this manual and any additional manuals or documentation provided with the crusher.
• Inspect all warning signs and caution decals. If they become torn or not readable contact your local
dealer or Johnson Crushers International for replacement.
• On portable plants be sure that the trailer is properly blocked and level. All blocking must be suit-
able to support the trailer dead load weight plus the crusher impact live loading.
• Before starting the crusher visually check the tramp iron and clamp cylinder pressure gauges on the
hydraulic manifold. Both pressures should range from 2700 psi to 3000 psi. Occasionally check the
system pressure gauge with the hydraulic pump motor running. This pressure shall not exceed 3000
psi.
• Avoid stopping the crusher with material inside the crushing chamber. In the event that the crushing
chamber is full of rock use the hydraulic clearing feature. Always inspect the crushing chamber and
U-seat after a clear for loose or jammed rock.
• Do not adjust the close side setting smaller than the recommended minimum setting for your mantle
and bowl liner combination.
• An oil flow meter has been provided as a safety device to protect the crusher components in the
event of a lubrication system failure. Should the flow meter detect a flow of oil less than its preset
value, the electrical panel will activate the warning horn alerting crusher operators that the machine
needs to be shut down immediately to prevent permanent damage to crusher components. In addi-
tion, it is strongly suggested that the control circuit be wired such that, when the warning system is
activated, the feed device feeding the crusher is shut down. The crusher should be shut down imme-
diately after the rock has cleared the crushing chamber (less than 10 seconds).Wear your hard hat at
all times.
• Stop the crusher, lock out power, and tag controls:
1.Before performing any lubrication, maintenance, adjustments, or repairs.
2.Before removing any spilled materials.
3.Before clearing jams or working on the crusher.
4.Whenever any unusual noises or sudden changes in operation are noticed .
• Refer to the JCI Operation Manual for screen safety information. If your copy of the manual is miss-
ing, please contact your local JCI dealer or the JCI Parts Department for a replacement copy.Read
your Operation Manual for your screen. Be sure that you fully understand all phases of screen opera-
tion. A careful and well-trained operator is the best insurance against an accident.

JCI 24/7 Parts Number 888-474-0115

© 2006 JCI
 Factory Installed Counter Weight Configuration

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 450034 LEADING 1200LS
2 1 450035 MEDIUM 1200LS
3 1 450035 MEDIUM 1200LS
4 1 450035 MEDIUM 1200LS
5 1 450035 MEDIUM 1200LS
6 1 450035 MEDIUM 1200LS + 1 1/4 SHIM 450089 - 1/4 SHIM
7 1 450035 MEDIUM 1200LS + 1 1/4 SHIM 450089 - 1/4 SHIM
8 1 450035 MEDIUM 1200LS + 2 1/4 SHIM 450089 - 1/4 SHIM
9 1 450035 MEDIUM 1200LS + 2 1/4 SHIM 450089 - 1/4 SHIM
10 1 450035 MEDIUM 1200LS + 2 1/4 SHIM 450089 - 1/4 SHIM
11 1 450035 MEDIUM 1200LS + 2 1/4 SHIM 450089 - 1/4 SHIM
12 1 450035 MEDIUM 1200LS + 2 1/4 SHIM 450089 - 1/4 SHIM

JCI 24/7 Parts Number 888-474-0115

© 2006 JCI
 Factory Installed 1200LS Manganese Configuration

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 450128X MANTLE 66lbs poured
2 1 450127X BOWL LINER 44lbs poured
3 110 lbs 090037 MANGANESE BACKING MATERIAL

JCI 24/7 Parts Number 888-474-0115

© 2006 JCI
 Drive Sheave and Miscellaneous Items

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 060039 SHEAVE 6GR 8V 24.6 PD 24.8 OD
2 1 060005 QD BUSHING M 2 - 15/16
5 1 450076 SEAL, SHIM GUARD
6 8 450148 ADJ BOLT COUPLER 2 SPLITS
7 8 450358 ALIGNING WASHER-CLAMP CYL
8 8 084001 O-RING 6227-30
9 8 084065 O-RING PARK 2-329 2.375 OD
10 8 450162 ADJUSTING BOLT WASHER
12 8 450184 SHIM STACK KIT
N/A 1 090034 WRENCH ALLEN 7/8
N/A 1 450133 CONE LIFTING EYE
N/A 1 450030 WRENCH CLAMP CYLINDER
N/A 1 450132 WRENCH MANTLE NUT
N/A 1 N/A MOTOR 200HP

JCI 24/7 Parts Number 888-474-0115

© 2006 JCI
 Decals
PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
20 1 090023 DECAL, DRIVE GUARDS
21 1 090024 DECAL, EYE PROTECTION
22 1 090025 DECAL, HEARING PROTECTION
23 1 090026 DECAL, LOCKOUT
24 1 090027 DECAL, HARDHAT
25 1 090090 DECAL - JCI 1200 LS
26 1 090064 DECAL -DANGER EXP DECOMPRESS
27 1 090065 DECAL-DANGER-SERIOUS INJURY
28 1 090066 DECAL-NOTICE-BLOCK CONE HD
29 1 090067 DECAL-NOTICE-DO NOT ALLOW MAT
30 1 090068 DECAL-CAUTION-CONSULT YR OPER
31 2 090069 DECAL-NON-FLAMABLE GAS
33 1 090074 DECAL - WORLD CLASS...
34 1 090056 DECAL, MADE IN AMERICA
35 1 090022 SERIAL NUMBER PLATE

JCI 24/7 Parts Number 888-474-0115

© 2006 JCI
 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 1 360247 ACCUMULATOR BAG 2-1/2 GALLON
8 450266 NITROGEN PRESSURE GAUGE
9 1 450015 ACCUMULATOR CHARGE KIT
10 1 450364 PORT ASSEMBLY
11 1 084069 O-RING FOR THE PORT ASSEMBLY
Seal Kits
PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
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
1 1 082010 HOSE 1X144 1M SWIVEL X 1M SW
1 1 082009 HOSE 1/2X160 1/2 M SWIVELX1/2M
1 1 083067 5405-12-16 ADAPTER, PIPE

JCI 24/7 Parts Number 888-474-0115

© 2006 JCI
 Table of Contents

Upper Assembly 1200LS/SS ................................................................................. 1

Clamp Cylinder Assembly ...................................................................................... 5

Adjusting Jack Assembly ....................................................................................... 6

Relief Cylinder Assembly 1200LS .......................................................................... 7

Lower Assembly 1200LS ....................................................................................... 8

Wedgeplate Assembly 1200LS .............................................................................. 11

Cone Assembly 1200LS/SS ................................................................................... 12

Pinion Assembly 1200LS ....................................................................................... 13

Floating Plate Assembly ........................................................................................ 14

Pin Clutch Assembly .............................................................................................. 15

Heater Assembly 2000W 120V .............................................................................. 17

Shim Guard ............................................................................................................ 19

Shim Stack Kit ....................................................................................................... 20

External Lube Panel Assembly 1200LS ................................................................. 21

Horn Assembly ....................................................................................................... 24

Lube Panel J-Box Assembly .................................................................................. 25

Bonnet Components ............................................................................................. 26

JCI 24/7 Parts Number 888-474-0115

© 2006 JCI
 PAGE 1

REFERENCE # 450519

Upper Assembly 1200LS/SS

Rev. 0 JCI 24/7 Parts Number 888-474-0115 06/19/03

© 2003 JCI
 PAGE 2

REFERENCE # 450519

Upper Assembly 1200LS/SS

Rev. 0 JCI 24/7 Parts Number 888-474-0115 06/19/03

© 2003 JCI
 PAGE 3

REFERENCE # 450519

Upper Assembly 1200LS/SS

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 450042 BONNET
2 1 450221 BONNET SUPPORT
3 8 450055 PRESSURE ROD
4 4 087001 VALVE, RELIEF, 3/8
5 4 450130 WEDGE, BOWL, CASTING
6 4 076011 NUT, JAM, ADJUSTING JACK
7 8 450006 FLUID CONNECTOR
8 32 080007 O-RING, 2-012
9 1 450065 MANIFOLD BLOCK
10 1 540166 ACCUMULATOR, 1 GAL 1-1/4NPT
11 8 450109 CLAMP CYLINDER ASSEMBLY
12 4 450116 ADJUSTING JACK ASSEMBLY
13 1 082012 HOSE 1/4X 12IN - 04MB X 04MC
14 2 083019 MALE BRANCH TEE, 1/4
15 2 083018 C2404-04-04, MALE CONN TU 1/4
16 4 083017 C2501-04-04, MALE ELBOW T 1/4
17 8 450044 DUST COVER, RELIEF CYLINDER
18 4 083038 PVV-14-F, COUPLER QUICK DISC F
19 4 083051 TMP-14, 1/4 DUST PLUG
20 168 081001 TUBING, 1/4 X .049 WALL
21 4 450218 ROTATION STOP PIN - 1200
22 4 450217 LOWER ROTATION STOP - BOLT ON
23 8 450216 PRESS RING BOLT SOLID MANIFOLD
24 2 540168 ACCUM, 5 GAL 1-7/8-12UN, SPLI
25 1 450511 RING BEAM RELIEF CYL-1200
26 8 450215 RELIEF CLY ASSEMBLY - 1200
27 2 540157 ACCUM BRACKET-5 GAL 180 DEG
28 12 540173 ACCUMULATOR BRACKET BLOCK
29 2 450222 ACCUM MOUNT M/BRACKET-1200
30 8 070180 "CAPSCREW HEX 1"" 8NC X 5 G8 ZIN"
31 8 078030 WASHER, HT, 1
32 2 083022 MALE ELBOW 1/4
33 2 083023 FLARELESS TUBE END CAP 1/4
34 1 083078 PIPE PLUG-1-1/4-PARK 1-1/4HP
35 6 083055 MOUNTING CLIP, 1/4 TUBE
36 8 083124 SPLIT FLANGE, 51H32
37 2 540203 ACCUMULATOR BRACKET, 1 GALLON
38 16 084016 O-RING 6230-12
39 32 070107 CAP SCREW HEX 3/4 10NC X 4-1/2

Rev. 0 JCI 24/7 Parts Number 888-474-0115 06/19/03

© 2003 JCI
 PAGE 4

REFERENCE # 450519

Upper Assembly 1200LS/SS

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
40 2 070086 CAP SCREW HEX 5/8 11NC X 5 G5
41 10 070134 CAP SCREW HEX 5/8 11NC X 6 G5
42 4 070014 CAP SCREW HEX 5/8 11NC X2-1/2
43 38 076001 NUT, NYLOCK 5/8-11 NC
44 16 076040 NUT HEAVY HEX JAM 2-1/4X4-1/2
45 6 070055 CAP SCREW HEX 1/4 20NC X 3/4
46 2 070080 CAP SCREW HEX 5/8-11NC X3-1/2
47 9 051006 FB .250 X 1.500
48 32 078026 WASHER, LOCK, 3/4
49 2 090063 OAKUM, DARK
50 8 540236 ANGLE CLIP, 2 X 2 X 3/8
51 20 078000 WASHER, HT, .625
52 4 540303 ACCUM BRKT HD BOLT CLAMP
53 2 450301 ACCUMULATOR BRACKET
54 2 540304 ACCUM BRKT 5 GAL BOTTOM
55 4 070151 SETSCREW 1/2-13NC X 3/4 SOC HD
56 6 078022 WASHER, LOCK, 1/4
57 4 450302 CAP ROT STOP PLG CCF2 1/2-8-12
58 4 084069 O-RING 2-228 32 SPLIT FLANGE
59 8 070415 CAPSCREW HEX 1/2 13NC X 5-1/2
60 8 078025 WASHER, LOCK, 1/2
61 20 070038 CAP SCREW HEX 5/8 11NC X2G5
62 1 450520 HOPPER, 1200LS
63 4 070016 CAP SCREW HEX 1/2 13NC X1-1/2
64 4 076005 NUT NYLOCK 1/2-13NC
65 2 450518 TUBE ASSEMBLY WELDMENT, 1200
66 2 450521 HOSE, ACCUMULATOR, SEE TEXT
68 2 088203 5151HK-24, SAE FLANGE KIT-24

Rev. 0 JCI 24/7 Parts Number 888-474-0115 06/19/03

© 2003 JCI
 PAGE 5

REFERENCE # 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 JCI 24/7 Parts Number 888-474-0115 03/20/03

© 2003 JCI
 PAGE 6

REFERENCE # 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 JCI 24/7 Parts Number 888-474-0115 03/20/03

© 2003 JCI
 PAGE 7

REFERENCE # 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 JCI 24/7 Parts Number 888-474-0115 06/19/03

© 2003 JCI
 PAGE 8

REFERENCE # 450242

Lower Assembly 1200LS

Rev. M JCI 24/7 Parts Number 888-474-0115 12/8/06

© 2006 JCI
 PAGE 9

REFERENCE # 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 1200 LS
4 1 450043 RING SEAL BASEFRAME
5 4 450068 PIN PUSH BASEFRAME
6 4 084009 O-RING 6227-27
7 1 450497 PL FLOATING W/ INSERTS
8 1 406087 SHAFT CONE BRAKE
9 1 546467 PIN CLUTCH ASSEMBLY
11 1 450166 PL THRUST
12 1 406109 PL CONE BRAKE
14 1 406014 RING GUIDE CLUTCH
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 SHAFT KEY BRAKE
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 32 070027 CAPSCREW HEX 1/2 13NC X 1-1/4
29 4 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
37 1 083024 5502-12-12
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
44 1 620150 ARROW
45 32 078025 WASHER LOCK 1/2
46 8 078014 WASHER LOCK 5/8

Rev. M JCI 24/7 Parts Number 888-474-0115 12/8/06

© 2006 JCI
 PAGE 10

REFERENCE # 450242

Lower Assembly 1200LS

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
47 1 083061 5503-08-08
48 1 083082 1404-08-08
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
52 2 070061 CAPSCREW HEX 1/4 20NC X 1/2
53 1 083005 5502-08-08
54 1 083068 5406-SHP-08
55 1 083083 5502-16-16

Rev. M JCI 24/7 Parts Number 888-474-0115 12/8/06

© 2006 JCI
 PAGE 11

REFERENCE # 450243

Wedgeplate Assembly 1200LS

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 450207 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 450021 BEARING, RADIAL
6 3 450228 UPPER RADIAL RETAINER
7 1 450022 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 14 070083 CAP SCREW HEX 7/8-9NC X2-1/2
16 14 078034 WASHER, LOCK, 7/8
17 1 450134 WEAR BAND WEDGE PL SEAL RG

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

© 2003 JCI
 PAGE 12

REFERENCE # 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 450021 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
17 1 540103 FOAM, 1

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

© 2003 JCI
 PAGE 13

REFERENCE # 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 JCI 24/7 Parts Number 888-474-0115 06/19/03

© 2003 JCI
 PAGE 14

REFERENCE # 450497

Floating Plate Assembly

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

Rev. C JCI 24/7 Parts Number 888-474-0115 12/22/04

© 2003 JCI
 PAGE 15

REFERENCE # 546467

Pin Clutch Assembly

Rev. A JCI 24/7 Parts Number 888-474-0115 12/8/06

© 2006 JCI
 PAGE 16

REFERENCE # 546467

Pin Clutch Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 546640 DRIVE BLOCK
2 1 546454 RATCHET BLOCK
3 6 546641 DRIVE PIN
4 1 546460 THRUST WASHER
5 6 090442 SPRING C0600-0490-1750 COMPRES
6 6 070496 CAPSCREW BUTTON 1/2-13NCX3/4
7 1 079052 RET RING SMALLEY WS-250

Rev. A JCI 24/7 Parts Number 888-474-0115 12/8/06

© 2006 JCI
 PAGE 17

REFERENCE # 450485

Heater Assembly 2000W 120V

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

© 2003 JCI
 PAGE 18

REFERENCE # 450485

Heater Assembly 2000W 120V

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 450254 HEATER COVER WELDMENT
2 1 540327 HEATER MACHINED,2000W,120V
3 1 540294 HEATER ELECTRICAL BOX COVER
4 1 020026 THERMO ON 60 DEG OFF 80 DEG.
5 2 540254 GASKET, HEATER
6 4 070032 CAP SCREW HEX 3/8 16NC X1-1/4
7 2 070008 CAP SCREW HEX 3/8 16NC X1G5
8 1 076042 NUT 1-1/2-6NC
9 1 070056 MACH SCREW RD HD #8-32NC X 3/4
10 2 020036 LUG, T & B C-10-8
11 2 020037 CONNECTOR 3/4X90 FITS 3/4 FLEX
12 192 020033 CONDUIT, 3/4 FLEX, NON-METALLI
13 2 020041 DISCONNECT FEM 10-12 GA, NYLON
14 2 020042 DISCONNECT FEM 14-16 GA, NYLON
15 2 020043 DISCONNECT MALE 14-16GA NYLON
16 196 020028 WIRE, 10 GA THHN, WHITE
17 196 020029 WIRE, 10 GA, THHN RED
18 196 020030 WIRE, 16 GA MTW BLACK
19 196 020031 WIRE, 16 GA MTW BLUE
20 196 020032 WIRE, 16 GA MTW GREEN
21 1 076046 NUT, #8-32NC
22 1 078037 WASHER, LOCK, #8
23 4 078024 WASHER, LOCK, 3/8
24 2 020018 SEALING RING 5263
25 2 020019 LOCKNUT, RID METAL CON, 3/4 T
26 1 080032 PLUG, MAGNETIC 1

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

© 2003 JCI
 PAGE 19

REFERENCE # 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 JCI 24/7 Parts Number 888-474-0115 06/19/03

© 2003 JCI
 PAGE 20
450184

REFERENCE # 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 JCI 24/7 Parts Number 888-474-0115 04/01/03

© 2003 JCI
 PAGE 21

REFERENCE # 450197

External Lube Panel Assembly 1200LS

Rev. F JCI 24/7 Parts Number 888-474-0115 07/29/03

© 2003 JCI
 PAGE 22

REFERENCE # 450197

External Lube Panel Assembly 1200LS

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 060033 MTR 2HP1800TEFC60HZ 145T TOS
2 1 080024 PUMP, LUBE .761 CU IN/REV
3 1 089005 COUP LUBE ASSY LOVEJOY L090, S
4 1 080030 PUMP ADAPTOR (FIL-4AA)
5 1 085004 FILTER ASSY, DONALDSON HAK05
6 1 456154 EXT LUBE PANEL
7 1 080027 FLOW SWITCH, 54
8 1 450187 HORN ASSY, 115V - NO PROJECTOR
9 1 456169 J-BOX 110V/60HZ 8.0 X 6.0
10 1 082064 HOSE 1/2X28.5 1/2MX1/2M SWIVEL
11 2 083527 BUSHING 1-1/2 NPT X 3/4 NPT
12 1 083030 PIPE NIPPLE 3/4X1/2FF 0101-8-1
13 2 083191 TEE,FEMALE 3/4 HP, 022T-12-12
14 1 080034 REDUCER 3/4P-1/4P HP 0102-12-4
15 1 083026 5502-04-02, ST ELBOW 1/4X1/8
16 1 083016 SAMPLER PLUG
17 1 090114 THERM, 40-240F, 5' CAPILLARY
18 1 083005 5502-08-08, ST ELBOW 90D 1/2
19 1 083024 5502-12-12, ST ELBOW 3/4
20 1 083067 5405-12-16 ADAPTER, PIPE
21 1 080043 COVER PLATE PUMP ADAPTOR
22 1 083074 OIL SAMPLER NEEDLE W/TUBIN
23 1 020027 CONNECTOR, 3/4 X 90 T&B 2272
24 4 070224 CAPSCREW SOC 5/16 18NC X 1-1/4
25 4 076022 NUT, 5/16-18NC
26 4 078023 WASHER, LOCK, 5/16
27 4 070066 CAP SCREW HEX 5/16-18NC X3/4
28 4 076027 NUT, NYLOCK 5/16-18NC
29 4 070009 CAP SCREW HEX 3/8 16NC X3/4G5
30 2 070056 MACH SCREW RD HD #8-32NC X 3/4
31 8 078024 WASHER, LOCK, 3/8
32 4 070008 CAP SCREW HEX 3/8 16NC X1G5
33 6 070062 CAP SCREW 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 LOCKNUT, RID METAL CON, 3/4 T
37 2 020018 SEALING RING 5263
38 1 083025 ST ELBOW 3/4X1/2 CD 2102-8-12
39 40 020034 WIRE, S/O, 16/4

Rev. F JCI 24/7 Parts Number 888-474-0115 07/29/03

© 2003 JCI
 PAGE 23

REFERENCE # 450197

External Lube Panel Assembly 1200LS

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
40 1 020138 COVER,RECEPT,FLIP LID
41 1 020139 OUTLET BOX, SINGLE GANG
42 1 020140 RECEPT,2P,3WIRE,15AMP,125V
43 1 083192 NIPPLE,PIPE,3/4 X 5.0 SCH 40
48 3 020014 "CONNECTOR,CGB 194,1/2"",.38-.50"
49 3 020038 SEALING RING, 1/2 (T&B 5262)
50 3 020039 LOCKNUT RID METAL CONDUIT 1/2
51 2 020147 "KNOCKOUT SEAL, 3/4"" "
52 1 083193 5404-12-12,NIPPLE,PIPE,3/4X3/4
53 2 083160 HEX BUSHING 3/4 X 1/2 PTR-S
54 1 020199 CONNECTOR 1/2X90 CGE194 .38X.5
55 3 020016 TERMINAL, LOCKING FORK, VINYL

Rev. F JCI 24/7 Parts Number 888-474-0115 07/29/03

© 2003 JCI
 PAGE 24

REFERENCE # 450187

Horn Assembly

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

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

© 2003 JCI
 PAGE 25

REFERENCE # 456169

Lube Panel J-Box Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 020136 BOX,HOFFMAN,A-806 CHNF,8.0X6.0
2 1 020137 PANEL, HOFFMAN, A-8P6
3 12 020500 TERM BLOCK (J4) AB1492-J4
4 2 020512 END STOP AB1492-EAJ35
5 4.75 020182 DIN MOUNTING RAIL, DIN #3
6 2 020510 END PLATES AB 1492-EBJ3
7 0.5 020103 GROUND BAR KIT, 14 POS
8 1 020505 CENTER JUMPER,2POLE (J4)
9 1 020145 TERMINAL BLOCK NO. TABS 0-9
10 2 070341 MACH SCREW RD HD 10-24 x .500
11 2 076072 NUT, 10-24 NC

Rev. D JCI 24/7 Parts Number 888-474-0115 12/8/06

© 2005 JCI
 10/20/08

REF# 450042

Bonnet Components

Rev. D 26
 10/20/08

REF# 450042

Bonnet Components
PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 450188 CASTING BONNET HD C1200LS
2 2 450219 EAR BONNET 12
3 4 090086 BUSH DRILL 2 ID X2.5025/2.5021
4 4 450489 RETAINER BUSHING
5 8 070016 CAPSCREW HEX 1/2 13NC X 1-1/2

Rev. D 27