JT820. Parts Manual. CMW Issue

Transcription

1 JT820 Parts Manual CMW Issue

2 1 JT820 ISSUE NO. 09PL-08/11 For Replacement Copy Order P/N This product is covered by one or more of the following patents: US B1 4,858,704; 4,953,638; 5,148,880; 5,242,026; 5,341,887; 5,490,569; 5,684,466; 5,713,423, 5,794,719; 5,880,680; 5,941,322; 6,085,852; 6,109,371; 6,179,065; 6,216,803; 6,250,403; 6,250,404; 6,290,606; 6,311,790; 6,411,094; 6,543,551; 6,550,547; 6,672,409; 6,739,413; 6,776,246; 6,808,210; 6,827,158; RE37,450; RE37,923; RE37,975; RE38,418 AU 689,533; 706,544; 718,034, 755,862 CA 2,156,398 FR 674,093 DE ; ; EP ; ; ; GB 2,209,239; 2,312,006; EP674,093; EP846,841 JP 3,458,247 Other U.S. and foreign patents pending This manual contains information concerning the following models: JT820 Directional Drilling System Copyright 1996, 2011 by The Charles Machine Works, Inc., Ditch Witch, CMW, AutoCrowd, Modularmatic, Jet Trac, Roto Witch, Subsite, Fluid Miser, Perma-Soil, Power Pipe, Super Witch, Super Witch II, Pierce Arrow, The Underground, and The Underground Authority Worldwide are registered trademarks of The Charles Machine Works, Inc. ID

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4 FOREWORD 3 This manual contains illustrated parts lists to help you select quality ProTech Replacement parts for your Ditch Witch equipment. Using other replacement parts will lessen the productivity of your equipment. Part numbers enclosed in a box are no longer available from The Charles Machine Works, Inc. Your local Ditch Witch dealer may be able to locate the part for you. Footnotes provide more information to help you identify parts shown in the manual. Assembly instructions and Tech Bits articles referenced in footnotes are available through your local Ditch Witch dealer. Description and specifications in this book were current at publication. However, The Charles Machine Works, Inc. reserves the right to improve equipment, so this manual might not reflect the most current improvements. Instructions on recommended equipment use and maintenance are in the Operator s Manual that was shipped with your equipment. Keep the following in mind when ordering ProTech replacement parts: Specify parts you need by part number and description, not by illustration reference numbers. Have equipment model and serial number on hand to help ensure you get the right parts for your machine whether it s old or new. Thank you for buying and using Ditch Witch equipment and ProTech replacement parts. 8/6/2010, Rev-B

5 4 WARRANTY DW WARRANTY Policy July, 2005 POLICY 1: DITCH WITCH EQUIPMENT AND REPLACEMENT PARTS LIMITED WARRANTY POLICY Subject to the limitation and exclusions herein, free replacement parts will be provided at any authorized Ditch Witch dealership for any Ditch Witch equipment or parts manufactured by The Charles Machine Works, Inc. (CMW) that fail due to a defect in material or workmanship within one (1) year of first commercial use (Exception: 2 years for all SK500 Attachments). Free labor will be provided at any authorized Ditch Witch dealership for installation of parts under this warranty during the first year following initial commercial use of the serial numbered Ditch Witch equipment on which it is installed. The customer is responsible for transporting their equipment to an authorized Ditch Witch dealership for all warranty work. EXCLUSIONS FROM PRODUCT WARRANTY All incidental or consequential damages. All defects, damages, or injuries caused by misuse, abuse, improper installation, alteration, neglect, or uses other than those for which products were intended. All defects, damages, or injuries caused by improper training, operation, or servicing of products in a manner inconsistent with manufacturer s recommendations. All engines and engine accessories (these are covered by original manufacturer s warranty). Tires, belts, and other parts which are subject to another manufacturer s warranty. (Such warranty will be available to purchaser.) ALL IMPLIED WARRANTIES NOT EXPRESSLY STATED HEREIN, INCLUDING ANY WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY. IF THE PRODUCTS ARE PURCHASED FOR COMMERCIAL PURPOSES, AS DEFINED BY THE UNIFORM COMMERCIAL CODE, THEN THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE FACE HEREOF AND THERE ARE NO IMPLIED WARRANTIES OF ANY KIND WHICH EXTEND TO A COMMERCIAL BUYER. ALL OTHER PROVISIONS OF THIS LIMITED WARRANTY APPLY INCLUDING THE DUTIES IMPOSED. Ditch Witch products have been tested to deliver acceptable performance in most conditions. This does not imply they will deliver acceptable performance in all conditions. Therefore, to assure suitability, products should be operated under anticipated working conditions prior to purchase. Defects will be determined by an inspection within thirty (30) days of the date of failure of the product or part by CMW or its authorized dealer. CMW will provide the location of its inspection facilities or it s nearest authorized dealer upon inquiry. CMW reserves the right to supply remanufactured replacement parts under this warranty as it deems appropriate. Extended warranties are available upon request from your local Ditch Witch dealer or CMW. Some states do not allow exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply. Further, some states do not allow exclusion of or limitation of how long an implied warranty lasts, so the above limitation may not apply. This limited warranty gives product owner specific legal rights and the product owner may also have other rights which vary from state to state. For information regarding this limited warranty, contact CMW s Product Support Department, P.O. Box 66, Perry, OK , or contact your local Ditch Witch dealer. Ver. 03 ID

6 CONTENTS 5 Decals Decal Location - JT Frame Components Carriage Chain Tensioner Covers/Guards Cylinder Grease Drill Frame Front Wrench Fuel Tank/Hydraulic Reservoir Idler Mud Mixing System Output Shaft Rear Stabilizer Roller Seat Mount Shift Lever Spring Track Group - Rubber Track Group - Steel Water Tank Support Engine Components Air Filter System Alternator Engine Fuel Filter Radiator Throttle Hydraulic Anchor Driver Hydraulics Break-out Hydraulics - Begins Break-out Hydraulics - Ends Carriage Thrust Hydraulics Control Valves/Levers Drive Control Valve/Levers Flow Divider Frame Tilt Ground Drive Hydraulics Hydraulic Cylinder (2.0 X1.0 X10.0 ) Hydraulic Cylinder (3.0 X1.5 X4.0 ) Hydraulic Cylinder (3.0 X1.5 X20.0 ) Hydraulic Motor - Rotation Hydraulic Oil Cooler Hydraulic Reservoir Hydraulic Schematic - Begins Hydraulic Schematic - Ends Mud Motor Hydraulics - Begins Mud Motor Hydraulics - Ends Mud Pump Plumbing Mud Tank Plumbing Pump Hydraulics Pump Hydraulics - Begins Pump Hydraulics - w/o Water Tank Rotation Hydraulics Stabilizer Supply Hydraulics Track Extend Hydraulics Water Motor Hydraulics - Begins Water Motor Hydraulics - Ends Water Pump Water Pump Plumbing Water Tank Plumbing Electrical Console Gauges Electrical Diagram - Engine/Frame Electrical Diagram - Gauge Harness Electrical Diagram - Operator Console Electrical Schematic Electrical Strike System Ground Cables Operators Station Gauges Relay Panel Options 2-Point Anchor Parts Point Anchor System Anchor Extension Anchoring Hydraulics Heavy Duty Anchoring Parts Curb Stakes Drill Pipe Accessories EZ-Connect Hydraulic Motor Hydraulic Stake Driver Mud Mixing Accessories Soil Sampler Transmitter Housing Wash Wand Water Transfer System Working Light Miscellaneous Bolt/Nut Torque Chart Parts Manual Change Request Replacement O-Ring Chart Warranty Registration ID

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8 7 DECALS ID

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13 12 NOTES: ID

14 13 FRAME COMPONENTS ID

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33 32 GREASE CYLINDER ID

34 33 GREASE CYLINDER REF NO. PART NUMBER QTY DESCRIPTION REMARKS GREASE CYLINDER INCL REF NO'S 3-6; SEE FOOTNOTE GREASE CYLINDER PARTS ASS'Y GREASE CYLINDER ZERK (02N) RELIEF VALVE (5/8-NF,02N) O-RING (222 D90) BACKUP RING (222 D90) GREASE CYLINDER BARREL GREASE CYLINDER ROD EARLY STYLE USE ON 921 ONLY GREASE CYLINDER WELDMENT USE ON 921 ONLY GREASE CYLINDER ROD USE ON 921 ONLY NOT SHOWN: FOOTNOTES: NOTE: 01 ID

35 34 IDLER ID

36 35 IDLER REF PART NO. NUMBER QTY DESCRIPTION REMARKS IDLER SEE FOOTNOTES 1 & IDLER SHAFT BALL BEARING (1.378") GREASABLE EXTERNAL SNAP RING (1.375") ROLL PIN (3/8" X 2-3/4") PUSH BLOCK EXTERNAL SNAP RING (1.500") MACHINERY BUSHING (1.585") INTERNAL SEAL (1.574") INT SNAP RING (3.149") BALL BEARING (1.574") IDLER SHAFT IDLER SEE FOOTNOTE ZERK (02N) NOT SHOWN: FOOTNOTES: NOTE: 1. REF NO'S 1-6 & 14, NEW STYLE (DOUBLE BEARING) 2. REF NO'S 5-13 OLD STYLE (SINGLE BEARING) 3. AFTER ASSEMBLY, ADD GREASE TO IDLER. 09 ID

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43 42 REAR STABILIZER F

44 43 REAR STABILIZER REF NO. PART NUMBER QTY DESCRIPTION REMARKS TAPERED PIN (1.75" X 6.6") TAPERED INSERT (1.75") W/O WATER TANK FLG BOLT (5/8-NC X 1-1/2", GD8) COMPOSITION BUSHING (1.75") CYL (3" X 1.5" X 20") 32" COMPOSITION BUSHING (1.5") STABILIZER BASE BEGINS WITH 2M TAPERED INSERT (1.5") VALVE ENCLOSURE TAPERED PIN (1.5" X 5.4") CLIP NUT (M8-1.25) FLG LK SCREW (M X 25MM) UPPER STABILIZER TUBE UPPER STABILIZER TUBE (WET) BEGINS WITH S/N 2M2288 W/O WATER TANK WITH WATER TANK W/O WATER TANK WITH WATER TANK - ENDS W/ SN 2M2287 FOOTNOTES NOTE: F

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51 50 NOTES: ID

52 51 ENGINE COMPONENTS ID

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57 56 ALTERNATOR ID

58 57 ALTERNATOR REF NO. PART NUMBER QTY DESCRIPTION REMARKS ALTERNATOR (12V, 61 AMP) TORQUE NUT TO 50 FT-LBS. OBSOLETE ALTERNATOR KIT INCLUDES WIRING UPGRADE ADJUSTING STRAP SPACER (2") BOLT (5/16-NC X 4", GD8) WASHER (5/16") WASHER (1/4") LOCKNUT (5/16-NC) LOCK WASHER (5/16") SCREW (M X 20MM) ALTERNATOR SHEAVE (4-GROOVE) FLG SCREW (M X 50MM) NOT SHOWN: FOOTNOTES: NOTE: 10 ID

59 58 FUEL FILTER 410SX LISTER-PETTER DIESEL IN FROM LIFT PUMP ID

60 59 FUEL FILTER 410SX LISTER-PETTER DIESEL REF NO. PART NUMBER QTY DESCRIPTION REMARKS FUEL FILTER ELEMENT (CARTRIDGE) FUEL FILTER ELEMENT (SPIN-ON) BANJO BOLT (M X 25MM) SEAL WASHER (.531", COPPER) SCREW (M X 20MM) LOCK WASHER (M6) NUT (M6-1.00) SCREW (M X 16MM) ENDS WITH ENGINE S/N BEGINS WITH ENGINE S/N NOT SHOWN: FOOTNOTES: NOTE: 03 ID

61 60 AIR FILTER SYSTEM ID

62 61 AIR FILTER SYSTEM REF NO. PART NUMBER QTY DESCRIPTION REMARKS AIR CLEANER WORM CLAMP (1-5/16" TO 3-1/4") AIR INTAKE HOSE AIR CLEANER ELEMENT WING NUT (7/16 NF) BAFFEL BOTTOM CUP CLAMP 6-1/2" SAFETY ELEMENT HEX NUT (M ) 10 2P SCREW (M X 16) MOUNTING CLAMP (6-1/2") STACK CAP ELBOW (20N90) SLIP-ON COUPLER AR BULK HOSE (3MM ID) BULK HOSE (7/64" ID) FLG LK NUT (M8-1.25) FLG LK SCREW (M X 16MM) SOLD PER 25.4MM SOLD PER 1" NOT SHOWN: FOOTNOTES: NOTE: 01 ID

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65 64 NOTES: ID

66 65 FLUID SYSTEMS ID

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77 76 OIL COOLER HYDRAULICS FROM 6 DRILL CONTROL VALVES RETURN FROM VALVE BODY L

78 77 OIL COOLER HYDRAULICS REF NO. PART NUMBER QTY DESCRIPTION REMARKS CONNECTOR (12S-12O) HYD LINE (-12) UNION RUN TEE (12OFX-12O-12O) HOSE (12OFX90-95"-3000) WITH WATER TANK. USE WITH JT920 & JT HOSE (12OFX-54"-4000) WITHOUT WATER TANK. USE WITH JT921S RUN TEE (12S-12O-12O) CHECK VALVE (12SF-12SF) FLOW CHECK VALVE (12SF-12SF) S/O BR TEE (12S-20H-20H) WORM CLAMP (1-1/6" /16") AR BULK HOSE (1.250", SOLD PER 1") S/O COUPLER (12S-20H90) UNION RUN TEE (12OFX-12O-12O) REDUCER STEM (08O) REDUCER NUT (12OF) ABRASION SLEEVE (1.59" X 88") ABRASION SLEEVE (1.59" X 50") SLIP-ON COUPLER (20S-20H90) HYDRAULIC OIL FILTER (20SF-20SF) FILTER ELEMENT (1-1/2-UNF) HOSE 12OFX90-80"-3000) AR BULK HOSE ((1.250", SOLD PER 1") RADIATOR/OIL COOLER OIL COOLER RADIATOR ENDS WITH S/N 2N1740 BEGINS WITH S/N 2N1741 USE 17" WITH WATER TANK WITHOUT WATER TANK USE 65" UNION (12O-12OFX90) WITHOUT WATER TANK. USE WITH JT921S FOOTNOTES NOTE: L REFER TO O-RING CHART ( ) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS

79 78 DRIVE CONTROL VALVE & LEVERS 1 BLACK 9 GREEN 1 BLACK ORANGE 8 ORANGE NA ID K

80 79 DRIVE CONTROL VALVE & LEVERS REF NO. PART NUMBER QTY DESCRIPTION REMARKS HANDLE (1/2-NC, BLACK) CONTROL LEVER CONTROL LEVER JAM NUT (1/2-NC) HYD CONTROL VALVE (_-SPOOL) FLG LK BOLT (3/8-NC X 1-1/4") FLG LOCKNUT (3/8-NC) KNOB (1/2-NC, ORANGE) HANDLE (1/2-NC, GREEN) CONTROL LEVER OUTLET COVER VALVE SECTION (#V12W-1FBCAS) VALVE SECTION (#V12W-1FBCJLEE) INLET COVER PILOT OPERATED RELIEF (ADI, 1850 PSI) USE 242 LOCTITE USE 242 LOCTITE BEGIN WITH S/N 2N2402 USE 242 LOCTITE BEGINS WITH S/N: 2z1825 NOT SHOWN: FOOTNOTES: NOTE: 14 ID

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83 82 GROUND DRIVE HYDRAULICS DRIVE CONTROL VALVE LEFT RIGHT ID

84 83 GROUND DRIVE HYDRAULICS REF NO. PART NUMBER QTY DESCRIPTION REMARKS FLG LK BOLT (3/8-NC X 1-1/4") ORFICE, WORK PORT CONNECTOR (08S-08O) UNION (08O-08OFX90) HOSE (08OFX MM-207BAR) HOSE (08OFX90-66"-3000PSI) HOSE (08OFX MM-207BAR) HOSE (08OFX90-54"-3000PSI) ABRASION SLEEVE (1.59" X 84") ABRASION SLEEVE (41MM X 2134MM) ABRASION SLEEVE (41MM X 1270MM) ABRASION SLEEVE (1.59" X 50") BOLT (5/16-NC X 2-1/2",GD8) COUNTERBALANCE MANIFOLD COUNTERBALANCE CARTRIDGE KIT CONNECTOR (10S-08O90) HOSE (08OFX MM-207BAR) HOSE (08OFX90-82"-3000PSI) HOSE (08OFX MM-207BAR) HOSE (08OFX90-54"-3000PSI) HOSE (08OFX MM-207BAR) HOSE (08OFX90-66"-3000PSI) HOSE (08OFX MM-207BAR) HOSE (08OFX90-54"-3000PSI) CONNECTOR (08O-10S) ABRASION SLEEVE (41MM X 2235MM) ABRASION SLEEVE (1.59" X 88") ABRASION SLEEVE (1.59" X 50") ABRASION SLEEVE (41MM X 1270MM) CONNECTOR (08S-08O) FLG LOCKNUT (3/8-NC) ENDS W/ SN 2M2002 WITH WATER TANK WITHOUT WATER TANK WITH WATER TANK WITHOUT WATER TANK WITH WATER TANK WITHOUT WATER TANK WITH WATER TANK WITHOUT WATER TANK WITH WATER TANK WITHOUT WATER TANK NOT SHOWN: FOOTNOTES: NOTE: REFER TO O-RING CHART ( ) IN BACK OF THE BOOK FOR REPLACEMENT OF SAE AND ORS O-RINGS. 02 ID

85 84 TRACK EXTEND HYDRAULICS DRIVE CONTROL VALVE ID

86 85 TRACK EXTEND HYDRAULICS REF NO. PART NUMBER QTY DESCRIPTION REMARKS CONNECTOR (04O-08S) HOSE (04OFX90-106"-3000) WITH WATER TANK HOSE(04OFX90-77"-3000) WITHOUT WATER TANK ABRASION SLEEVE (1.59" X 100") WITH WATER TANK ABRASION SLEEVE (1.75" X 70") WITHOUT WATER TANK CONNECTOR (04S-04O90) CYL (2.0" X 1.00" X 10.00") HOSE (04OFX90-110"-3000) WITH WATER TANK HOSE (04OFX90-77"-3000) WITHOUT WATER TANK HYD CONTROL VALVE (_-SPOOL) BEGINS WITH S/N 2N2402 NOT SHOWN: FOOTNOTES: NOTE: REFER TO O-RING CHART ( ) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS 11 ID

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89 88 FRAME TILT DRIVE CONTROL VALVE ID

90 89 FRAME TILT REF NO. PART NUMBER QTY DESCRIPTION REMARKS CONNECTOR (04O-08S) HOSE 04OFX90-116"-3000) HOSE (04OFX90-94"-3000) ABRASION SLEEVE (1.59" X 115") ABRASION SLEEVE (1.59" X 95") CONNECTOR (04O-06S90) CYL (3.0" X 1.50" X 4.000") UNION (04O-04OFX90) HOSE (04OFX-130"-3000) HOSE (04OFX90-106" HYD CONTROL VALVE (_-SPOOL) HYD CONTROL VALVE (5-SPOOL) ABRASION SLEEVE (1.00" X 16") WITH WATER TANK. USE WITH JT920 & 921 WITHOUT WATER TANK.USE WITH JT921S WITH WATER TANK. USE WITH JT920 & JT921 WITHOUT WATER TANK. USE WITH JT921S WITHOUT WATER TANK. USE WITH JT921S WITH WATER TANK. USE WITH JT920 & JT921 WITH WATER TANK. USE WITH JT920 & JT921S WITHOUT WATER TANK. USE WITH JT921S BEGINS WITH S/N 2N2402 ENDS WITH S/N 2N2401 NOT SHOWN: FOOTNOTES: NOTE: REFER TO O-RING CHART ( ) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS. 13 ID

91 90 ANCHOR DRIVER HYDRAULICS THRUST AND ROTATION CONTROL VALVE ID

92 91 ANCHOR DRIVER HYDRAULICS REF NO. PART NUMBER QTY DESCRIPTION REMARKS CONNECTOR (08S-08O) HOSE (08OFX45-356MM-207BAR) HOSE (08OFX45-14"-3000PSI) QDC ADAPTER (08-08SF) WASHER (3/4") BK CONNECTOR (08O-08O90BK) CONNECTOR (08OFX TO 08JIC M) QDC BODY (08-09SF) HOSE (08O-08O45M-381MM-207BAR) HOSE (08OFX45M-15"-3000PSI) NOT SHOWN: FOOTNOTES: NOTE: REFER TO O-RING CHART ( ) IN BACK OF THE BOOK FOR REPLACEMENT OF SAE AND ORS O-RINGS. 01 ID

93 92 CARRIAGE THRUST HYDRAULICS 1 2 THRUST AND ROTATION CONTROL VALVE ID

94 93 CARRIAGE THRUST HYDRAULICS REF NO. PART NUMBER QTY DESCRIPTION REMARKS CONNECTOR (10S-10O) HOSE (10OFX MM-207BAR) HOSE (10OFX45-132"-3000PSI) ABRASION SLEEVE (60MM X 3048MM) ABRASION SLEEVE (2.38" X 120") CONNECTOR (10O-12S) REDUCER (16S-12SF) BOLT (5/8-NC X 2-1/4") LOCKNUT (5/8-NC) HOSE RETAINER FLG NUT (M6-1.00) NOT SHOWN: FOOTNOTES: NOTE: REFER TO O-RING CHART ( ) IN BACK OF THE BOOK FOR REPLACEMENT OF SAE AND ORS O-RINGS. 01 ID

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97 96 BREAK-OUT HYDRAULICS ENDS WITH S/N 2M BREAK-OUT CONTROL VALVE ID

98 97 BREAK-OUT HYDRAULICS ENDS WITH S/N 2M0950 REF NO. PART NUMBER QTY DESCRIPTION REMARKS CONNECTOR (04O-08S) HOSE (04OFX MM-207BAR) HOSE (04OFX90-238"-3000PSI) HOSE (04OFX MM-207BAR) HOSE (04OFX90-82"-3000PSI) HOSE (04OFX MM-207BAR) HOSE (04OFX-238"-3000PSI) HOSE (04OFX MM-207BAR) HOSE (04OFX90-88"-3000PSI) CONNECTOR (08S-04O90) ABRASION SLEEVE (4MM X 2134MM) ABRASION SLEEVE (1.59" X 84") CONNECTOR (02N-04O90) CONNECTOR (02N-04O) NOT SHOWN: FOOTNOTES: NOTE: REFER TO O-RING CHART ( ) IN BACK OF THE BOOK FOR REPLACEMENT OF SAE AND ORS O-RINGS. 01 ID

99 98 BREAK-OUT HYDRAULICS BEGINS WITH S/N: 2M0951 BREAK-OUT CONTROL VALVE ID

100 99 BREAK-OUT HYDRAULICS BEGINS WITH S/N: 2M0951 REF NO. PART NUMBER QTY DESCRIPTION REMARKS CONNECTOR (04O-08S) HOSE (04OFX90-762MM-207BAR) HOSE (04OFX90-30"-3000PSI) CONNECTOR (04O-06S) HOSE (04OFX-6248MM-207BAR) HOSE (04OFX-246"-3000PSI) CONNECTOR (02N90-04O) HOSE (04OFX-2286MM-207BAR) HOSE (04OFX-90"-3000PSI) FLG NUT (M6 X 1.00) CONNECTOR (04O-O2N) HOSE (040FX MM-207BAR) HOSE (04OFX90-88"-3000PSI) WASHER (1/4") SCREW (M6-1 X 70MM) CHECK VALVE NOT SHOWN: FOOTNOTES: NOTE: REFER TO O-RING CHART ( ) IN BACK OF THE BOOK FOR REPLACEMENT OF SAE AND ORS O-RINGS. 01 ID

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107 106 MUD MOTOR HYDRAULICS ENDS W/ SN 2M1669 DRIVE CONTROL VALVE RETURN PRESSURE 3 PILOT LINE 4 SUPPLY MOUNTS TO FRAME 6 01 ID

108 107 MUD MOTOR HYDRAULICS ENDS W/ SN 2M1669 REF NO. PART NUMBER QTY DESCRIPTION REMARKS CONNECTOR (08O-10S) HOSE (08OFX90-18"-3000PSI) ABRASION SLEEVE (1.59" X 32") RUN TEE (105-08O-04O) HYDRAULIC FLOW VALVE BOLT (5/16-NC X 3-1/4") UNION (08S-10S) FLOW CONTROL VALVE CONNECTOR (08S-08O45) HOSE (08OFX-86"-3000PSI) FLG LOCKNUT (5/16-NC) HOSE (04OFX90-94"-5000PSI) ELECTRONIC SOLENOID CONNECTOR (12O-10S90) UNION RUN TEE (12OFX-12O-12O) HOSE (12OFX90-95"-3000PSI) REDUCER BUSHING STEM (12O) REDUCER BUSHING UNIT (12OF) UNION RUN TEE (08OFX-08O-08O) HOSE (08OFX90-13"-3000PSI) CONNECTOR (08S-08O) HOSE (08OFX90-32"-3000PSI) CONNECTOR (10S-08O90) NOT SHOWN: FOOTNOTES: NOTE: REFER TO O-RING CHART ( ) IN BACK OF THE BOOK FOR REPLACEMENT OF SAE AND ORS O-RINGS. 01 ID

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129 128 HYDRAULIC CYLINDER 3.0" ID BARREL X 1.50" OD ROD X 4.0" STROKE ID

130 129 HYDRAULIC CYLINDER 3.0" ID BARREL X 1.50" OD ROD X 4.0" STROKE REF NO. PART NUMBER QTY DESCRIPTION REMARKS CYL (3.0" X 1.50" X 4.0") INCLUDES REF NO.'S 1 THRU SEAL REPAIR KIT (3.0" X 1.50") LOCK RING (3") CYLINDER BARREL (3") FLG BOLT (3/4-NC X 2",GD 8) SEE FOOTNOTE CYL PISTON (3.0" X 1.50") CYL HEAD (3") CYL ROD (1-1/2") NOT SHOWN: U-SEAL INSTALLER (1.500" - UP) ROD WIPER INSTALLER (1.5") PISTON SEAL INSTALLER (3") PISTON INSTALLER (3") CYL HEAD SPANNER-TWO PIN FOOTNOTES: 1. USE LOCTITE 277, TORQUE TO FT-LBS ( N.M) NOTE: 02 ID

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133 132 HYDRAULIC CYLINDER 3.0" ID BARREL X 1.50" OD ROD X 20.0" STROKE ID

134 133 HYDRAULIC CYLINDER 3.0" ID BARREL X 1.50" OD ROD X 20.0" STROKE REF PART NO. NUMBER QTY DESCRIPTION REMARKS CYLINDER (3.0 X 1.5 X 20.0) INCLUDES REF NO.'S 1 THRU SEAL REPAIR KIT (3.0" X 1.5") LOCK RING (3") CYLINDER BARREL FLG BOLT (3/4-NC X 2",GD 8) SEE FOOTNOTE CYL PISTON CYLINDER HEAD CYLINDER ROD NOT SHOWN: U-SEAL INSTALLER (1.5"-UP) ROD WIPER INSTALLER (1.5") PISTON SEAL INSTALLER (3") PISTON INSTALLER (3") CYLINDER HEAD SPANNER-TWO PIN FOOTNOTES: 1. USE LOCTITE 277, TORQUE TO FT-LBS ( N, M) NOTE: 01 ID

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138 137 ELECTRICAL ID

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143 142 CONSOLE GAUGES JT ID

144 143 CONSOLE GAUGES JT820 REF NO. PART NUMBER QTY DESCRIPTION REMARKS FUEL GAUGE VOLT METER WATER TEMPERATURE GAUGE FILTER MINDER AUDIO ALARM IGNITION SWITCH KEY, PAIR SWITCH MOUNTING NUT KEYS (PAIR) BEZEL NUT (1-NS) HORN BUTTON SWITCH GASKET ROCKER SWITCH HORN BUTTON CAP ROCKER SWITCH (SEALED) INSERT - HYD OIL PSI (YEL) INSERT - BLANK (BLK) PILOT LIGHT REPLACEMENT BULB INSERT - HYD OIL HI TEMP (RED) INSERT - ENG OIL PSI (RED) HOUR METER NOT SHOWN: FOOTNOTES: NOTE: 02 ID

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154 153

155 154 ELECTRICAL DIAGRAM GAUGE HARNESS JT820 TO ENGINE/FRAME WHT/BLK (14) YEL/BLU (48) RED/BLK GRN (25) (31) GRA (17) BLU/GRN (30) ORG/BLK (12) WHT/BLK (8) ORG (3) ORG/BLU BRN/ORG (5) (6) WHT/BLU (15) BLK (1) RED (4) FUEL SENDER FUEL GAUGE 1 BRN (29) I G S 2 REMOTE START SWITCH FLUID SELECT SWITCH 15 ORG (3) BLK (1) BRN (29) BLU/GRN (30) ORG/BLU (5) 12 HYDRAULIC FILTER LIGHT ORG/BLU (5) RED/BLK (25) 2 3 ORG/BLU (5) YEL/BLU (48) BLK (1) ORG/BLK (12) 3 WARNING LIGHT ALARM HYDRAULIC TEMP LIGHT 11 ENGINE OIL PSI LIGHT ORG/BLU (5) ORG/BLU (5) GRA (17) WHT/BLK (14) WHT/BLU (15) ORG/BLU (5) HOUR METER GRN (33) S G I WATER TEMP GAUGE ORG (3) ORG (3) BLK (1) G I BLK (1) VOLT METER GAUGE 6 ORG/BLU (5) 3 2 BRN/ORG (6) ORG (3) ORG/BLU (5) ORG/BLU (5) WHT/BLK (8) RED (4) COLD START SWITCH 4 IGN ST BAT ACC 5 IGNITION SWITCH 05 ID

156 155 ELECTRICAL DIAGRAM GAUGE HARNESS JT820 REF PART NO. NUMBER QTY DESCRIPTION REMARKS FUEL GAUGE AUDIO ALARM HOUR METER ROCKER SWITCH SWITCH GASKET IGNITION SWITCH KEY, PAIR (BASE CODE) SWITCH MOUNTING NUT VOLT METER WATER TEMPERATURE GAUGE PILOT LIGHT REPLACEMENT BULB INSERT - BLANK (BLK) INSERT - ENG OIL PSI (RED) INSERT - HYD OIL HI TEMP (RED) INSERT - HYD OIL PSI (YEL) HORN BUTTON HORN BUTTON CAP ROCKER SWITCH (SEALED) SWITCH GASKET FUEL SENDER GAUGE HARNESS ON-MOMENTARY ON ON-ON NOT SHOWN: FOOTNOTES: NOTE: ALL CONNECTORS ARE SHOWN WITH REAR VIEWS 05 ID

157 156

158 157

159 158

160 159

161 160 NOTES: ID

162 161 OPTIONS ID

163 162 ANCHOR HYDRAULICS HEAVY DUTY ANCHOR SYSTEM ID

164 163 ANCHOR HYDRAULICS HEAVY DUTY ANCHOR SYSTEM REF NO. PART NUMBER QTY DESCRIPTION REMARKS HYDRAULIC MOTOR CONNECTOR (060-10S) UNION (06O-06OFX90) HOSE (06OFX-185"-3000PSI) ABRASION SLEEVE (2.54" X 190") CABLE TIE (1/16" TO 4") CONNECTOR (06O-O8S) QDC ADAPTER (080-08SF) QDC BODY (080-08SF) SCREW (M X 45MM, 10.9) MOTOR TROLLEY FLANGE NUT (M ) TROLLEY SPACER SCREW (M X 70MM) HANDLE GRIP (1", BLK) YOKE (1-1/4", 5/16" KWY) CROSS AND BEARING KIT (1.125") ZERK (O2N22.5) BEARING CAP (1-1/8") YOKE (7/8" HEX) FLANGE NUT (M ) SEE FOOTNOTE 1 FOR SEAL KIT OBSOLETE NOT SHOWN: FOOTNOTES: 1. USE SEAL KIT FOR MOTOR VERSION 002, 003, 004 & 005. SEAL KIT IS TO BE USED WITH VERSION 006 MOTORS. NOTE: 04 ID

165 164 HYDRAULIC MOTOR TAPERED KEYED SHAFT 1-1/4" ID

166 165 HYDRAULIC MOTOR TAPERED KEYED SHAFT 1-1/4" REF NO. PART NUMBER QTY DESCRIPTION REMARKS HYDRAULIC MOTOR HYDRAULIC MOTOR HYDRAULIC MOTOR SEAL REPAIR KIT O-RING (011 D70) O-RING (904 D90) KEY (5/16" X 1") LOCKNUT (1-20 NEF) COTTER PIN (1/8" X 2") INCL REF NO.'S 1 THRU 6, SEE FOOTNOTES 1 AND 4 INCL REF NO.'S 1 THRU 5, SEE FOOTNOTES 2 AND 3 INCL REF NO.'S 1 THRU 5, SEE FOOTNOTE 2 INCL REF NO.'S 2 AND 3, SEE FOOTNOTE 4 NOT SHOWN: FOOTNOTES: 1. USED ON ROTO WITCH II BORING UNITS. 2. USED ON ROTO WITCH 111 AND 1V BORING UNITS. 3. SHAFT AND BEARING KIT USE SEAL KIT FOR MOTOR VERSION 002, 003, 004 & 005. SEAL KIT IS TO BE USED WITH VERSION 006 MOTORS. NOTE: 08 ID

167 166 TRANSMITTER HOUSING ID

168 167 TRANSMITTER HOUSING REF NO. PART NUMBER QTY DESCRIPTION REMARKS TRANSMITTER HOUSING ASSY TRANSMITTER HOUSING ASSY BOLT 3/8-NC X 5/8" GD8) DOWEL PIN (1/8 X 1/2") DOWEL PIN (1/8 X 3/4") PLUG WRENCH FLUID NOZZLE (03) FLUID NOZZLE (04) FLUID NOZZLE (05) FLUID NOZZLE (06) SPRING STUD BOLT HEX WRENCH STAINLESS STEEL BALL BEACON 83BR BEACON 80B O-RING (025 D90) BATTERY (5 PER PAC) BEACON HOUSING 83BR BEACON HOUSING 80B END CAP TRANSMITTER HOUSING PLUG O-RING (127 D70) PLUG WEAR RING CHEATER (60" LG) WRENCH FLANGE LOCKNUT BEACON WRENCH BEACON HOUSING TUBE DRILL PIPE END CAP JT 2510 AND JT 2320 SEE FOOTNOTE 1 SEE FOOTNOTE 1 SEE FOOTNOTE 3 SEE FOOTNOTE 2 INCL REF NO.'S 2, 5, 8, 14, 15 & 20; SEE FOOTNOTE 1 INCL REF NO.'S 2, 5, 8, 14, 15 & 20 SEE FOOTNOTE 1 SEE FOOTNOTE 2 NOT SHOWN: FOOTNOTES: 1. BEFORE ASSEMBLING THESE ITEMS USE CLEANER AND APPLY CLEANER AND APPLY LOCTITE 242 (OR EQUIVALENT). REFER TO OPERATOR'S MANUAL FOR COMPLETE ASSEMBLY INFORMATION. 2. S/N BEGINS WITH 3. USED WITH 80B BEACON NOTE: 01 ID

169 168

170 169

171 170

172 171

173 172

174 173

175 174 4 POINT ANCHOR SYSTEM ID

176 175 4 POINT ANCHOR SYTEM REF NO. PART NUMBER QTY DESCRIPTION REMARKS DOUBLE ANCHOR BRACKET NUT HOUSING NUT RETAINER ANCHOR SHAFT ANCHOR NUT AR 10" AUGER ASSEMBLY TROLLEY RAIL TUBE MOTOR TROLLEY HANDLE GRIP CLIP PIN (5/16" X 2-1/2") SCREW (M16-2 X 130MM) FLG NUT (M ) SCREW (M X 50MM) HEX NUT (M ) FLG NUT (M10-1.5) SCREW (M X 70MM) TROLLEY SPACER NUT DRIVER SCREW (M X 100MM) STAKE BIT (INCL. REF. NO'S 23, 24, AND 25) AR 6" AUGER ASSEMBLY TUBE SOCKET AR COUPLING SEAR AR COMPRESSION SPRING AR ROLL PIN (1/8 IN. X IN.) AR SLIP-LATCH REPAIR KIT (INCL. REF. NO'S. 23, 24, AND 25) NOT SHOWN: FOOTNOTES: NOTE: 01 ID

177 176

178 177

179 178

180 179

181 180

182 181

183 182

184 183

185 184 EZ-CONNECT ID

186 185 EZ-CONNECT REF NO. PART NUMBER QTY DESCRIPTION REMARKS EZ-CONNECT ASS'Y (1.41-6, PT621) EZ-CONNECT ASS'Y (1.41-6, JT440) EZ-CONNECT ASS'Y (1.41-6, JT920) EZ-CONNECT ASS'Y (1.63-6) EZ-CONNECT ASS'Y (2610T ) EZ-CONNECT ASS'Y (1.94-4) EZ-CONNECT PIN ( X ) EZ-CONNECT PIN ( X ) EZ-CONNECT PIN ( X ) EZ-CONNECT PIN ( X ) EZ-CONNECT PIN ( X ) O-RING (031 D90) POLYURETHANE O-RING (028 D90) POLYURETHANE O-RING (032 D90) POLYURETHANE COLLAR (2.5") COLLAR (3.0") COLLAR (3.25") EZ-CONNECT BOX ( X ) EZ-CONNECT BOX ( X ) EZ-CONNECT BOX ( X ) EZ-CONNECT BOX ( X ) EZ-CONNECT BOX ( X ) EZ-CONNECT BOX ( X ) EZ-CONNECT BOX ( X ) BOLT (3/8-NC X 1/2 ") BOLT (1/2-NC X 3/4 ") SEE FOOTNOTES 1, 2 & 10 FITS PT620 & PT621 SEE FOOTNOTES 1, 3 & 10 FITS JT440A, JT910 & JT911 SEE FOOTNOTES 1, 4 & 10 FITS JT1210, JT820, PT1010 & JT920 SEE FOOTNOTES 1, 5 & 10 FITS JT2510, JT2511 & JT2320 SEE FOOTNOTES 1, 7 & 10 FITS JT1720 HD DRILL PIPE SEE FOOTNOTES 1, 6 & 10 FITS JT3510, JT2520 & 860JT C THD PIPE SEE FOOTNOTE 10 SEE FOOTNOTE 10 FOOTNOTES: 1. LUBE THREADS & SHANK BEFORE ASSEMBLY AND EVERY BORE WITH TOOL JOINT COMPOUND. 2. EZ-CONNECT ASS'Y ( ) INCL'S: 2X (EZ-CON. PIN), 2X (O-RING), 1X (SCREW), 1X (EZ-CON. BOX), 1X (COLLAR). 3. EZ-CONNECT ASS'Y ( ) INCL'S: 2X (EZ-CON. PIN), 2X (O-RING), 1X (SCREW), 1X (EZ-CON. BOX), 1X (COLLAR). 4. EZ-CONNECT ASS'Y ( ) INCL'S: 2X (EZ-CON. PIN), 2X (O-RING), 1X (SCREW), 1X (EZ-CON. BOX), 1X (COLLAR). 5. EZ-CONNECT ASS'Y ( ) INCL'S: 2X (EZ-CON. PIN), 2X (O-RING), 1X (SCREW), 1X (EZ-CON. BOX), 1X (COLLAR). 6. EZ-CONNECT ASS'Y ( ) INCL'S: 2X (EZ-CON. PIN), 2X (O-RING), 1X (SCREW), 1X (EZ-CON. BOX), 1X (COLLAR). 7. EZ-CONNECT ASS'Y ( ) INCL'S: 2X (EZ-CON. PIN), 2X (O-RING), 1X (SCREW), 1X (EZ-CON. BOX), 1X (COLLAR). 8. EARLY STYLES USE (3/8-NC X ", LOW HD ALN). 9. EARLY STYLES USE (1/2-NC X 1", LOW HD ALN). 10. BEFORE INSTALLATION OF RETAINING BOLTS ( & ), APPLY ANTI-SEIZE TO THE THREADS. NOTE: ALL EZ-CONNECT ASSEMBLIES INCLUDE REFERENCE NUMBERS 1 THRU ID

187 186 WASH WAND ID

188 187 WASH WAND REF NO. PART NUMBER QTY DESCRIPTION REMARKS WATER SPRAY GUN (PARTS ASS'Y) NOZZLE (04N, ORF. 047", TC) COLLAR (04NF) WASH WAND (04N-36") SPRAY GUN SEAL REPAIR KIT CONNECTOR (06N-08O) HOSE (08OFX-290"-3000) CONNECTOR (08S-08O) QDC ADAPTER (08-08SF) SEAL REPAIR KIT INCL REF NO.'S 1 THRU 8 NOT SHOWN: FOOTNOTES: NOTE: REFER TO O-RING CHART ( ) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS. 07 ID

189 188 FLUID MIXING ACCESSORIES ID

190 189 FLUID MIXING ACCESSORIES REF NO. PART NUMBER QTY DESCRIPTION REMARKS VISCOSITY FUNNEL VISCOSITY CUP AR BENTONITE, QUIK-GEL (50 LB) AR LIQUID POLYMER, EZ-MUD (5 GAL) AR BENTONITE, BORE-GEL (50 LB) AR VISCOSIFIER, LIQUI-TROL (5 GAL) AR POWDER POLYMER, QUIK-TROL (20 LB) AR WET AGENT, CON-DET (5 GAL) AR 'PAC-R' FILTRATION CONTROL AR 'BARAZAN D+' VISCOSIFIER AR 'NO SAG' (20# BOX/10-2#BAGS) NOT SHOWN: DRILLING FLUID TEST KIT SHEAROMETER FOOTNOTES: NOTE: 10 ID

191 190

192 191

193 192 SOIL SAMPLER ID

194 193 SOIL SAMPLER REF NO. PART NUMBER QTY DESCRIPTION REMARKS SOIL SAMPLER (440) SOIL SAMPLER (25/23) SOIL SAMPLER (860) SOIL SAMPLER (3510) NOSE CONE O-RING (129 D70) NOSE CONE GUIDE MISSILE BODY PUSH SHAFT SPECIMAN TUBE STAGE TWO O-RING (124 D70) LOCK TAILPIECE INTERNAL SEAL SOIL SAMPLER ADAPTER /23 SOIL SAMPLER ADAPTER SOIL SAMPLER ADAPTER SOIL SAMPLER ADAPTER SPREADER INCL REF NO.'S 1 THRU 12 AND 16 INCL REF NO.'S 1 THRU 11, 13 AND 16 INCL REF NO.'S 1 THRU 11, 14 AND 16 INCL REF NO.'S 1 THRU 11, 15 AND 16 NOT SHOWN: FOOTNOTES: NOTE: 01 ID

195 194 NOTES: ID

196 195 MISCELLANEOUS ID

197 196 SAE Bolt and Nut Torque Value Chart Grade 5: UNC or UNF Thread Size Hex nut, or bolt tapped into hex nut, or d&t hole Hex top deformed locknut Flange nut, locknut, or bolt tapped into flange nut or d&t* hole ft lb N m ft lb N m ft lb N m 1/ / / / / / / / / / / Grade 8: UNC or UNF Thread Size Hex nut, or bolt tapped into hex nut, or d&t hole Hex top deformed locknut Flange nut, locknut, or bolt tapped into flange nut or d&t* hole ft lb N m ft lb N m ft lb N m 1/ / / / / / / / / / / *drilled and tapped VS02 ID

198 Metric Bolt and Cap Screw Torque Values 197 Size Class 4.8 Class 8.8 and 9.8 Class 10.9 Class 12.9 Lubricated Dry Lubricated Dry Lubricated Dry Lubricated Dry N m ft lb N m ft lb N m ft lb N m ft lb N m ft lb N m ft lb N m ft lb N m ft lb M M M M M M M M M M M M M M Do not use these values if a different torque value or tightening procedure is given for specific application. Torque values listed are for general use only. Check tightness of fasteners periodically. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class fasteners. Fasteners should be replaced with the same or higher property class. If higher property class fasteners are used, these should only be tightened to strength of original. Make sure fastener threads are clean and that the threads are properly started. This will prevent them from cross threading or galling when tightened. Tighten plastic insert or crimped type steel locknuts to approximately 50% of dry torque indicated on chart. Apply torque to the nut - not the bolt head. Tighten toothed or serrated type locknuts to full torque value. LUBRICATED means coated with lubricant. DRY means plain or zinc plated without any type of lubricant.

199 198 Hydraulic Cylinder Bolt Torque Chart Bolt Size (inch) Bolt Part No. Cylinder Repair Kit Part No. Torque (ft lb) Torque (N m) 1/ / & / & / & & / As a general rule: 1/2-inch bolts are used in cylinders with 1-inch rods 5/8-inch bolts are used in cylinders with 1 1/4-inch rods 3/4-inch bolts are used in cylinders with 1 1/2-inch rods 7/8-inch bolts are used in cylinders with 1 3/4-inch rods 1-inch bolts are used in cylinders with 2-inch rods (one with 1 3/4-inch) 1-1/8-inch bolts are used in cylinders with 2-1/4-inch rods IMPORTANT: Do not reuse cylinder piston bolts when rebuilding a hydraulic cylinder. Each cylinder repair kit contains a new bolt. Use it. Lubricate lightly and torque to value shown on chart. VS02 ID

200 SAE & ORS Hydraulic Fitting Replacement O-Ring Chart 199 Fraction Size Dash Size SAE (Port Seal O-Ring) ORS (Face Seal O-Ring) Thread Size O-Ring P/N Thread Size O-Ring P/N 1/16 1 NA NA NA NA 1/8 2 5/16-24 NA NA NA 3/16 3 3/8-24 NA NA NA 1/4 4 7/ / /16 5 1/2-20 NA NA NA 3/8 6 9/ / /2 8 3/ / /8 10 7/ / / / / / NA NA / / / / /16-12 NA 1-1/ / NA /2-12 NA NA NA 2-1/ NA NA NA /2-12 NA NA NA Thread size indicates the diameter of the threaded area in fractions of an inch and number of threads per inch. NA = not a current CMW part numbered o-ring, or dash size does not occur in current CMW applications SAE = straight thread fitting that seals by sandwiching a hard o-ring between a shoulder on the male part and an angular surface at the mouth of the female port. ORS = o-ring face seal; a type of fitting that seals by compressing a hard, captive o-ring between two flat parallel faces, one grooved for the o-ring and the other plain to act as the sealing surface

201 200

202 201 Parts Manual Change Request (Please print clearly) Date: Dealer No. (required): Your Name: Position: Phone: Fax: Publication Information: Parts Manual No.: - Model: Illustration Part No.: Manual Page No.: Nature of Change Request: Text Graphics Missing Information Describe change requested (if possible, include copy of publication page with changes marked.): Please fax completed form to Parts Manual Department (580) Thank you for taking the time to submit this request. We will contact you if further information is needed to process your request. ID

203 202

204 203 ID

205 204 ID