Ditch Witch JT920 JT920C Parts Manual 053-467

1

JT920 JT920C ISSUE NO. 16PL-05/16

For Replacement Copy Order P/N 053-467

This product and its use may be coverd by one or more patents at http://patents.charlesmachine.works.

This manual contains information concerning the following models: JT920/JT920C Directional Drilling System

Copyright 2004, 2005, 2006, 2007, 2008, 2011, 2012, 2014, 2016, 2019

by The Charles Machine Works, Inc. , Ditch Witch, CMW, AutoCrowd, Jet Trac, Roto Witch, Subsite, Fluid Miser, Power Pipe, Super Witch, Pierce Arrow, Zahn, The Underground, and The Underground Authority Worldwide are registered trademarks of The Charles Machine Works, Inc.

2

3

FOREWORD_________________________________________ This manual contains illustrated parts lists to help you select quality Ditch Witch® replacement parts for your Ditch Witch equipment. Using other replacement parts will lessen the productivity of your equipment.

•

Descriptions 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.

•

Part numbers enclosed in a box or marked as “obsolete” in the remarks column 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 referenced in footnotes are available through your local Ditch Witch dealer.

•

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 Ditch Witch 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 replacement parts.

Ver. 05

ID0128552

4

WARRANTY _________________________ POLICY 1: DITCH WITCH® EQUIPMENT AND REPLACEMENT PARTS LIMITED WARRANTY POLICY

DW WARRANTY Policy August, 2016

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 Ditch Witch factory that fail due to a defect in material or workmanship within one (1) year of first commercial use. 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 Ditch Witch Product Support (DWPS) or its authorized dealer. DWPS will provide the location of its inspection facilities or it’s nearest authorized dealer upon inquiry. DWPS 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 the Ditch Witch factory.

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 the DWPS, P.O. Box 66, Perry, OK 73077-0066, or contact your local dealer.

Ver. 06

ID0134872

CONTENTS______________________ Decals

Decal Location - JT920 ................................ 8

Engine Components

Air Filter System ........................................ 32 Air Filter System - Caterpillar Diesel .............. 34 Alternator .................................................. 26 Engine - Caterpillar Diesel ............................. 18 Engine - Lister-Petter Diesel .......................... 14 Engine Installation - Caterpillar Diesel .......... 20 Engine Service - Caterpillar Diesel ................. 22 Fuel Filter System - Caterpillar Diesel ............ 24 Radiator..................................................... 28 Radiator - Caterpillar Diesel........................... 30 Throttle .................................................... 36 Throttle - Caterpillar Diesel ........................... 38

Frame Components

Carriage .................................................... 52 Carriage - Begins/Ends ................................. 58 Carriage – Ends .......................................... 56 Covers - Caterpillar Diesel ............................. 70 Covers/Guards ......................................... 68 Cylinder Grease ......................................... 78 Drill Frame Components .......................... 42 Fuel Reservoir ........................................... 66 Gear Box - Rotation Drive ............................. 62 Idler .......................................................... 74 Stabilizer - Rear .......................................... 72 Tension Spring - Track ................................ 76 Track Group - Rubber .................................. 64 Wrench - Front ........................................... 46 Wrench - Front - Begins ................................ 50 Wrench - Front - Ends .................................. 48

Operator Station

Console Gauges ........................................ 86 Operators Station Gauges ........................ 84 Seat Mount ............................................... 82

Hydraulics

Anchor Control - Ends .............................. 152 Anchor Driver Hydraulics ....................... 164 Anchor Hydraulics ................................... 156 Anchor System ........................................ 160 Anchoring Hydraulics ............................. 154 Anchoring Hydraulics H.D system .......... 162 Auxiliary Backup wrench Hydraulic ........ 146 Breakout Hydraulics - Begins ................... 144 Breakout Hydraulics - Ends ...................... 142 Carriage Rotation Hydraulics ................. 130 Carriage Thrust Hydraulics ..................... 136 Control Valve/Levers - 3-spool ................. 128 Control Valves & Levers .......................... 122 Cylinder (2” x 1”) ..................................... 168 Cylinder (3” x 1.5”) .................................. 170 Drive Control Supply Hydraulics ............. 104 Drive Control Valve & Levers .................. 108 Flow Divider - Ends.................................. 118 Frame Tilt Hydraulics ............................. 110 Ground Drive Hydraulics ........................ 106 Hydraulic Control Valve .......................... 126 Hydraulic Control Valve - 2-spool ............. 120 Hydraulic Control Valve - Ends ................ 124 Hydraulic Diagram..................................... 92 Hydraulic Diagram - Auto-Bore ................... 94 Hydraulic Motor - Tapered Keyed 1-1/4” ..... 166 Hydraulic Reservoir .................................. 96 Hydraulic Schematic - w/Auto-Bore S-off ...... 90 Main Supply Hydraulics .......................... 116 Mud Motor Hydraulics ........................... 148 Oil Cooler Hydraulics ................................ 98 Oil Cooler Hydraulics - Caterpillar Diesel..... 102 Rotation Hydraulics ................................ 132 Rotation Hydraulics - Auto-Bore ............... 134 Stabilizer Hydraulics ............................... 112 Thrust Hydraulics ................................... 138 Thrust Hydraulics - Auto-Bore ................... 140 Track Extended Hydraulics ..................... 114

ID0135083

5

6

CONTENTS______________________ Electrical

Electrical Diagram - Bore Console. ............. 196 Electrical Diagram - Engine/Frame ............. 190 Electrical Diagram - Gauge........................ 198 Electrical Diagram - Gauge - Auto-Bore ...... 200 Electrical Diagram - Relay ........................ 194 Electrical Schematic ............................... 174 Electrical Schematic - Auto-Bore .............. 184 Electrical Schematic - JT920T2 .................. 180 Electrical Strike Mat - Early Models ........... 204 Electrical Strike System .......................... 202 Electrical Strike System - Ends ................. 206 Relay Panel ............................................. 208 Relay Panel - Caterpillar Diesel .................... 210

Accessories

Drilling Fluid Transfer .............................. 270 Garden Hose Adapter ............................. 272 Grounding Cables .................................... 266 Mud Mixing Accessories ......................... 264 Water Transfer System ........................... 268

Miscellaneous

Bolt/Nut Torque Chart ............................ 276 Filters....................................................... 282 Optional Kits............................................ 283 Related Publications ............................... 282 Replacement O-Ring Chart ..................... 281 Warranty Registration............................. 286

Lubricator Systems

Thread Lubricator.................................... 214

Anchor Systems

2-Point Anchor Parts ............................... 218 4-Point Anchor System ........................... 220 Anchor Counterbalance Weight ............. 226 Anchor Extension .................................... 228 Anchoring Parts ....................................... 230 Auto-Anchor System ............................... 222 Curb Stakes ............................................. 232 Hydraulic Stake Driver ............................ 234 Spring Loaded Pin ................................... 236

Fluid Systems

Mud Pump............................................... 242 Mud Pump............................................... 244 Mud Pump Plumbing .............................. 248 Mud Pump Plumbing - Ends ..................... 246 Mud Pump Plumbing w/o Tank .............. 252 Mud Pump Plumbing w/o Tank - Ends ..... 250 Mud Tank Plumbing ................................ 254 Tank Support ........................................... 240 Wash Wand ............................................. 256

Pipe Loader Systems

Drill Pipe Accessories .............................. 260

ID0135083

7

DECALS

8

DECAL LOCATION JT920

4.00 1.05

4.000 1.00

15.04

18

6.03

10.01 10.01

7.00

1.00

28 OPTION FOR JT920 20 5 6

01

32

8

ID0152569

9

DECAL LOCATION JT920

36 38

2

12 17 16

30

14 3 21 29 23

37 4

31

8 10

20 34 33

7

27 15

13

25

9

35

6 41 8

20 10 4 39 24

1 26 8 19 6

01

11 22

ID0152569

10

DECAL LOCATION JT920

REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

QTY

275-821 274-876 1 274-049 1 274-050 1 274-877 AR 274-881 1 274-318 3 274-375 1 274-442 3 274-880 1 274-721 1 274-635 2 274-705 1 274-706 1 274-879 1 274-707 1 274-198 1 275-048 1 275-120 1 275-148 1 273-198 1 275-184 1 275-197 3 275-341 1 275-383 1 275-400 1 275-449 1 275-450 1 274-724 1 274-780 1 274-809 1 274-415 1 274-883 1 274-884 1 274-885 2 275-033 1 275-203 1 275-306 1 275-355 1 274-291 1 274-947 1 273-138 1 273-267 1 273-278 1

DESCRIPTION

DECAL KIT - JT920 DITCH WITCH GRAPHIC STRIPE DANGER ELECTROCUTION WARNING JOBSITE HAZARD GRAPHIC STRIPE (SOLD PER INCH) FLUID PRESSURE SCALE 1500 PSI TIE DOWN LOCATION MASTER DISCONNECT SWITCH LIFT LOCATION RIGHT CONSOLE PANEL BORE CONTROL PANEL JT920 MODEL-ID SET-UP CONTROL PANEL INSTRUMENT PANEL LEFT CONSOLE PANEL LEFT CONTROL PANEL JT920 NOTICE OIL LEVEL IMPORTANT SAFETY RULES RESERVOIR (THF) FUEL TANK (DIESEL) TRACKER CONTROL WARNING MOVING PARTS DANGER ROTATING SHAFT WARNING SLIDING PARTS NOTICE SLOPE PARKING NOTICE OIL LEVEL DITCH WITCH LOGO PLACARD LOGO PLACARD ONE CALL NOTIFICATION JET TRAC PATENT(S) ANCHOR DRIVER CONTROL PANEL ROTATION MARKER DITCH GRAPHIC STRIPE WITCH GRAPHIC STRIPE JET TRAC LOGO TYPE NOTICE ELECTRICAL SYSTEM BATTERY DITCH WITCH EMBLEM CAUTION HOT PARTS SOUND POWER 10 AUTO BORE OVERRIDE PANEL NOTICE COOLANT DITCH WITCH BATTERY DANGER WRENCH

REMARKS

USE 55.00"

NOT PART OF KIT - REQ'D FOR S/N 2R0896 AND BELOW

NOT PART OF KIT - REQ'D FOR S/N 2R0896 AND BELOW

DIESEL

OPTIONAL

SEE FOOTNOTE 1 APPLY DECAL OVER THROTTLE SEE FOOTNOTE 2

FOOTNOTES:

1. NOT PART OF KIT, FOR EUROPEAN UNITS ONLY. 2. LOCATE DECAL ON BATTERY SO THAT DECAL IS VISIBLE WHEN VIEWING BATTERY.

NOTE:

01

ID0152569

11

12

NOTES:

ID0134963

13

ENGINE COMPONENTS

14

ENGINE

24 1 29

29

31

23

25

8 27

3

19

30

2 26 21 20

28 18 22

4 5

16

17

6

15 14

10 7

9 13

18

14

12 11

9

ID0112752

15

ENGINE REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

QTY

196-307 1 105-274 2 353-684 1 196-252 1 105-444 1 194-408 1 353-745 1 105-845 2 317-032 4 170-099 1 115-161 1 514-106 1 105-833 4 105-245 14 105-088 4 105-002 4 353-670 1 194-417 1 165-771 1 105-826 2 158-420 1 500-461 217-862 1 194-428 1 106-945 2 344-572 1 363-684 1 105-826 2 105-117 2 355-608 2 106-076 6

DESCRIPTION

MUFFLER SCREW (M10-1.5 X 20mm) LEFT REAR ENGINE MOUNT COOLING FAN WASHER (1-1/4") FAN NUT FRONT ENGINE MOUNT FLG LOCKNUT (3/8-NC) GROMMET (1-1/8", T-MOUNT) FAN BELT NIPPLE (08N, 3-1/2") CAP (08NF) FLG LOCKNUT (1/2-NC) SCREW (M10-1.50 X 25mm) WASHER (9/16") BOLT (1/2-NC X 2-1/4") RIGHT REAR ENGINE MOUNT ENGINE - LISTER PETTER DIESEL EXHAUST FLANGE GASKET FLG LK BOLT (3/8-NC X 1") HYDRAULIC PUMP SEAL REPAIR KIT FUEL SOLENOID SOLENOID MOUNT BRACKET SCREW (M6-1.00 X 100mm) MUFFLER GUARD MUFFLER BRACKET FLG LOCK BOLT (3/8-NC X 1") WASHER (5/16") SPACER WASHER (1/4")

REMARKS

SEE FOOTNOTE 1

SEE "NOT SHOWN" BELOW

NOT SHOWN:

FOOTNOTES:

1.

18

105-444 USED ONLY WITH 194-408 (FAN NUT) WITHOUT COUNTERBORE IN IT

ID0112752

16

ENGINE REF PART NO. NUMBER

QTY

30. 499-297 153-290 153-291 153-292 31. 106-234

1 1 1 1 3

TURBOCHARGER, LPWT4 GASKET, TURBO OUTLET FLANGE GASKET, TURBO DRAIN PIPE SEAL, TURBO OIL PIPE SCREWS (M6-1.00 X 12mm)

-

DIPSTICK OIL PRESSURE SWITCH HEATER ELEMENT FUEL LIFT PUMP FUEL LIFT PUMP GASKET THERMOSTAT HOUSING GASKET THERMOSTAT STARTER TEMPERATURE SENDER 100 - 280 F FUEL FILTER ELEMENT OIL FILTER ELEMENT FLYWHEEL END DRIVE MEMBER FLYWHEEL END SAE B ADAPTER PLATE SPLINE HUB (13 TOOTH) JT920 FLYWHEEL PUMP ADAPTER KIT (INCLUDES 194-423,194-424, 194-425 W/ MOUNTING HARDWARE) SOLENOID MOUNT BRACKET WATER PUMP JT920 WATER PUMP GASKET WATER PUMP GASKET

DESCRIPTION

REMARKS

NOT SHOWN:

194-401 217-721 217-910 194-406 165-877 165-772 194-404 194-407 217-565 194-420 159-141 194-423 194-424 194-425 194-427 194-428 149-923 166-601 166-602 FOOTNOTES:

18

ID0112752

17

18

ENGINE (CATERPILLAR / PERKINS DIESEL) JT921

23 12

.20 DISTANCE FROM END OF PUMP SHAFT TO FACE OF SPLINE HUB

26

20 20 4 3 6

21

27 1

24 25

15 27

5 12

2 17 18 23 13 14 7

22

16 19

8

19 9 10

06

11

ID0028308

19

ENGINE (CATERPILLAR / PERKINS DIESEL) JT921

REF PART NO. NUMBER

1.

QTY

194-453 194-670 2. 170-400 1 3. 179-693 1 4. 194-519 1 5. 105-079 4 6. 107-025 4 7. 115-251 1 8. 217-565 1 9. 150-1385 1 10. 515-265 1 11. 154-330 1 12. 194-544 1 194-545 194-546 105-757 13. 105-091 8 14. 105-094 8 15. 324-791 1 16. 320-617 1 17. 105-072 12 18. 105-286 12 19. 211-306 2 20. 106-380 2 21. 105-215 4 22. 106-367 4 23. 158-420 1 500-461 24. 105-071 2 25. 105-048 2 26. 344-726 1 27. 110-333 2

DESCRIPTION

REMARKS

ENGINE (CATERPILLAR DIESEL T2) ENGINE - PERKINS 404C-22 DIESEL T2 FAN BELT FAN SPACER FAN (16" PULLER) LOCK WASHER (1/4") SCREW (M6-1.00 X 50MM) REDUCER (06N-02NF) TEMPERATURE SENDER (100 - 280F) BANJO FITTING (M16) HOSE (06OFX-14"-3000) PLUG (06O) FLYWHEEL / PUMP COUPLER NYLON FLANGE 13 TOOTH SPLINE HUB BOLT (3/8"-NC X 1.25) LOCK WASHER (5/16") BOLT (5/16"-NC X 1") MOUNT PLATE FUSE BRACKET LOCK WASHER (3/8") BOLT (3/8"-NC X 1-3/4") FB/HVAMI FUSE HOLDER FLG LK SCREW (M8-1.25 X 16MM) NUT (#6-32) SCREW (#6-32 X 1/2" PLPS SS) HYDRAULIC PUMP SEAL REPAIR KIT WASHER (1/2") BOLT (1/2-NC X 1-1/2") SUPPORT PLATE BOLT-ON CLAMP (1")

OBSOLETE ENGINE OPTION

TORQUE TO 8 FT-LBS.

USE LOCTITE 242 OR EQUIVALENT

BEGINS WITH S/N: BEGINS WITH S/N: BEGINS WITH S/N:

TORQUE TO 50 FT-LBS TORQUE TO 25 FT-LBS.

USE LOCTITE 271 OR EQUIVALENT

TORQUE TO 40 FT-LBS SUPERSEDED BY 363-714

USE LOCTITE 242 OR EQUIVALENT

NOT SHOWN:

FOOTNOTES:

NOTE:

06

ID0028308

20

ENGINE INSTALLATION (CATERPILLAR / PERKINS DIESEL)

16 17 18

15

9

19

12 14 8

10 11

1 9

4

12 5

10 11

6

21 23 22

3

7

20 21

24

2

13

07

ID0028361

21

ENGINE INSTALLATION (CATERPILLAR / PERKINS DIESEL) REF PART NO. NUMBER

1.

QTY

DESCRIPTION

194-453 - ENGINE (CATERPILLAR DIESEL T2) 194-670 - ENGINE - PERKINS 404C-22 DIESEL T2 2. 350-501 - TRACK FRAME WELDMENT 3. 320-608 1 BOTTOM PLATE 4. 320-496 1 FORWARD ENGINE MOUNT 5. 105-071 12 WASHER (1/2") 6. 107-494 8 SCREW (M14-1.50 X 30MM) 7. 320-498 1 RIGHT REAR ENGINE MOUNT 8. 320-497 1 LEFT REAR ENGINE MOUNT 9. 105-826 8 FLG LK BOLT (3/8"-NC X 1") 10. 105-088 4 WASHER (9/16") 11. 116-496 4 SHOCK MOUNT 12. 106-336 4 SCREW (M12-1.75 X 90MM) 13. 106-709 4 FLG LK NUT (M12-1.75) 14. 157-417 - MUFFLER GASKET 15. 194-483 1 MANIFOLD ADAPTER 16. 196-362 1 MUFFLER 17. 105-806 4 SCREW (M8-1.25 X 25MM) 18. 105-091 4 LOCK WASHER (5/16") 19. 196-195 1 LOWER CLAMP (HEADER PIPE) 20. 179-875 1 PROP ROD 21. 118-211 2 GROMMET (1/4") 22. 118-151 1 SOUND INSULATION 23. 115-686 AR BULK EDGE (5/32", SOLD PER 1") 24. 118-151 AR BULK EDGE (5/32", SOLD PER 1")

REMARKS

OBSOLETE ENGINE OPTION

USE LOCTITE 242 OR EQUIVALENT

USE LOCTITE 242 OR EQUIVALENT

TORQUE TO 20 FT-LBS

USE 10" USE 8.5"

NOT SHOWN:

FOOTNOTES:

NOTE:

07

ID0028361

22

ENGINE SERVICE (CATERPILLAR / PERKINS DIESEL)

4 2

8

7 6

1 11

5

10

12

3

9

OTHER SIDE OF ENGINE 4

07

ID0028356

23

ENGINE SERVICE (CATERPILLAR / PERKINS DIESEL) REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

194-453 194-670 170-474 153-113 194-582 194-488 194-491 194-550 194-551 194-075 215-223 213-403 194-177 194-581 194-178 194-583 194-887

QTY

1 1 1 1 2 1 1 1 1 1 1 1 1 1

DESCRIPTION

ENGINE (CATERPILLAR DIESEL T2) ENGINE (PERKINS 404C-22 DIESEL T2) FAN BELT OIL FILTER ELEMENT OIL FILLER CAP FUEL FILTER / WATER SEPERATOR FUEL FILTER ELEMENT (30 MICRON) FUEL FILTER (FINAL) FUEL FILTER ELEMENT (2 MICRON) FUEL FILTER ELEMENT KIT (2 MICRON) ALTERNATOR ALTERNATOR (DENSO) WATER PUMP ENGINE OIL DIP STICK STARTER OIL RESERVOIR FUEL TRANSFER PUMP

REMARKS

OBSOLETE ENGINE OPTION

SEE NOT SHOWN LIST - USE WITH OIL FILLER CAP SEAL (118-466)

OBSOLETE

SEE NOT SHOWN LIST - USE WITH WATER PUMP GASKET (194-504)

SEE NOT SHOWN LIST - USE WITH OIL RESERVOIR GASKET (153-139) SEE NOT SHOWN LIST - USE WITH FUEL TRANSFER PUMP SEAL (194-888)

NOT SHOWN:

194-888 1 194-504 1 215-246 1 153-135 1 153-139 1 215-1080 1 194-889 1 153-136 1 053-144 1 054-128 1 055-076 1 056-005 1

FUEL TRANSFER PUMP SEAL WATER PUMP GASKET THERMOSTAT THERMOSTAT GASKET OIL RESERVOIR GASKET OIL PRESSURE SWITCH INTAKE MANIFOLD GASKET EXHAUST MANIFOLD GASKET CAT 3024C PARTS MANUAL CAT 3013C / 3024C OPER / MAINT MANUAL CAT 3013C / 3024C SERVICE MANUAL CAT 3013C / 3024C USER HANDBOOK

FOOTNOTES:

NOTE:

07

ID0028356

24

FUEL FILTER SYSTEM (CATERPILLAR/PERKINS DIESEL) TO FUEL INJECTOR FROM FUEL PUMP

3

25 18 14

3

22

20 21

17

24

3

23

19

3 1

7

2 3

7

11 4

10

TO FINAL FUEL FILTER FROM FINAL FUEL FILTER

OUT

17 18

14 8

15 16 14 13

IN

15 16 14

6

12

14

5 FROM

T FUEL

ANK

9 25

OTHER SIDE OF ENGINE

14

04

13

MP EL PU TO FU

ID0032055

25

FUEL FILTER SYSTEM (CATERPILLAR/PERKINS DIESEL) REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

QTY

194-453 194-670 320-622 1 106-380 15 107-585 1 194-488 1 194-491 106-162 2 106-386 11 364-566 1 106-379 2 106-388 2 106-237 2 116-108 AR 116-108 AR 110-249 8 155-120 2 155-162 2 116-108 AR 116-108 AR 320-618 1 323-200 1 118-147 1 320-621 1 194-550 194-551 194-075 106-992 2 325-644 1

DESCRIPTION

REMARKS

ENGINE (CATERPILLAR DIESEL T2) ENGINE - PERKINS 404C-22 DIESEL T2 COOLANT BOTTLE BRACKET FLG LK SCREW (M8-1.25 X 16MM) FLG LK SCREW (M10-1.50 X 16MM) FUEL FILTER / WATER SEPERATOR WO FUEL FILTER ELEMENT (30 MICRON) FLG SCREW (M8-1.25) FLG LOCKNUT (M8-1.25) COOLANT OVERFLOW RESERVOIR FLG LK SCREW (M6-1.00 X 20MM) WASHER (M6) LOCKNUT (M6-1.00, PRV TRQ, NLK) BULK HOSE (5/16", SOLD PER 1") BULK HOSE (5/16", SOLD PER 1") WORM CLAMP (1/4" TO 5 /8 ") STREET ELBOW (04N-04NF90) S/O COUPLER (04N-05H) BULK HOSE (5/16", SOLD PER 1") BULK HOSE (5/16", SOLD PER 1") FUEL FILTER BRACKET HEAT SHIELD SOUND INSULATION AIR FILTER BRACKET FUEL FILTER (FINAL) FUEL FILTER ELEMENT (2 MICRON) FUEL FILTER ELEMENT KIT (2 MICRON) FLG LK SCREW (M8-1.25 X 25MM) COOLANT BOTTLE BRACKET

OBSOLETE ENGINE OPTION

USE 1 @ 50" USE 1 @ 46"

USE 1 @ 24" USE 1 @ 24"

OBSOLETE

NOT SHOWN:

FOOTNOTES:

NOTE:

04

ID0032055

26

ALTERNATOR

9 8 5 2 11

1

1 10

1

7 3 8 6 5 4

10

ID0132425

27

ALTERNATOR REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

QTY

215-159 1 190-1244 1 363-359 1 184-334 1 106-588 1 105-117 2 105-095 1 105-089 1 105-091 2 106-083 1 194-419 1 107-194 1

DESCRIPTION

ALTERNATOR (12V, 61 AMP) ALTERNATOR KIT 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 (M8-1.25 X 20MM) ALTERNATOR SHEAVE (4-GROOVE) FLG SCREW (M8-1.25 X 50MM)

REMARKS

TORQUE NUT TO 50 FT-LBS. OBSOLETE INCLUDES WIRING UPGRADE

NOT SHOWN:

FOOTNOTES:

NOTE:

10

ID0132425

28

29

30

RADIATOR (CATERPILLAR / PERKINS DIESEL) 22

21

21 29 26 6

17

3

5

16

7

8 19 18 19

28 24

15

4

23

14

7

28

7

6

8 25

2

5 10 12 9

27 1

21 7

11

24 23

13 20 21

06

ID0028375

31

RADIATOR (CATERPILLAR / PERKINS DIESEL) REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

QTY

320-496 194-463 1 111-084 362-975 1 117-948 AR 115-380 AR 106-396 9 106-654 5 116-539 2 106-162 4 106-386 4 105-071 2 106-642 2 105-894 2 320-607 2 106-987 4 106-385 4 116-540 2 105-832 4 118-067 1 110-133 4 118-068 1 116-108 AR 110-249 2 364-566 118-173 1 118-150 1 106-397 5 116-421 AR

DESCRIPTION

FORWARD ENGINE MOUNT RADIATOR/HOC RADIATOR CAP SHROUD BULK EDGE (3/32", SOLD PER FT) WEATHER STRIP (3/8" X 3/4") WASHER (M10, HARDENED) FLG LK SCREW (M10-1.50 X 16MM) ISOLATOR FLG SCREW (M8-1.25 X 20MM, GD8) FLG LOCKNUT (M8-1.25) WASHER (1/2") SCREW (M10-1.5 X 65MM) LOCKNUT (M10-1.50, PRV TRQ 10.9) RADIATOR BRACKET FLG LK SCREW (M6-1.00 X 16MM) FLG LOCKNUT SHEAR MOUNT FLG LOCKNUT (1/4-NC) COOLANT HOSE WORM CLAMP (1.062" TO 1.937") COOLANT HOSE BULK HOSE (5/16", SOLD PER 1") WORM CLAMP (1/4" TO 5/8") COOLANT OVERFLOW RESERVOIR GROMMET (9/16") SOUND INSULATION WASHER (M12, HARDENED) BULK EDGE (1/8", SOLD PER FT)

REMARKS

USE 2 @ 23.7" USE 2 @ 17"

OBSOLETE

USE 1 @ 55"

USE 1 @ 24"

NOT SHOWN:

FOOTNOTES:

NOTE:

06

ID0028375

32

33

34

AIR FILTER SYSTEM (CATERPILLAR / PERKINS DIESEL)

UUM VAC TO

L TRO CON N E O GAG

EL PAN

12

17 13 14

6

4 7

16 5 15

11 9

10 3

18

7

15

8 2

1 19

04

ID0028392

35

AIR FILTER SYSTEM (CATERPILLAR / PERKINS DIESEL) REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

QTY

194-453 194-670 320-618 320-621 194-297 1 194-758 194-759 194-760 149-165 1 106-328 2 106-389 4 107-096 2 118-070 1 110-815 1 111-135 1 118-071 1 110-169 1 118-169 1 110-031 7 155-150 1 116-192 AR 118-148 1 118-149 1

DESCRIPTION

ENGINE (CATERPILLAR DIESEL T2) ENGINE - PERKINS 404C-22 DIESEL T2 FUEL FILTER BRACKET AIR FILTER BRACKET AIR FILTER ELEMENT (SAFETY) ELEMENT (PRIMARY) COVER MOUNTING CLAMP SCREW (M8-1.25 X 40MM) WASHER (M8) LOCKNUT (M8-1.25,NLK) AIR INTAKE HOSE T-BOLT CLAMP (2.25" TO 2.56") T-BOLT CLAMP (2.750" TO 3.062") AIR INTAKE HOSE WORM CLAMP (2.812" TO 3.750") SOUND INSULATION CABLE TIE (1-1/2" TO 7") S/O COUPLER (02N-02H) BULK HOSE (7/64", SOLD PER 1") SOUND INSULATION SOUND INSULATION

REMARKS

OBSOLETE ENGINE OPTION

USE WITH PIPE THREAD SEALANT USE 1 @ 53"

NOT SHOWN:

FOOTNOTES:

NOTE:

04

ID0028392

36

THROTTLE

1

2

9

3

6

8

4

7

MOUNTED TO MOTOR

5

F

805-083

37

THROTTLE REF PART NO. NUMBER

1.

2.

353-294 215-231 196-331 501-358 195-911 3. 363-627 4. 365-415 5. 107-046 6. 105-860 7. 106-205 8. 196-058 9. 105-194

QTY

DESCRIPTION

REMARKS

1 1 1

HOOD LINEAR ACTUATOR CABLE (LINEAR ACTUATOR) ROLL PIN (3/32" X 3/4") 1 THROTTLE CABLE 1 CABLE SUPPORT 1 THROTTLE LINKAGE 1 BOLT (#8-32 X .375",SLT) 1 SCREW (M6-1.00 X 10MM) 1 WASHER (.191") 1 CABLE SWIVEL (.081") 1 SCREW (#8-32 X 1/2")

FOOTNOTES

NOTE:

F

805-083

38

THROTTLE (CATERPILLAR / PERKINS DIESEL)

1

8 7

2

3

2 2 4

6 5

B

808-908

39

THROTTLE (CATERPILLAR / PERKINS DIESEL) REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

322-509 215-231 196-331 501-358 195-911 196-058 320-826 179-720 106-271 106-224 105-836 106-076

QTY

1 1 1 1 2 2 2

DESCRIPTION

REMARKS

HOOD LINEAR ACTUATOR CABLE (LINEAR ACTUATOR) ROLL PIN (3/32" X 3/4") THROTTLE CABLE CABLE SWIVEL (.081) THROTTLE CABLE BRACKET THROTTLE CABLE PIN SCREW (M5-0.80 X 8MM,PLPS) FLG SCREW (M6-1.00 X 10MM) FLG LK BOLT (1/4"-NC X 1/2") WASHER (1/4")

FOOTNOTES

NOTE:

B

808-908

40

NOTES:

ID0134963

41

FRAME COMPONENTS

42

DRILL FRAME COMPONENTS 33 34

27

28

35 24 37

39 38 25 31

32

26

42 36

41 42

21

40

10 44 19

47

46

6

20 43

20

22 1 9

16 18

8 45

17 30

15

48

7 5

29 19

2 14

11 12

4

23

3

13

10

21

ID0035729

43

DRILL FRAME COMPONENTS REF PART NO. NUMBER

1. 306-478 2. 183-843 3. 125-614 4. 106-079 5. 165-963 6. 344-751 184-711 7. 105-883 8. 305-256 9. 110-270 10. 309-585 325-629 11. 125-773 12. 151-054 13. 181-975 14. 106-470 15. 179-078 16. 125-772 17. 179-037 18. 181-974 19. 105-969 20. 125-438 21. 110-033 22. 181-975 23. 105-223 24. 158-908 190-728 106-324 166-829 105-501 25. 174-018 26. 106-551 27. 353-138 28. 106-381 29. 106-685 30. 106-333 31. 105-357 32. 105-462 33. 346-052 118-213 357-328 323-902 357-329 323-903 359-944 323-900 359-945 323-900 359-946 118-214 179-917

QTY

1 1 2 2 1 2 2 2 2 4 1 1 1 1 1 1 1 1 1 1 2 2 2 1 2 1 1 3 1 3 8 8 4 4 1 1 AR AR AR AR AR AR AR AR AR

DESCRIPTION

REMARKS

SPROCKET (120/9T) ROLLER PIN FLANGE BEARING (1.625") SCREW (M10-1.50 X 30mm) KEY (3/8" X 1-1/8") PIN PIN FLG LK BOLT (3/8-NC X 2") BACKUP SPACER BOLT-ON CLAMP (9/16", HALF) WELDMENT,JT920 DRILL FRAME WELDMENT,JT920 DRILL FRAME COMPOSITION BUSHING (1.75") CYL (3.0" X 1.50" X 4.0") TAPERED INSERT (1.75") FLG SCREW (M16-2.0 X 40mm) TAPERED PIN (1.500" X 4.440") COMPOSITION BUSHING (1.5") TAPERED PIN (44.45mm X 132mm) TAPERED INSERT (1.5") FLG BOLT (5/8-NC X 1-1/2", GD8) COMPOSITION BUSHING (1.75") HAIR CLIP PIN (1/8" X 1/2") TAPERED INSERT (1.75") WASHER (3/8") HYD MOTOR (THRUST, 8600#) SEAL REPAIR KIT CASTLE JAM NUT (1-1/2-NF) KEY (9/16" X 2") COTTER PIN (.125" X 2") SPROCKET (120B9) CLIP NUT (M8-1.25) COVER PLATE FLG LK SCREW (M8-1.25 X 25mm) LOCKNUT (M12-1.75,PRV TORQ,10.9) SCREW (M12-1.75 X 40mm, 8.8) LOCKNUT (5/8-NC) BOLT (5/8-NC X 2-1/4") HOSE CARRIER HOSE CARRIER UPPER MOUNT BRACKET - LEFT MOUNTING BRACKET (LH) UPPER MOUNT BRACKET - RIGHT MOUNTING BRACKET (RH) EASY-OUT BAR (1/2" X 4.00") EASY-OUT BAR (1/2" X 4.000") ALUMINUM BAR (1/2" X 4.00") ALUMINUM BAR (1/2" X 4.000") REPAIR SECTION REPAIR SECTION (4" X 16") 4" FLAT ALUMINUM BAR

BEGINS WITH S/N 253690

USE WITH JT921 USE WITH JT921S

USE WITH EARLY STYLE JT920 USE WITH JT921, JT921L, JT921P, AND JT92SP TORQUE TO 175 FT-LB

PRIOR TO S/N______, USE 106-470 BEGINS WITH S/N 2V0213

SEE FOOTNOTE #1 SEE FOOTNOTE #1 BEGINS WITH S/N 253690

BEGINS WITH S/N BEGINS WITH S/N BEGINS WITH S/N BEGINS WITH S/N BEGINS WITH S/N BEGINS WITH S/N BEGINS WITH S/N

NOT SHOWN:

FOOTNOTES:

NOTE:

21

ID0035729

44

DRILL FRAME COMPONENTS REF PART NO. NUMBER

34. 105-823 35. 105-003 36. 344-800 344-875 37. 344-878 38. 106-709 39. 106-559 40. 344-801 344-876 41. 110-981 42. 350-275 43. 178-190 44. 116-431 45. 105-826 46. 105-059 47. 105-834 48. 105-708

QTY

DESCRIPTION

8 8 1 1 1 17 17 1 1 AR 4 1 1 2 2 2 1

FLG LK BOLT (5/16-NC X 3/4") FLG LOCKNUT (5/16-NC) REAR ROD SUPPORT SIDE PLATE DRILL PIPE GUARD FLG LK NUT (M12-1.75) SCREW (M12-1.75 X 25mm) FRONT ROD SUPPORT SIDE PLATE BULK CABLE (1/16", SOLD PER FT) ALUMINUM SLEEVE (1/16") BAR (1.75 X 8 TPRD PIN W/CMFR) OUTBOARD SPOILS FLAP FLG LK BOLT (3/8-NC X 1") WASHER (7/16") FLG LOCKNUT (3/8"-NC) SET SCREW (3/8-NC X 3/8", NLK)

REMARKS

USE WITH JT921 USE WITH JT921S

USE WITH JT921 USE WITH JT921S USE 2 @ 18" BEGINS WITH S/N 2V0213

NOT SHOWN:

FOOTNOTES:

1. TORQUE CASTLE NUT TO 475 N-M (350 FT-LBS) NOTE:

21

ID0035729

45

46

FRONT WRENCH

23

40

41 37 31

24

32 22

35

18

1

21 2

3 17

36

16

38

19

39 19

5 6

15 14 30 29

25

27 13

34 33

12

8

26

4 7 9

11

28

10

20

20

19

ID0035756

47

FRONT WRENCH REF PART NO. NUMBER

QTY

1. 106-806 2. 106-397 3. 307-806 4. 105-059 5. 117-017 6. 183-966 7. 307-884 8. 301-973 9. 106-685 10. 183-818 11. 110-033 12. 106-618 13. 305-678 14. 106-380 15. 106-260 16. 117-052 17. 184-945 18. 150-725 19. 110-078 20. 346-800 309-585 325-629 21. 214-692 22. 346-726 23. 217-577 24. 105-826 25. 105-834 26. 149-578 27. 307-665 28. 115-505 29. 115-001 30. 106-333 31. 115-170 32. 154-482 33. 107-453 34. 305-866 35. 106-427 36. 106-850 37. 214-691 38. 308-946 39. 106-428 40. 106-205 41. 106-138

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

DESCRIPTION

REMARKS

FLG LK SCREW (M12-1.75 X 25mm) WASHER (M12, HARDENED) SLIDE PLATE WASHER (7/16") COMPRESSION SPRING BUSHING (.530" X 1" X 3.6") PIPE GUIDE BEARING FRONT WRENCH SUPPORT LOCKNUT (M12-1.75, PRV TRQ, 10.9) PIN (19mm X 220mm) CLIP PIN (1/8" X 1/2") SCREW (M12-1.75 X 130mm) WRENCH PLATE FLG LK SCREW (M8-1.25 X 16mm) WASHER (3/8") COMPRESSION SPRING SPRING GUIDE CYLINDER (1" X 2.5") STROKE THRD MACHINERY BUSHING (1",14 GA) 10'DRILL FRAME WELDMENT, JT920 DRILL FRAME WELDMENT, JT920 DRILL FRAME PROXIMITY SWITCH GAUGE MOUNT ASS'Y 3000 PSI PRESSURE GAUGE FLG LOCK BOLT (3/8-NC X 1") FLG LOCKNUT (3/8-NC) ROD WIPER PIPE GUIDE INTERNAL SNAP RING (5.118") ZERK (02N) SCREW (M12-1.75 X 40mm) COLLAR (04NF) CONNECTOR (04N-04O90) RETAINER RING GUIDE BEARING SCREW (M5-0.80 X 22MM, SOC) LOCKNUT (M5-0.80) STRAIGHT JUMPER HARNESS SHEET, WRENCH MOUNT BOLT-ON MNT SCREW (M5-0.80 X 14MM,SOC) WASHER (.191") NUT (M5-0.80)

USED ON JT920L USED ON JT920.

USED ON JT921, JT921S, JT921P & JT92SP OBSOLETE SEE FOOTNOTE 1

NOT SHOWN:

FOOTNOTES:

1. IF DECALS ARE NEEDED ORDER KIT 191-047

NOTE:

19

ID0035756

48

49

50

51

52

CARRIAGE 38 1

8 2

3

9 19 4

7

10

5

37

6

11

12 14

16

53 41 43

42

24

46 44

26

15

40 19 17

47

50

25 29

51

30 46

23

18

39 31

28

21 20

33 46

32 27

19

34 46

35

22

45 50

19 27

13

45

36

49

48

19

45 52

22

ID0042825

53

CARRIAGE REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

QTY

107-044 4 158-881 1 500-641 500-711 500-758 185-067 1 185-074 1 106-865 1 184-749 1 153-242 1 106-397 4 166-113 1 115-534 1 118-033 1 106-806 2 107-035 2 343-192 1 347-605 1 150-724 2 106-660 8 157-019 1 106-685 14 105-151 2 301-891 1 353-763 1 106-081 6 106-031 4 344-574 1 344-761 2 125-770 4 105-894 12 107-045 8 107-043 2 306-489 1 150-723 1 343-046 8 343-047 16 343-038 4 106-332 12 125-117 1 346-738 1

DESCRIPTION

REMARKS

BOLT (M12-1.75 X 40mm, SOC) HYD MOTOR MOUNTING FLANGE SEAL REPAIR KIT - REAR SEAL REPAIR KIT SHAFT THRUST LOCKNUT(1.767-NF-18) TANG LOCK WASHER (1.792") NUT (3.25") SPACER WATER SWIVEL WASHER (M12, HARDENED) GEARBOX (1.78:1, ROTATION) INTERNAL SNAP RING (5.485") EXTERNAL SNAP RING (2.5") FLG LK SCREW (M12-1.75X25mm) BOLT (7/16-NC X 3",GD8) BEARING HOUSING SLIDING SPINDLE SHAFT CYL (1" X 2") SCREW (M12-1.75 X 30mm, SOC) O-RING (139 D90) LOCKNUT (M12-1.75, PRV TRQ, 10.9) LOCKNUT (7/16-NC) SAVER SUB (1.41-6 FM DS) WRENCH COLLAR SCREW (M10-1.5 X 35mm, 12.9) LOCKNUT (M12-1.75, NLK) PUSH PLATE WEAR PAD COMPOSITION BUSHING (1") LOCKNUT (M10-1.50,PRV TRQ,10.9) SCREW (M16-2.0 X 35mm, 10.9) SHLD BOLT (M12 X 35mm, M10-1.5) WELDMENT, JT920L CARRIAGE 120P CYL (1" X 2") SLIDE SPACER CLAMP PLATE SCREW (M10-1.5 X 70mm) BALL BEARING (_.___") LOWER HOSE TRACK MOUNT

USE 242 LOCTITE THREAD LOCKER USE 518 LOCTITE FLANGE SEALANT

SEE FOOTNOTE 1 1.78:1 ROTATION DRIVE

USE 242 LOCTITE TORQUE TO 55 FT. LBS

NOT SHOWN:

FOOTNOTES:

1. INSTALL USING NICKLE THREAD SEALING TAPE (117-555) AND (500-1948) THREAD COMPOUND OVER THE NICKLE TAPE ON MALE THREADS.

NOTE:

22

ID0042825

54

CARRIAGE REF PART NO. NUMBER

39.

40.

41.

42.

43.

44.

45.

46.

47.

48.

49.

50.

51.

52.

53.

QTY

105-338 1 105-351 1 130-526 1 129-006 1 130-524 2 343-053 1 105-384 2 106-334 4 343-058 4 105-273 2 346-730 1 346-729 1 346-737 2 130-530 1 346-763 1 110-095 AR

DESCRIPTION

LOCKNUT (3/4-NC) HEX NUT (3/4-NC) ROLLER CHAIN (#120, 215P) ROLLER CHAIN #120 171P CONNECTOR LINK (#120H) (REX) CHAIN ADJUSTER WASHER (3/4") SCREW (M12-1.75 X 50mm) BUSHING SCREW (M12-1.75 X 30mm) BACK AUX WRENCH BACKUP WRENCH AUXILIARY WRENCH MOUNT OFFSET LINK (#120H) PIN MACHINERY BUSHING (3/4" X 18GA)

REMARKS

THIS ITEM IS USED ON JT920L ONLY

NOT SHOWN:

FOOTNOTES:

NOTE:

22

ID0042825

55

56

57

58

CARRIAGE

BEGINS WITH S/N 2P0770 ENDS WITH S/N ______

38 1

8 2

3

9 19

54

4 10

5 7

6

40 20

37 11

12 13

39

14

16

41

24 42

26

25 26

43 44 19 51

47

15

27 17

50 29 23

18 46

30 21 31 33

19

22

45 32

35

53

19

34

50

19 53

17

45

36

49

48

19

28 52

K

805-322

59

CARRIAGE BEGINS WITH S/N 2P0770 ENDS WITH S/N ______ REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

K

QTY

106-707 4 158-881 1 500-641 500-711 500-758 185-067 1 185-074 1 106-865 1 184-749 1 159-240 1 500-837 500-836 106-397 4 166-113 1 130-323 1 115-534 1 118-033 1 106-806 2 106-551 2 343-192 1 347-605 1 151-152 2 150-724 2 106-660 16 157-019 1 106-685 20 118-119 1 343-179 1 301-891 1 353-763 1 106-081 6 106-031 4 344-574 1 344-761 2 106-077 2 107-008 2 107-045 8 107-043 2 343-078 1 159-464 1 150-723 1 343-046 8 343-047 16 343-048 4 343-038 4 106-332 12 125-117 1 346-738 1 514-278 1 118-120 1 130-459 1 130-401 2 353-615 1 106-398 1 106-334 2 130-323 2

REMARKS

DESCRIPTION

SCREW (M12-1.75 X 45mm, SOC) HYD MOTOR MOUNTING FLANGE SEAL REPAIR KIT - REAR SEAL REPAIR KIT - SHAFT THRUST LOCKNUT(1.767-NF-18) TANG LOCK WASHER (1.792") NUT (3.25") SPACER WATER SWIVEL REBUILD KIT PACKING/SEAL KIT WASHER (M12, HARDENED) GEARBOX ROLLER BUSHING (#100) INTERNAL SNAP RING (5.485") EXTERNAL SNAP RING (2.5") FLG LK SCREW (M12-1.75 X 25mm) CLIP NUT (M8-1.25) BEARING HOUSING SLIDING SPINDLE SHAFT CYL (1.5" X .437" X 2") CYL (1" X 2") SCREW (M12-1.75 X 30mm, SOC) O-RING (139 D90) LOCKNUT (M12-1.75, PRV TRQ, 10.9) ZERK (1/8 NPT-27) SAVER SUB SAVER SUB (1.41-6 FM DS) WRENCH COLLAR SCREW (M10-1.5 X 35mm, 12.9) LOCKNUT (M12-1.75, NLK) PUSH PLATE WEAR PAD HEX NUT (M16-2.00, 10.9) ZP FLG LK SCREW (M12-1.75 X 50mm) SCREW (M16-2.0 X 35mm, 10.9) SHLD BOLT (M12 X 35mm, M10-1.5) CARRIAGE HYD CYLINDER CYL (1' X 2") W/EYE SLIDE SPACER SLIDE MOUNT CLAMP PLATE SCREW (M10-1.5 X 70mm) BALL BEARING (_._") LOWER HOSE TRACK MOUNT LUBE ELBOW (1/4-NF-02NF90) ZERK (1/4-NF, 90) ROLLER CHAIN (#100, 208P) CONNECTOR LINK (#100) CHAIN ADJUSTER WASHER (M16, HARDENED) SCREW (M12-1.75 X 50mm) ROLLER BUSHING (#100)

1.78:1 ROTATION DRIVE

OBSOLETE

OBSOLETE, SEE FOOTNOTE 1

USE 242 LOCTITE. TORQUE TO 55 FT. LBS.

OBSOLETE

OBSOLETE

805-322

60

CARRIAGE BEGINS WITH S/N 2P0770 ENDS WITH S/N ______ REF PART NO. NUMBER

QTY

47.

48.

49.

50.

51.

52.

53.

54.

2 1 1 2 1 1 4 1

106-559 346-730 346-729 346-737 130-402 346-763 125-770 115-165

DESCRIPTION

REMARKS

SCREW (M12-1.75 X 25MM) BACK AUX WRENCH BACKUP WRENCH AUXILIARY WRENCH MOUNT OFFSET LINK (#100) PIN COMPOSITION BUSHING (1") PLUG (08N, SOC)

FOOTNOTE 1. USE 301-891 FOR ALL REPLACEMENTS.

K

805-322

61

62

ROTATION GEARBOX

4

14

13 8

9

21

20

7

12 19

17

18

2

4 22

3 1 4 5 6

16

15 10

10

11 ID0134795

63

ROTATION GEARBOX REF PART NO. NUMBER

QTY

166-113 166-1006 1 162-002 2 162-001 3 106-866 4 106-771 5 126-099 6 126-100 7 165-800 8 165-801 9 165-802 10 126-076 11 126-075 12 155-869 13 115-165 14 115-211 15 514-123 16 159-003 17 165-828 18 165-829 19 165-830 20 162-003 21 165-187 22 165-188

GEAR BOX (1.78:1, ROTATION) GEAR BOX (1.78:1, ROTATION) 1 GEARBOX HOUSING 1 COVER "B" 2 DOWEL PIN (M10 X 30MM) 10 SCREW (M12-1.75 X 60MM, SOC) 2 TAPERED RACE (3.25") 2 BEARING CONE 5 SHIM (.002") 5 SHIM (.003") 5 SHIM (.007") 2 TAPERED RACE (5.118") 2 TAPERED BEARING (3.346") 2 INTERNAL SEAL (3.250") 1 PLUG (08N, SOC) 1 PLUG (08N, SQ, MAG) 1 PICKUP TUBE (02N-02NF90-2") 1 AIR VENT (02N) 5 SHIM 5 SHIM 5 SHIM 1 OUTPUT SHAFT 1 INPUT PINION 1 OUTPUT GEAR

DESCRIPTION

REMARKS

INCLUDES GEAR BOX LIFT 300-4571, NOT SHOWN

NOT SHOWN:

FOOTNOTES:

NOTE:

10

ID0134795

64

TRACK GROUP

1

2

3 9 4 5 20

6

5 6

7 8

11

18 10

19

7 6

5 17 16 15

21

29

23

22

24

14 13

27

12

28 26

25

04

ID0145841

65

TRACK GROUP REF PART NO. NUMBER

QTY

DESCRIPTION

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

353-784 2 347-019 2 356-272 2 356-273 2 105-248 4 105-475 4 184-540 2 183-975 1 356-271 2 151-076 1 183-901 1 355-972 12 302-917 2 166-846 2 105-065 8 158-826 2 157-701 500-510

RUBBER TRACK (230MM, 56P, 72MM) IDLER YOKE GREASE CYLINDER SCREW (M12-1.75 X 25MM,SOC) WASHER (1/2") SPACER PIN (25.4MM X 68MM) JT3510 SPRING ASS'Y CYL (2.0" X 1.00" X 10.00") PIN (31.8MM X 68M) ROLLER WELDMENT MOTOR SPROCKET WOODRUFF KEY (5/16" X 1") LOCKNUT (1/2-NC) HYDRAULIC MOTOR (GEROLER) SHAFT SEAL SEAL REPAIR KIT

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

106-197 8 125-770 1 125-771 1 309-584 1 353-629 1 105-518 2 106-488 2 107-034 2 344-577 1 106-381 6 106-551 4 106-386 2 115-704 AR

BOLT (1/2-NC X 2-1/2", GD8) COMPOSITION BUSHING (1") COMPOSITION BUSHING (1.25") WELDMENT,JT920 TRACK FRAME TRACK FRAME COTTER PIN (1/8" X 1-1/2") WASHER (M24, HARDENED) CASTLE NUT (1-20 NEF) SKID PLATE FLG LK SCREW (M8-1.25 X 25MM) CLIP NUT (M8-1.25) FLG LOCKNUT (M8-1.25) BULK EDGE (1/4", SOLD PER 1")

REMARKS

TIGHTEN TO 250-350 FT-LBS

USE 9"

NOT SHOWN:

FOOTNOTES:

NOTE:

04

ID0145841

66

FUEL RESERVOIR 1

2

3 17

15

12 9

10 11

14 13

13

5

14 16

4

7 8

5 FROM INJECTOR

6 5

H

TO FUEL PUMP

804-740

67

FUEL RESERVOIR REF PART NO. NUMBER

QTY

DESCRIPTION

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

5 1 1 2 4 AR 1 AR 1 1 AR 1 6 6 1 AR 1

FLG SCREW (#10-24 X 1/2") FUEL SENDER GASKET S/O SHUT-OFF (02N-05H90) WORM CLAMP (1/4" TO 5/8") BULK HOSE (5/16", SOLD PER 1") S/O COUPLER (03H-05H) BULK HOSE (5/32", SOLD PER 1") SIGHT GLASS (2") ALARM FLEX GUARD (1/4", SOLD PER 1") GROMMET (1-1/2") FLG LK SCREW (M8-1.25 X 25MM) FLG LOCKNUT (M8-1.25) MOBILING STATION BULK HOSE (5/16", SOL PER 1") FUEL FILLER NECK FUEL CAP LOCKING, VENTED

105-214 217-549 165-704 156-239 110-249 116-108 156-253 105-1518 116-218 306-602 216-026 115-320 106-381 106-386 350-503 116-108 111-004 111-065

REMARKS

USE 32" USE 32"

USE 9 1/2"

USE 3"

FOOTNOTES

NOTE:

H

804-740

68

COVER & GUARDS

2 20 30

3

1

14 35

21 34

4 12 13

5

31

14

15 13

13 13

29

14

32

11

13 14

13

13 14 27

16

13 31 13

39

6 37 38

14

18 28

13 14 8 22

9

10 22

19

23

17

24

33

7 36

25

26

15

ID0133509

69

COVER & GUARDS REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

QTY

117-558 3 214-961 217-309 110-757 3 110-596 344-721 1 110-794 1 346-810 1 353-613 1 353-295 1 353-342 1 110-582 1 353-154 1 353-305 1 353-346 310-610 1 344-736 1 106-551 38 106-992 24 106-386 6 106-380 6 110-560 4 105-866 1 250-622 1 106-712 14 106-237 14 105-832 2 353-709 1 184-723 1 183-934 1 215-244 1 350-503 354-670 1 310-608 1 106-162 6 107-095 6 115-686 1 105-836 2 115-686 1 115-686 1 106-987 2 106-385 2 320-910 1 214-908 1

DESCRIPTION

REMARKS

ADJUST LEVER LATCH (LOCKING) KEY, PAIR (BASE CODE) LOCK PLUG 4/LATCH (BASE CODE) LEVER LATCH (ADJUST, LOCKING) KEYS (PAIR) RADIATOR ACCESS DOOR HINGE (11.39") HOOD LOUVER COVER PANEL ACCESS DOOR HINGE (20.5") BATTERY COVER TANK COVER COVER PANEL (LEFT) COVER PANEL (LEFT) INSTRUMENT PANEL CLIP NUT (M8-1.25) FLG LK SCREW (M8-1.25 X 25MM) FLG LOCKNUT (M8-1.25) FLG LK SCREW (M8-1.25 X 16MM) POP RIVET (3/16" X 1/2", ALUM) FLG LK BOLT (5/16-NC X 1.250) MANUAL COMPARTMENT FLG SCREW (M6-1.00 X 16MM) LOCKNUT (M6-1.00 PRV TRQ, NLK) FLG LOCKNUT (1/4-NC) BATTERY HOLDER BATTERY BAR BATTERY BOLT BATTERY MOBILING STATION PROP ROD ACCESS PANEL FLG SCREW (M8-1.25 X 20MM) FLG SCREW (M8-1.25 X 16MM) BULK EDGE (5/32", SOLD PER 1") FLG LOCK BOLT (1/4-NC X 1/2") BULK EDGE (5/32", SOLD PER 1") BULK EDGE (5/32", SOLD PER 1") FLANGE BOLT (M6-1.00 X 16) FLANGE NUT (M6-1.00) KEY SWITCH BRACKET ON-OFF KEY SWITCH

BEGINS WITH S/N 2W0970 OBSOLETE

OBSOLETE

USE 1 @ 11.2" USE 1 @ 29"

BEGINS WITH S/N_______, SEE NOT SHOWN FOR REPLACEMENT KEYS

NOT SHOWN:

105-512 353-173 106-862 215-1818 215-1819

1 1 1

COTTER PIN (3/32" X 3/4") CLIP POP RIVET (1/8" X _._) KEY, TRACKER CONTROL SWITCH, SINGLE KEY, TRACKER CONTROL SWITCH, DOUBLE

FOOTNOTES:

1.

15

FOR REPLACEMENT OF COVER PANEL ON EARLY UNITS, ORDER KIT 599-256.

ID0133509

70

COVERS (CATERPILLAR DIESEL) 4

18 20

4

6 22 36 21

4

24

13 16 22

4

15 13

13

22 9

25 10 13 11

19

8

23 9 5

9

19

12

14

9

5

17

9 13

13 7

9

9

9 9 13

13

9

11

38 13 3 27

1 5 15 37

9

28

4

29

30

13

2

5 34

35

4

32

26

33

31

07

ID0028397

71

COVERS (CATERPILLAR DIESEL) REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

322-521 322-525 110-582 105-836 105-832 117-558 214-961 217-309 110-596 322-517 323-844 106-551 106-162 115-686 353-613 107-095 106-386 106-991 322-509 115-686 323-198 110-794 323-196 179-825 118-211 118-146 118-144 320-619 118-143 118-145 353-305 250-622 110-560 215-244 184-723 183-934 353-709 353-154 322-612 350-503 105-117

QTY

DESCRIPTION

1 COVER PANEL - RIGHT WELDMENT 1 ACCESS DOOR 1 HINGE (20.5") 20 FLG LOCK BOLT (1/4-NC X 1/2") 22 FLG LOCKNUT (1/4-NC) 6 ADJUST LEVR LATCH (LOCKING) - KEY, PAIR (BASE CODE) - LOCK PLUG 4/LATCH (BASE CODE) - KEYS (PAIR) 1 COVER PANEL - LEFT WELDMENT 1 ACCESS PANEL 37 CLIP NUT(M8-1.25) 6 FLG SCREW (M8-1.25 X 20MM, GD8) AR BULK EDGE (5/32", SOLD PER 1") 1 LOUVER 34 FLG LK SCREW (M8-1.25 X 16MM) 6 FLG LOCKNUT (M8-1.25) 27 FLG LK SCREW (M8-1.25 X 20MM) 1 HOOD AR BULK EDGE (5/32", SOLD PER 1") 1 ACCESS PANEL 2 HINGE (11.39") 1 ACCESS PANEL 1 PROP ROD 3 GROMMET (1/4") 1 SOUND INSULATION 1 SOUND INSULATION 1 INSTRUMENT PANEL 1 SOUND INSULATION 1 SOUND INSULATION 1 TANK COVER 1 MANUAL COMPARTMENT 4 POP RIVET (3/16" X 1/2", ALUM) 1 BATTERY (12V, 800 AMP) 1 BATTERY BOLT 1 BATTERY BOLT 1 BATTERY HOLDER 1 BATTERY COVER 1 HOSE TRACK STAND - MOBLING STATION 3 WASHER (5/16")

REMARKS

USE 2 @ 18"

USE 1 @ 31"

NOT SHOWN:

FOOTNOTES:

NOTE:

07

ID0028397

72

REAR STABILIZER 9 2

1

3

14 12 13

11

12 11 4 5

6

7

10 8 3

F

803-579

73

REAR STABILIZER REF PART NO. NUMBER

QTY

DESCRIPTION

1. 179-052 1 TAPERED PIN (1.75" X 6.6") 2. 181-975 1 TAPERED INSERT (1.75") 3. 105-969 2 FLG BOLT (5/8-NC X 1-1/2", GD8) 4. 125-773 1 COMPOSITION BUSHING (1.75") 5. 151-147 1 CYL (3" X 1.5" X 20") 32" 6. 125-772 1 COMPOSITION BUSHING (1.5") 7. 353-291 1 STABILIZER BASE 8. 181-974 1 TAPERED INSERT (1.5") 9. 353-598 1 VALVE ENCLOSURE 10. 179-033 1 TAPERED PIN (1.5" X 5.4") 11. 106-551 8 CLIP NUT (M8-1.25) 12. 106-381 8 FLG LK SCREW (M8-1.25 X 25MM) 13. 353-289 1 UPPER STABILIZER TUBE 14. 353-290 1 UPPER STABILIZER TUBE (WET)

REMARKS

W/O WATER TANK

BEGINS WITH S/N 2M2288 BEGINS WITH 2M2288 W/O WATER TANK WITH WATER TANK

W/O WATER TANK WITH WATER TANK - ENDS W/ SN 2M2287

FOOTNOTES

NOTE:

F

803-579

74

IDLER 5 6

4 1

5

3

2

5

3 4 6

6 14 7 8 13

9 10

12 11 5

10 9 8

6

09

7

ID0088452

75

IDLER REF PART NO. NUMBER QTY DESCRIPTION 1. 347-019 1 IDLER

REMARKS SEE FOOTNOTES 1 & 3

2.

167-340

1

IDLER SHAFT

3.

125-550

2

BALL BEARING (1.378") GREASABLE

4.

115-465

2

EXTERNAL SNAP RING (1.375")

5.

105-561

2

ROLL PIN (3/8" X 2-3/4")

6.

347-023

2

PUSH BLOCK

7.

118-021

2

EXTERNAL SNAP RING

8.

110-478

2

MACHINERY BUSHING (1.585")

(1.500")

9.

157-650

2

INTERNAL SEAL (1.574")

10.

115-464

2

INT SNAP RING (3.149")

11.

125-107

1

BALL BEARING (1.574")

12.

347-024

1

IDLER SHAFT

13.

375-277

1

IDLER

14.

115-001

1

ZERK (02N)

SEE FOOTNOTE 2

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

ID0088452

76

77

78

GREASE CYLINDER

5

2

1

3 4

6

01

ID0149028

79

GREASE CYLINDER REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

QTY

DESCRIPTION

REMARKS

151-177 356-971 356-273 115-019

INCL REF NO'S 3 - 6; SEE FOOTNOTE 1 EARLY STYLE USE ON 921 ONLY

1

GREASE CYLINDER GREASE CYLINDER PARTS ASS'Y GREASE CYLINDER ZERK (02N)

159-093 157-078 155-712 356-970 347-038 356-969 347-039

1 1 1 1 1 1 1

RELIEF VALVE (5/8-NF,02N) O-RING (222 D90) BACKUP RING (222 D90) GREASE CYLINDER BARREL GREASE CYLINDER WELDMENT GREASE CYLINDER ROD GREASE CYLINDER ROD

USE ON 921 ONLY USE ON 921 ONLY

NOT SHOWN:

FOOTNOTES:

NOTE:

01

ID0149028

80

NOTES:

ID0134963

81

OPERATOR STATION

82

SEAT MOUNT

2 3

18

11

8

7

4 5 15

17

13 23 21

10 16

14 21

6

22

20 11 12

26 19

9

25

24

12

ID0033915

83

SEAT MOUNT REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

QTY

344-714 1 117-402 1 117-230 1 190-884 344-758 106-640 8 106-670 8 353-626 1 353-617 1 106-205 8 110-348 8 125-800 2 184-609 1 181-981 1 106-079 1 105-003 4 106-551 12 106-381 12 184-806 1 353-242 1 353-243 2 178-145 1 110-981 AR 350-275 4 110-981 AR 115-349 1 307-984 1 337-479 1 344-0001 1 500-1962 -

DESCRIPTION

COVER PLATE SEAT/ARM REST SEAT W/O ARM REST ARMREST KIT GUIDE BAR SCREW (M6-1 X 20mm, SOC BUT) NUTSERT (M6-1.00) TOP PLATE SEAT PIVOT WASHER (3/16") POP RIVET (3/16" X .664") COMPOSITION BUSHING (1.000") PIN (25.4MM X 190MM) TAPERED INSERT (1.000") SCREW (M10-1.50 X 30MM) FLG LOCKNUT (5/16-NC) CLIP NUT (M8-1.25) FLG LK SCREW (M8-1.25 X 25mm) SEAT LATCH PIN (1/2" X 5.8") TOP PLATE SHIFTER BOOT (RUBBER) PIN BULK CABLE (1/16", SOLD PER 1") ALUMINUM SLEEVE (1/16") BULK CABLE (1/16") GROMMET (1/2", SOLD PER 1") ACCESS PANEL COVER PLATE UMBRELLA (16") UMBRELLA POLE

REMARKS

USE 10" USE 12"

NOT SHOWN:

FOOTNOTES:

NOTE:

12

ID0033915

84

OPERATORS STATION GAUGES

1

3 4

5 2

9

2 7 9

2 5

6 11

8

10

D

808-321

85

OPERATORS STATION GAUGES REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

217-764 362-823 215-754 217-762 217-940 110-641 110-560 214-943 346-725 106-205 353-243 274-940

QTY

1 3 1 1 1 1 6 1 4 1 1

DESCRIPTION

REMARKS

ROCKER SWITCH (SPDT) COVER MC INSULATOR (2-TERMINAL) ROCKER SWITCH (SPDT) FLUID FLOW POTENTIOMETER KNOB (1/8", BLK) POP RIVET (3/16" X 1/2", ALUM) BUTTON SWITCH (SPST) COVER PLATE WASHER (.191") SHIFTER BOOT (RUBBER) INDICATOR

FOOTNOTES

NOTE:

D

808-321

86

CONSOLE GAUGES JT920 / JT920C / JT921

9

1 4

2 3

5

6

19

17

16 15

13

11

12 12

14 10

7 18 8

10

ID0028401

87

CONSOLE GAUGES JT920 / JT920C / JT921 REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

QTY

215-133 1 215-129 1 217-512 1 215-150 1 258-067 1 306-603 1 214-852 1 214-961 1 214-962 1 306-607 1 116-192 217-789 1 306-608 1 217-762 1 217-036 1 217-028 1 217-020 2 217-046 1 217-027 1 217-021 1 215-2594 1 320-619 -

DESCRIPTION

FUEL GAUGE VOLT METER WATER TEMPERATURE GAUGE RESTRICTION INDICATOR (20", H20) RESTRICTION INDICATOR (25", H20) AUDIO ALARM IGNITION SWITCH KEYS (PAIR) SWITCH MOUNTING NUT HORN BUTTON BULK HOSE (7/64", SOLD PER 1") ROCKER SWITCH BUTTON COVER ROCKER SWITCH (SPDT) INSERT (YEL) HYD OIL PSI INSERT (BLK) BLANK PILOT LIGHT BULB (12V DC) INSERT (RED) HYD OIL HI TEMP INSERT (RED) ENG OIL PSI HOUR METER INSTRUMENT PANEL

REMARKS

USE WITH LISTER-PETTER ENGINE USE WITH CATERPILLAR ENGINE INCL. KEYS & NUT

USE @ 55"

NOT SHOWN:

FOOTNOTES:

NOTE:

10

ID0028401

88

NOTES:

ID0134963

89

HYDRAULICS

90

HYDRAULIC SCHEMATIC W/AUTOBORE SHUTOFF BACKUP WRENCH

POWER BEYOND

b

RETURN 100 PSI

a

1000 PSI

RIGHT ANCHOR

THRUST

2750 PSI 1000 PSI

LEFT ANCHOR

ROTATION

2550 PSI STAKE DRIVERS OPTIONAL ANCHOR SYSTEM

IN 1500 PSI

1500 PSI

MUD 3000 PSI 2000 PSI

IN

3000 PSI

REAR WRENCH

1000 PSI

500 PSI

500 PSI

500 PSI

500 PSI

3000 PSI .5 CID

.5 CID

2.05 CID

FRONT WRENCH

14

ID0043871

91

HYDRAULIC SCHEMATIC W/AUTOBORE SHUTOFF

FROM RETURN

COOLER

FILTER

TRACK EXTEND

STABILIZER

FRAME TILT

TRACK DRIVE

TRACK DRIVE

1850 psi POWER BEYOND

14

ID0043871

92

HYDRAULIC DIAGRAM 27

18

THRUST

22 BACKUP WRENCH

ROTATION

25

26

THRUST

27

1

ROTATION

25

3

ANCHOR

2 2

10 MUD PUMP DRIVE

4 5

24

BREAKOUT CONTROL

6 23 PIPE ROTATION

7

FRONT WRENCH

20

21

17 17 9

PIPE THRUST

19

GROUND DRIVE 8

THRUST/ ROTAT

20

8 15

11

FRAME TILT

12

16 16 SPINDLE COLLAR

STABILIZER

13 TRACK WIDTH

DRIVE CONTROL

PRESSURE RETURN SUPPLY

14

P

805-128

93

HYDRAULIC DIAGRAM REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

QTY

DESCRIPTION

REMARKS

158-420 - HYD PUMP 158-601 - HYD RELIEF VALVE (300PSI) 158-814 - CONTROL VALVE 500-906 CONTROL VALVE CARTRIDGE 190-643 SEAL REPAIR KIT 158-687 - PRIORITY VALVE 157-784 - HYD FLOW VALVE 516-027 - HYD CONTROL VALVE (2-SPOOL) 158-881 - HYD MOTOR 158-826 - HYD MOTOR (GEROLER) 158-908 - HYD MOTOR (THRUST) 158-469 - GEAR MOTOR (3.0 CUI/REV) 151-054 - CYL (3.0" X 1.50" X 4.00") 151-147 - CYL (3" X 1.5" X 20")32" 151-076 - CYL (2.0" X 1.00" X 10.00") 158-937 - HYD CONTROL VALVE (_-SPOOL) 360-383 - OIL COOLER & RADIATOR ASS'Y 306-829 - OIL COOLER 306-830 - RADIATOR 150-724 - CYL, 1" BORE X 2." STROKE THRD 149-495 - HYD SOLENOID VALVE 217-941 1 SOLENOID COIL 500-620 1 SEAL REPAIR KIT 158-944 - HYD CONTROL VALVE 516-124 - HYD CONTROL VALVE 2 SECTION 155-259 - CHECK VALVE 159-081 - HYD OIL FILTER (20SF-20SF) 516-098 - SOLENOID VALVE (SINGLE) 150-725 - CYL, 1" BORE X 2.5" STROKE THRD 350-503 - MOBILING STATION 158-700 - HYD MOTOR 150-723 - CYL, 1" X 2" STROKE 151-096 - CYL (2" X 1" X 24")

FOOTNOTES

NOTE:

P

805-128

94

HYDRAULIC DIAGRAM AUTOBORE SHUTOFF

1

2

3 27

22

25

4 5 24 6 23 17

21

20

7 10

26

26 8

9

19

20

8

15

11 16 12

16

13

PRESSURE RETURN SUPPLY

14

D

806-591

95

HYDRAULIC DIAGRAM AUTOBORE SHUTOFF REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

158-420 158-601 158-814 158-687 157-784 516-027 158-881 158-826 158-908 190-728 159-029 151-054 151-117 151-076 158-937 360-383 306-829 306-830 150-724 159-030 158-815 516-028 155-259 159-081 155-622 151-125 350-503 158-403 149-495 155-724 217-941 500-620 158-569

QTY

1 1 -

DESCRIPTION

REMARKS

HYD PUMP HYD RELIEF VALVE (3000 PSI) CONTROL VALVE PRIORITY VALVE HYD FLOW VALVE HYD CONTROL VALVE (2-SPOOL) HYD MOTOR HYD MOTOR (GEROLER) HYD MOTOR (THRUST, 8600#) SEAL REPAIR KIT QDC BODY (08-08SF) CYL (3.0" X 1.50" X 4.00") CYL (3.0" X 1.50" X 20.00") CYL (2.0" X 1.00" X 10.00") HYD CONTROL VALVE (_-SPOOL) OIL COOLER & RADIATOR ASS'Y OIL COOLER RADIATOR CYL, 1" BORE X 2" STROKE THRD QDC ADAPTER (08-08SF) FLOW DIVIDER HYD CONTROL VALVE (_-SPOOL) CHECK VALVE HYD OIL FILTER (20SF-20SF) HYD RELIEF VALVE (2000 PSI) CYL (1.5" X 0.44" X 2.50") MOBILING STATION GEAR MOTOR (3.0 CUI\ REV) HYD SOLENOID VALVE O-RING (217 D70) SOLENOID COIL SEAL REPAIR KIT SOLENOID DIVERSION VALVE

FOOTNOTES

NOTE:

D

806-591

96

HYDRAULIC RESERVOIR ANCHOR RETURN

TO AUX BACKUP WRENCH

13

12

11 9 20

19

10

3

19

20 20

27

1

TO RELIEF

16 15

TO AUX BACKUP WRENCH

21

2 4 6

5

8

26 4 24

2 25 22 2

23

4

17

7

18

2

14 4 4

4

02

ID0138159

97

HYDRAULIC RESERVOIR REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

QTY

105-825 3 155-168 4 154-248 1 110-133 6 159-081 217-765 159-079 116-587 AR 110-336 1 215-148 214-819 1 154-233 1 110-996 1 165-626 1 153-766 1 154-942 1 154-272 1 154-265 1 116-587 AR 515-179 1 350-503 158-420 155-279 1 154-828 2 154-266 3 515-041 1 116-587 AR 154-342 1 154-722 1 117-676 1 154-330 1 153-900 1 105-189 2

DESCRIPTION

FLG LK BOLT (3/8-NC X 3/4") S/O CPLR (20S-20H90) REDUCER STEM (04O) WORM CLAMP (1-1/16" TO 1-15/16") HYD OIL FILTER (20SF-20SF) INDICATOR SWITCH FILTER ELEMENT (1-1/2-UNF) BULK HOSE (1.250") STRAINER TEMPERATURE SWITCH TEMPERATURE SWITCH CONNECTOR (08S-08O) FILLER BREATHER (2-1/8") GASKET LOCKING CAP (VENTED) HOSE (08OFX90S-13"-3000) REDUCER NUT (08OF) UNION RUN TEE (04OFX-04O-04O) BULK HOSE (1.250", SOLD PER 1') HOSE (04OFX90-11"-3000) MOBILING STATION HYDRAULIC PUMP S/O RUN TEE (20S-20H-20H) HOSE (08OFX-17"-3000) UNION RUN TEE (08OFX-08O-08O) HOSE (04OFX90-20"-3000) BULK HOSE (1.250") CONNECTOR (06S-06O90) HOSE (06OFX-32"-3000) ABRASUIB SLEEVE (1.00" X 30") PLUG (06O) STRAINER SCREW (#6-32 X 1/2")

REMARKS

USE 19.5" ENDS WITH S/N __________ BEGINS WITH S/N __________ ENDS WITH S/N, SEE FOOTNOTE 1 ENDS WITH S/N BEGINS WITH S/N 2V0893 JT920L USE WITH JT920 ONLY

USE 1@ 12"

USE 1@ 8.25"

NOT SHOWN:

FOOTNOTES:

REFER TO O-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS.

NOTE:

02

ID0138159

98

OIL COOLER HYDRAULICS

19

1 2

20 11

3 4

5

4

10 9

17

8 12 13

6 FROM DRILL CONTROL VALVES 7 8

14 8

18

RETURN FROM VALVE BODY

15 16 8

L

804-026

99

OIL COOLER HYDRAULICS REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

QTY

154-269 1 156-563 1 154-368 1 515-242 1 515-230 1 154-292 1 158-576 1 155-245 514-043 1 110-133 4 116-587 AR 514-027 1 154-368 1 154-249 1 154-271 1 115-924 1 115-903 1 155-168 1 159-081 1 159-079 1 515-218 1 116-587 AR 360-383 306-829 306-830 154-457 1

DESCRIPTION

CONNECTOR (12S-12O) HYD LINE (-12) UNION RUN TEE (12OFX-12O-12O) HOSE (12OFX90-95"-3000) HOSE (12OFX-54"-4000) 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" - 1-15/16") 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) BULK HOSE ((1.250", SOLD PER 1") RADIATOR/OIL COOLER OIL COOLER RADIATOR UNION (12O-12OFX90)

REMARKS

WITH WATER TANK. USE WITH JT920 & JT921 WITHOUT WATER TANK. USE WITH JT921S ENDS WITH S/N 2N1740 BEGINS WITH S/N 2N1741

USE 17"

WITH WATER TANK WITHOUT WATER TANK USE 65"

WITHOUT WATER TANK. USE WITH JT921S

FOOTNOTES

NOTE:

REFER TO O-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS.

L

804-026

100

OIL COOLER HYDRAULICS

19

1 2

RETURN FROM VALVE BODY 10

11

3 5

4

8 9

17

12 13

6 FROM DRILL CONTROL VALVES 7 8

14

TO MUD PUMP

8 18 15 16 8

01

ID0138766

101

OIL COOLER HYDRAULICS REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

QTY

154-269 1 156-563 1 154-368 1 515-242 1 154-292 1 155-245 1 514-043 1 110-133 4 116-587 AR 514-027 1 154-368 1 154-249 1 154-271 1 115-924 1 155-168 1 159-081 1 159-079 217-765 515-218 1 116-587 AR 360-383 -

DESCRIPTION

CONNECTOR (12S-12O) HYD LINE (12OFX-31.0") UNION RUN TEE (12OFX-12O-12O) HOSE (12OFX90-95"-3000) RUN TEE (12S-12O-12O) CHECK VALVE (12SF-12SF) S/O BR TEE (12S-20H-20H) WORM CLAMP (1-1/6" TO 1-15/16") BULK HOSE (1-1/4", 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") S/O COUPLER (20S-20H90) HYD OIL FILTER (20SF-20SF) FILTER ELEMENT (1-1/2-UNF) INDICATOR SWITCH HOSE (12OFX90-80"-3000) BULK HOSE (1-1/4", SOLD PER 1") OIL COOLER & RADIATOR

REMARKS

USE 1 @ 17"

USE 1 @ 65"

NOT SHOWN:

FOOTNOTES:

NOTE:

REFER TO O-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS.

01

ID0138766

102

OIL COOLER HYDRAULICS (CATERPILLAR DIESEL) 19

1 2

20 11 4

10

5

9

17

8 3

12 13

6 FROM DRILL CONTROL VALVES 7 8

14

RETURN FROM VALVE BODY

8 18 15 16 8

05

ID0028229

103

OIL COOLER HYDRAULICS (CATERPILLAR DIESEL) REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

QTY

154-269 1 159-639 1 159-640 1 515-242 1 515-001 1 154-294 1 155-245 1 514-043 1 110-133 4 116-587 AR 514-027 1 154-368 1 154-249 1 154-271 1 115-924 1 115-903 1 155-168 1 159-081 1 159-079 1 515-218 1 116-587 AR 194-463 154-455 1

DESCRIPTION

CONNECTOR (12S-12O) HYD LINE (-12) HYD LINE (-12) HOSE (12OFX90-95"-3000) HOSE 12OFX-90-60"-3000) BRANCH TEE (12S-12O-12O) FLOW CHECK VALVE (12SF-12SF) S/O BR TEE (12S-20H-20H) WORM CLAMP (1-1/6" - 1-15/16") 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) BULK HOSE ((1.250", SOLD PER 1") RADIATOR/HOC TEE (120)

REMARKS

WITH WATER TANK WITHOUT WATER TANK

USE 19"

WITH WATER TANK WITHOUT WATER TANK USE 61.5"

NOT SHOWN:

FOOTNOTES:

REFER TO O-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS.

NOTE:

05

ID0028229

104

DRIVE CONTROL SUPPLY HYD.

1

6

3 5

TO POWER BEYOND

2 4 3

J

805-307

105

DRIVE CONTROL SUPPLY HYD. REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

516-124 115-961 117-995 515-513 515-514 154-273 158-937 499-333 154-251

QTY

1 1 1 1 1 1

DESCRIPTION

REMARKS

HYD CONTROL VALVE 2 SECTION ABRASION SLEEVE (2.07" X 196") ABRASION SLEEVE (2.07" X 156") HOSE (12OFX45-195"-3000) HOSE (12OFX45-160"-3000) CONNECTOR (10S-12090) HYD CONTROL VALVE (5-SPOOL) VALVE SECTION (GROUND DRIVE) CONNECTOR (12S-12045)

BEGINS WITH S/N N2T1062 WITH WATER TANK. USE WITH JT920 & JT921 WITHOUT WATER TANK. USE WITH JT921S WITH WATER TANK. USEWITH JT920 & JT921 WITHOUT WATER TANK. USE WITH JT921S

FOOTNOTES

NOTE:

REFER TO O-RING CHART (800-301) IN BACK OF BOOK FOR REPLACEMENT OF O-RINGS.

J

805-307

106

GROUND DRIVE HYDRAULICS

17 15 1

2

3 4 14 3

11

4 10 10

11 13

6

16 5 5

7 8

7

8

10

9 LEFT

11 12

15

10

11

RIGHT

9

ID0039296

107

GROUND DRIVE HYDRAULICS REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

QTY

105-827 3 158-937 500-562 500-563 500-558 500-559 499-333 191-159 500-512 500-877 154-438 2 154-256 4 158-826 107-034 166-846 499-433 499-434 157-701 500-510 500-1576 500-1577 115-963 1 115-903 1 105-178 8 159-302 2 500-819 4 157-096 2 154-322 2 515-241 2 515-192 2 515-243 2 515-191 2 154-279 2 115-938 1 115-903 1 154-233 2 105-845 3 105-095 8 150-1064 1

DESCRIPTION

FLG LK BOLT (3/8-NC X 1-1/4") HYD CONTROL VALVE (_-SPOOL) SPOOL END CAP SPRING CENTERING KIT VALVE SECTION (#V12W-1FBCAS) VALVE SECTION (#V12W-1FBCJLEE) VALVE SECTION V12W-1FBCJS(GRNDDRV) CONTROL LEVER BRACKET LEVER PIVOT (CLEVIS) SPOOL CLEVIS (YOKE) CONNECTOR (08S-08O, LG) UNION (08O-08OFX90) HYD MOTOR (GEROLER) CASTLE NUT (1-20 NEF) WOODRUFF KEY (5/16" X 1") COUPLING SHAFT OUTER SHAFT BEARING SHAFT SEAL SEAL REPAIR KIT ASSEMBLY BOLT SERVICE HOUSING ABRASION SLEEVE (1.59" X 75") ABRASION SLEEVE (1.59" X 50") BOLT (5/16-NC X 2-1/2",GD8) COUNTERBALANCE MANIFOLD COUNTERBALANCE CARTRIDGE KIT O-RING (017 D70) CONNECTOR (08O-10S90) HOSE (08OFX90L-82"-3000) HOSE (08OFX90L-54"-3000) HOSE(08OFX90-66"-3000) HOSE (08OFX90S-54"-3000) CONNECTOR (08O-10S) ABRASION SLEEVE (1.59" X 66") ABRASION SLEEVE (1.59" X 50") CONNECTOR (08S-08O) FLG LOCKNUT (3/8-NC) WASHER (1/4") PILOT OPERATED RELIEF(ADJ.1850 PSI)

REMARKS

SEE FOOTNOTE 1 SEE FOOTNOTE 1 SEE FOOTNOTE 1 SEE FOOTNOTE 1 SEE FOOTNOTE 1 SEE FOOTNOTE 1 SEE FOOTNOTE 1 SEE FOOTNOTE 1

WITH WATER TANK WITHOUT WATER TANK

WITH WATER TANK WITHOUT WATER TANK WITH WATER TANK WITHOUT WATER TANK WITH WATER TANK WITHOUT WATER TANK

BEGINS WITH S/N: 2z1825

FOOTNOTES:

1. THESE PART ARE RELATIVE TO 158-801 AND 158-937 VALVES.

NOTE:

REFER TO O-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS.

15

ID0039296

108

DRIVE CONTROL VALVE & LEVERS

ORANGE

BLACK

9

ORANGE

8

GREEN

BLACK

1

1

2

2

15

10 3

4

5

11 6 12 13

NA

14

7

K

14

ID0031131

109

DRIVE CONTROL VALVE & LEVERS REF PART NO. NUMBER

QTY

DESCRIPTION

1. 110-531 2. 353-140 3. 353-141 4. 105-044 5. 158-937 6. 105-827 7. 105-845 8. 110-465 9. 110-530 10. 353-311 11. 500-565 12. 500-559 13. 500-558 14. 500-556 15. 150-1064

2 3 1 5 1 3 3 2 1 1 1

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)

REMARKS

USE 242 LOCTITE USE 242 LOCTITE BEGIN WITH S/N 2N2402

USE 242 LOCTITE

BEGINS WITH S/N: 2z1825

NOT SHOWN:

FOOTNOTES:

NOTE:

14

ID0031131

110

FRAME TILT

8

1

1 DRIVE CONTROL VALVE

6 2

7

4 3 9

4 5

13

ID0031128

111

FRAME TILT REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

154-261 515-239 154-933 116-633 116-787 154-226 151-054 154-255 154-742 155-488 158-937 158-801 117-194

QTY

2 1 1 1 1 2 1 1 1 1 1

DESCRIPTION

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"-3000 HYD CONTROL VALVE (_-SPOOL) HYD CONTROL VALVE (5-SPOOL) ABRASION SLEEVE (1.00" X 16")

REMARKS

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 (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS.

13

ID0031128

112

113

114

TRACK EXTEND HYDRAULICS 7

1

6

1

2

DRIVE CONTROL VALVE

3

4

4

5

11

ID0042838

115

TRACK EXTEND HYDRAULICS REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

154-261 155-488 515-074 115-902 115-935 154-252 151-076 154-771 515-074 158-937

QTY

2 1 1 1 1 2 1 1 1 -

DESCRIPTION

CONNECTOR (04O-08S) HOSE (04OFX90-106"-3000) HOSE(04OFX90-77"-3000) ABRASION SLEEVE (1.59" X 100") ABRASION SLEEVE (1.75" X 70") CONNECTOR (04S-04O90) CYL (2.0" X 1.00" X 10.00") HOSE (04OFX90-110"-3000) HOSE (04OFX90-77"-3000) HYD CONTROL VALVE (_-SPOOL)

REMARKS

WITH WATER TANK WITHOUT WATER TANK WITH WATER TANK WITHOUT WATER TANK

WITH WATER TANK WITHOUT WATER TANK BEGINS WITH S/N 2N2402

NOT SHOWN:

FOOTNOTES:

NOTE:

REFER TO O-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS

11

ID0042838

116

MAIN SUPPLY HYDRAULICS

THRUST AND ROTATION CONTROL VALVE

8

15

14

17

14 15

16 BREAK-OUT CONTROL VALVE

3

7

1

17 4 10

9

FROM FRONT SECTION OF PUMP

9

5

6 11

TO RETURN ON OIL COOLER

12 FROM MID SECTION OF PUMP

13

2

E

805-037

117

MAIN SUPPLY HYDRAULICS REF PART NO. NUMBER

QTY

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

2 1 1 1 1 1 2 1 1 1 1 6 6 1 5

154-269 154-907 515-213 154-292 515-218 154-338 516-027 516-124 154-322 515-242 154-249 154-271 154-902 105-292 105-117 106-386 107-096

DESCRIPTION

CONNECTOR (12S-12O) HOSE (08OFX90-32"-3000) HOSE (12OFX-20"-3000) RUN TEE (12S-120-120) HOSE (12OFX90-80"-3000) CONNECTOR (12S-12O90, XL) HYDRAULIC CONTROL VALVE (2-SPOOL) HYDRAULIC CONTROL VALVE 2 SECTION CONNECTOR (08O-10S90) HOSE (12OFX90-95"-3000) REDUCER STEM (08O) REDUCER NUT (12OF) HOSE (08OFX90S-66"-3000) SCREW (M8-1.25 X 75MM) WASHER (5/16") FLG LOCKNUT (M8-1.25) LOCKNUT (M8-1.25,NLK)

REMARKS

BEGINS WITH S/N 2N2T1062

FOOTNOTES

REFER TO O-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF ORS AND SAE O-RINGS,

NOTE:

E

805-037

118

119

120

HYDRAULIC CONTROL VALVE

5

2-SPOOL

INLET 8 6

WRENCH

4 1 6

WRENCH 6 4 OUTLET

9 6

3 2 10

7

1

02

ID0138780

121

HYDRAULIC CONTROL VALVE 2-SPOOL

REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

516-027 500-592 500-302 155-709 500-951 500-948 500-587 500-949 500-580 500-581 500-962 500-585 500-950 500-952 N/A 500-588 500-582 500-418 105-053

QTY

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

DESCRIPTION

REMARKS

HYD CONTROL VALVE (2-SPOOL) STANDARD SPOOL POSITIONER KIT PLUG (12S, SOC) O-RING (912 D90) OUTLET COVER VALVE SECTION (#_) SPOOL SEAL REPAIR KIT SECTION SERVICE REPAIR KIT NR MAIN RELIEF PLUG KIT SEAL REPAIR KIT RC RELIEF CARTRIDGE (500PSI) SEAL REPAIR KIT RELIEF CARTRIDGE SEAL REPAIR KIT POWER BEYOND SLEEVE KIT INLET COVER SECTIONAL O-RING REPAIR KIT TIE-BOLT KIT (2-SECTION) BOLT (3/8-NC X 6") NUT (3/8-NC)

INCL REF NO'S

1 THRU 10

INCL REF NO'S

2, 7 & 9

INCL REF NO

9

SEE FOOTNOTE 1

NOT SHOWN:

499-179

CLEVIS ADAPTER

FOOTNOTES:

1. TORQUE TO 32 FT LBS; INCL'S 3 BOLTS & 3 NUTS.

NOTE:

02

ID0138780

122

CONTROL VALVE/LEVERS

6 BRN BLK BLU 1

2

CAV. PLUG

4

3

7

SEE FOOTNOTE 1 16 15

BREAK-0UT CONTROL VALVE

5 1 BRN BLK BLUE CAV. PLUG 4 2 3 1

8 16

SEE FOOTNOTE 1

THRUST AND ROTATION CONTROL VALVE

9

2 10 14 13

10 14 11

10

3

12

14 2

4 3

09

ID0035762

123

CONTROL VALVE/LEVERS REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

516-027 106-206 107-096 516-028 214-466 501-822 217-946 214-133 217-202 217-203 217-204 308-646 214-467 501-823 217-946 214-133 217-202 217-203 308-646 185-146 185-145 500-965 110-575 499-018 499-019 499-020 105-213 217-271 105-044

QTY

DESCRIPTION

1 6 6 1 1 -

HYDRAULIC CONTROL VALVE (2-SPOOL) SCREW (M10-1.5 X 90) LOCKNUT (M8-1.25, NLK) HYDRAULIC CONTROL VALVE (3-SPOOL) JOYSTICK (ON-OFF-(ON)) JOYSTICK (ON-OFF-(ON)) MICRO SWITCH (JOYSTICK) TERMINAL PIN (DEUTSCH) CAVITY PLUG-DEUTSCH 4-WAY MALE LOCK-DEUTSCH 4-WAY MALE CONN. (DEUTSCH) ROCKER BOOT (RUBBER) JOYSTICK (ON-OFF-ON) JOYSTICK (ON-OFF-(ON MICRO SWITCH (JOYSTICK) TERMINAL PIN (DEUTSCH) CAVITY PLUG-DEUTSCH 4-WAY MALE LOCK-DEUTSCH ROCKER BOOT (RUBBER) JOYSTICK LEVER (OFFSET) JOYSTICK LEVER (STRAIGHT) L.H. JOYSTICK 'TOWER' ROD END (5/16-NF,FM) "SLIDE" BOLT ROD END SCREW ROD END STUD (ROD END) NUT (5/16-NF) R.H. JOYSTICK "TOWER" JAM NUT (1/2-NC)

1 1 1 1 6 2 2 2 6 1 2

REMARKS

NOT SHOWN:

FOOTNOTES:

1. SUPPLIER CHANGE WIRE COLOR ON JOYSTICK. RED IS NOW BLUE, GREY IS NOW BLACK AND YELLOW IS NOW BROWN.

NOTE:

09

ID0035762

124

HYDRAULIC CONTROL VALVE (3-SPOOL) ENDS WITH S/N ______

INLET

7 2

10 STAKE DRIVER 9

13

1 6

10

ROTATE

8 9 5

THRUST

10

11 1

OUTLET

14 3

12

4 8

2

16 15

1

02

ID0138781

125

HYDRAULIC CONTROL VALVE (3-SPOOL) ENDS WITH S/N ______ REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

516-028 500-588 500-592 500-302 155-709 500-961 500-960 500-949 500-959 500-949 500-958 500-949 500-956 500-957 500-321 500-585 500-638 500-585 500-587 499-402 500-585 499-406 500-585 N/A 500-588 155-074 155-706 500-744 500-301 105-053

QTY

DESCRIPTION

HYD CONTROL VALVE (3-SPOOL) 4 SECTIONAL O-RING REPAIR KIT 3 STANDARD SPOOL POSTIONER KIT 2 PLUG (12S, SOC) O-RING (912 D90) 1 OUTLET COVER 1 VALVE SECTION (#) SECTION SERVICE REPAIR KIT 1 VALVE SECTION (#) SECTION SERVICE REPAIR KIT 1 VALVE SECTION (#) SECTION SERVICE REPAIR KIT 1 WH RELIEF CARTRIDGE (3000PSI) SEAL REPAIR KIT 2 LOAD CHECK PLUG KIT SEAL REPAIR KIT 2 RC RELIEF CARTRIDGE (1500PSI) SEAL REPAIR KIT 6 SPOOL SEAL REPAIR KIT 1 PORT RELIEF CARTRIDGE 2750 ADJ 1 SEAL REPAIR KIT 1 PORT RELIEF CARTRIDGE 2550 ADJ 1 SEAL REPAIR KIT 1 INLET COVER 4 SECTONAL O-RING REPAIR KIT 1 PLUG (08S, SOC, FM) O-RING (908 D90) 3 TIE-BOLT KIT (3-SECTION) BOLT (3/8-NC X 8") NUT (3/8-NC)

REMARKS

INCL REF NO'S. 1 THRU 16

INCL REF NO'S. 2, 14 & 15 INCL REF NO 14 INCL REF NO 14 INCL REF NO 14

SEE FOOTNOTE 1

NOT SHOWN:

FOOTNOTES:

1. TORQUE TO 32 FT LBS: INCLS 3 BOLTS & 3 NUTS

NOTE:

02

ID0138781

126

HYDRAULIC CONTROL VALVE (2-SPOOL) INLET

7 2

13 10

ROTATE

8

5 THRUST

10

11

1

12

4 OUTLET

9

8

3 2 6 1

E

807-271

127

HYDRAULIC CONTROL VALVE (2-SPOOL) REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

516-124 500-588 500-592 500-302 155-709 500-961 500-960 500-949 500-959 500-949 155-074 155-706 500-956 500-957 500-321 500-585 500-588 500-587 499-402 500-585 499-406 500-585 N/A

QTY

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

DESCRIPTION

REMARKS

HYD CONTROL VALVE (2-SPOOL) SECTIONAL O-RING REPAIR KIT STANDARD SPOOL POSTIONER KIT PLUG (12S, SOC) O-RING (912 D90) OUTLET COVER VALVE SECTION (#) SECTION SERVICE REPAIR KIT VALVE SECTION (#) SECTION SERVICE REPAIR KIT PLUG (08S, SOC, FM) O-RING (908 D90) WH RELIEF CARTRIDGE (3000PSI) SEAL REPAIR KIT LOAD CHECK PLUG KIT SEAL REPAIR KIT SECTIONAL O-RING REPAIR KIT SPOOL SEAL REPAIR KIT PORT RELIEF CARTRIDGE 2750 ADJ SEAL REPAIR KIT PORT RELIEF CARTRIDGE 2550 ADJ SEAL REPAIR KIT INLET COVER

INCL REF NO'S. 1 THRU 16

INCL REF NO'S. 2, 14 & 15 INCL REF NO 14 INCL REF NO 14

F/N 2 F/N 3

FOOTNOTES

1. TORQUE TO 32 FT LBS: INCLS 3 BOLTS & 3 NUTS 2. SET AT 2750 PSI - ADJUSTABLE FROM 2550 TO 2750 PSI 3. SET AT 2550 PSI - ADJUSTABLE FROM 2550 TO 2750 PSI

NOTE:

E

807-271

128

CONTROL VALVE/LEVERS - 3-SPOOL

2

BREAK-0UT CONTROL VALVE

1

6

5 3

THRUST AND ROTATION CONTROL VALVE

6

4 5

F

805-044

129

CONTROL VALVE/LEVERS - 3-SPOOL REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

516-027 110-575 105-213 499-020 499-019 499-018 500-965 499-021 499-179 185-146 185-145 516-124 107-096 106-206

QTY

DESCRIPTION

1 3 3 1 1 1 3 1 1 1 1 6 6

HYD CONTROL VALVE (2-SPOOL) ROD END LOCK NUT STUD, ROD END SCREW, ROD END SLIDE, ROD END JOYSTICK TOWER SPACER CLEVIS ADAPTER ASS'Y JOYSTICK LEVER (OFFSET) JOYSTICK LEVER (STRAIGHT) HYD CONTROL VALVE 2 SECTION LOCKNUT (M8-1.25 NLK) SCREW (M10-1.50 X 90mm)

REMARKS

BEGINS WITH S/N N2T1062

FOOTNOTES

NOTE:

F

805-044

130

CARRIAGE ROTATION HYDRAULICS 2 TO RETURN ON DRIVE CONTROL VALVE

1 12

13

11 2

9

1

4

10

8

4 5 3 7 16

5

19

15

1

6

15

17 14 18

T

805-040

131

CARRIAGE ROTATION HYDRAULICS REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

154-308 515-432 515-436 154-870 514-090 154-399 515-048 117-683 516-124 158-881 117-843 154-278 515-185 117-841 154-300 149-495 149-496 155-724 217-941 500-620 106-561 106-160 105-117 153-907

QTY

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

DESCRIPTION

CONNECTOR (10O-12S) HOSE (10OFX90S-154"-3000) HOSE (10OF-112"-3000) HOSE(10OFX-84"-2750) CONNECTOR (10O-10O90) CONNECTOR (10S-10O45) HOSE (1O0FX45-18"-3000) ABRASION SLEEVE (2.38" X 84") HYD CONTROL VALVE 2 SECTION HYDRAULIC MOTOR ABRASION SLEEVE (2.38" X 164") CONNECTOR (04S-04O) HOSE (04OFX90M-238"-3000) ABRASION SLEEVE (1.00" X 164") CONNECTOR (10O-12S90) ASS'Y HYD. SOLENOID VALVE STEEL, MANIFOLD BLOCK O-RING (217 D70) SOLENOID COIL SEAL REPAIR KIT LOCKNUT (M8-1.25,PRV TRQ,10.9) FLG LK SCREW (M8-1.25 X 120MM) WASHER (5/16") HOSE (10OFX45-16"-3000)

REMARKS

SEE FOOTNOTE 1 SEE FOOTNOTE 2

BEGINS WITH S/N 2N2T1062

FOOTNOTES

1. USED WITHOUT OPERATORS PRESENCE SWITCH 2. USED WITH OPERATORS PRESENCE SWITCH

NOTE:

REFER TO O-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS.

T

805-040

132

ROTATION HYDRAULICS

1 2

17 9 BOTTOM PORT 7

9

4

8 19

18

3

5 6

16

TO THRUST ROTATION VALVE

15 14 10 13

11

12

F

805-086

133

ROTATION HYDRAULICS REF PART NO. NUMBER

QTY

DESCRIPTION

1.

2.

3.

4.

5.

2 2 2 2 1

FLG LK BOLT (3/8-NC X 5/8") FLG LOCKNUT (1/4-NC) SUPPORT PLATE FLG LOCK BOLT (1/4-NC X 1/2") CONTROL VALVE SEAL REPAIR KIT VALVE CARTRIDE (1000PSI) PLUG (04N, SQ) UNION RUN TEE (06OFX-06O-06O) HOSE (06OFX90-12"-3000) UNION (06O-06OFX90) REDUCER NUT (12OF) REDUCER STEM (06O) CONNECTOR (12S-12O90) HYDRAULIC PUMP UNION RUN TEE (12OFX-12O-12O) HOSE (12OFX90-95"-3000) ABRASION SLEEVE (1.59" X 88") QDC ADAPTER (02-06OF) DUST CAP (1/8") CONNECTOR (06S-06O, ORF .031") PLUG (06S)

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

501-153 105-832 344-726 105-836 158-814 190-643 500-906 115-153 154-344 515-583 154-228 154-271 154-459 154-270 158-420 154-368 515-242 115-924 159-157 159-148 156-067 155-130

1 1 1 2 1 1 1 1 2 1 1 1 1 1

REMARKS

FOOTNOTES

NOTE:

REFER TO O-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF SAE AND ORS O-RINGS.

F

805-086

134

135

136

CARRIAGE THRUST HYDRAULICS 8

1

2

6

7 9

3

10

5 4

11

2

TO RETURN ON DRIVE CONTROL VALVE

13

ID0042871

137

CARRIAGE THRUST HYDRAULICS REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

154-301 515-216 117-842 154-470 155-222 355-586 106-385 516-124 158-908 190-728 154-226 154-220 154-921

QTY

DESCRIPTION

2 2 1 2 2 1 4 1 1 1

CONNECTOR (10S-10O) HOSE (10OFX45-132"-3000) ABRASION SLEEVE (2.38" X 128") CONNECTOR (10O-12S45) REDUCER (16S-12SF) HOSE RETAINER FLG LOCKNUT (M6-1.00) HYD CONTROL VALVE (2-SPOOL) HYD MOTOR (THRUST, 8600#) SEAL REPAIR KIT CONNECTOR (04O-06S90) CONNECTOR (04O-06S) HOSE (04OFX-54"-3000-AR)

REMARKS

BEGINS WITH S/N 2N2T1062

WITH WATER TANK WITHOUT WATER TANK

NOT SHOWN:

FOOTNOTES:

NOTE:

REFER TO O-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS.

13

ID0042871

138

THRUST HYDRAULICS

1 3 2 16 6 5

17 6

15 TO BREAKOUT VALVE

20 7 9 8 7

14

11

13

21

TEST PORT 22 12

19

18

11

9

10

TO RETURN

F

805-092

139

THRUST HYDRAULICS REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

158-814 190-643 500-906 156-066 156-065 159-157 159-148 154-344 154-737 154-262 154-279 154-266 154-942 154-298 158-420 514-079 153-675 153-219 154-971 154-221 117-713 154-488 159-159 159-148 515-583 154-310 154-312

QTY

1 1 1 1 1 1 1 2 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1

DESCRIPTION

CONTROL VALVE SEAL REPAIR KIT CONTROL VALVE CARTRIDGE CONNECTOR (06S-06O, ORF) CONNECTOR (06S-06O, ORF) QDC ADAPTER (02-06OF) DUST CAP (1/8") UNION RUN TEE (06OFX-06O-06O) HOSE (06OFX90-17"-3000) REDUCER (06O-08OF) CONNECTOR (08O-10S) UNION RUN TEE (08OFX-08O-08O) HOSE (08OFX90-13"-3000) CONNECTOR (10O-10S90) HYDRAULIC PUMP UNION (10S-10OFX) ADJ HYD RELIEF VALVE 3000 PSI WH-A RELIEF CARTRIDGE (3000PSI) HOSE (08OFX90-78"-3000) CONNECTOR (06S-06O) ABRASION SLEEVE (1.00" X 76") UN RUN TEE (100FX-10O-10O) QDC ADAPTER (02-100FX) DUST CAP (1/8") HOSE (06OFX90-12"-3000) REDUCER NUT (10OF) REDUCER STEM (08O)

REMARKS

BEGIN WITH S/N 2V0571

FOOTNOTES

NOTE:

REFER TO O-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT O-RINGS.

F

805-092

140

THRUST HYDRAULICS WITH AUTOBORE SELECT

21 1 3 2 16 6 5

24

17

22

20 TO BREAKOUT VALVE

15

7 9 8

18 19 7

14 11 TEST PORT

26 13

12

23

25

27 9

10 11 TO RETURN

G

806-478

141

THRUST HYDRAULICS WITH AUTOBORE SELECT REF PART NO. NUMBER

QTY

DESCRIPTION

1. 158-814 2. 156-066 3. 156-065 4. 159-157 159-148 5. 154-344 6. 154-737 7. 154-262 8. 154-279 9. 154-266 10. 154-942 11. 154-298 12. 158-420 13. 514-079 14. 153-675 153-219 15. 154-971 16. 154-221 17. 154-731 18. 154-225 19. 158-569 20. 154-227 21. 515-583 22. 515-377 23. 159-159 159-148 24. 117-713 25. 154-488 26. 154-310 27. 154-312

1 1 1 1 2 1 2 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 3

CONTROL VALVE CONNECTOR (06S-06O, ORF) CONNECTOR (06S-06O, ORF) QDC ADAPTER (02-06OF) DUST CAP (1/8") UNION RUN TEE (06OFX-06O-06O) HOSE (06OFX90-17"-3000) REDUCER (06O-08OF) CONNECTOR (08O-10S) UNION RUN TEE (08OFX-08O-08O) HOSE (08OFX90S-13"-3000) CONNECTOR (10S-10O90) HYDRAULIC PUMP UNION (10S-10OFX) ADJ HYD RELIEF VALVE 3000PSI WH-A RELIEF CARTRIDGE HOSE (08OFX90-78"-3000) CONNECTOR (06S-06O) HOSE (060FX-17"-3000) CONNECTOR (06O-08S45) SOLENOID DIVERSION VALVE CONNECTOR (060-08S90) HOSE (06OFX90-12"-3000) HOSE (06OFX90-9"-3000) QDC ADAPTER (02-10OFX) DUST CAP (1/8") ABRASION SLEEVE (1.00" X 76") UN RUN TEE (10OFX-100-10O) REDUCER NUT (10OF) REDUCER STEM (080)

REMARKS

BEGINS WITH S/N 2V0571

FOOTNOTES

NOTE:

REFER TO O-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS.

G

806-478

142

BREAKOUT HYDRAULICS ENDS WITH S/N 2P0769 1

2

19

2 3

3 3

23 20

2 3 20 23 21

22 6

25

24 4

18

6

15

18

5

24 7

17 14 26

15

17

13 13 11 10

16 12

13 13

9 8

12

F

805-087

143

BREAKOUT HYDRAULICS ENDS WITH S/N 2P0769 REF PART NO. NUMBER

QTY

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

4 4 2 2 2 1 1 1 3 1 2 2 2 1 1 2 6 2 1

516-027 154-261 154-727 107-054 106-076 154-379 515-190 151-125 154-365 156-273 154-725 151-141 154-365 156-088 156-774 156-089 154-424 515-433 154-355 154-694 116-640 115-902 155-259 154-220 106-353 115-817

DESCRIPTION

REMARKS

HYD CONTROL VALVE (2-SPOOL) CONNECTOR (04O-08S) HOSE (04OFX90-30"-3000) SCREW (M6-1.00 X 90MM) WASHER (1/4") UN BR TEE (04OFX-04O-04O) HOSE (04OFX90S-88"-3000) CYL (1.5" X 0.44" X 2.50") CONNECTOR (02N-040) CONNECTOR (02N-04O90) HOSE (04OFX-90"-3000) CYL (1.1 " X .31" X 2") CONNECTOR (02N-04O) HYD LINE (-04) HYD LINE (-04) HYD LINE (-04) BK RUN TEE (040-040-04OBK) HOSE (04OFX-144"-3000) BK CONNECTOR (04O-04O90BK) HOSE (04OFX-98"-3000) ABRASION SLEEVE (1.59" X 150") ABRASION SLEEVE (1.59" X 100") CHECK VALVE CONNECTOR (04O-06S) FLG NUT (M6-1.00) ABRASION SLEEVE (1.59" X 84")

FOOTNOTES

NOTE:

REFE TO O-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS.

F

805-087

144

BREAKOUT HYDRAULICS BEGINS WITH S/N 2P0770

1

2

19

2

3 25

27

3 3

23

20

2 3

20 28

21

24

22 6

24 24

24

4 24 18

7

18

5

27

14 15

17 26 9

13

13 16

11

17

10

10

12

13 13

8

12

N

805-464

145

BREAKOUT HYDRAULICS BEGINS WITH S/N 2P0770 REF PART NO. NUMBER

QTY

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

4 4 2 2 1 1 1 1 2 1 4 1 1 1 2 2 2 1 1 2 7 2 1 2 1

516-027 154-261 154-727 105-843 106-076 154-379 515-189 150-725 156-860 154-252 154-725 150-724 154-278 156-861 156-862 156-863 154-424 515-433 154-355 154-725 117-741 115-924 155-259 154-220 106-353 115-817 338-101 155-623

DESCRIPTION

REMARKS

HYD CONTROL VALVE (2-SPOOL) CONNECTOR (04O-08S) HOSE (040FX90-30"-3000) SCREW (M6-1.00 X 80mm) WASHER (1/4") UN BR TEE (04OFX-04O-04O) HOSE (04OFX90L-88"-3000) CYL (1" X 2.5") HYD LINE (-04) CONNECTOR (04S-04O90) HOSE (04OFX-90"-3000) CYL (1" X 2") CONNECTOR (04S-04O) HYD LINE (-04) HYD LINE (-04) HYD LINE (-04) BK RUN TEE (04O-04O-04OBK) HOSE (04OFX-144"-3000) BK CONNECTOR (04O-04O90BK) HOSE (04OFX-90"-3000) ABRASION SLEEVE (1.59" X 145") ABRASION SLEEVE (1.59" X 88") CHECK VALVE CONNECTOR (04O-06S) FLG NUT (M6-1.00) ABRASION SLEEVE (1.59" X 84") CLAMP STRAP DOUBLE LOCKOUT VALVE

FOOTNOTES

NOTE:

REFER TO O-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS.

N

805-464

146

AUXILIARY BACKUP WRENCH HYDRAULICS

16

TO CASE DRAIN

7

15

12

14 9 PIPE LOADER

ANCHORS 11

5

6

17 3

6

10 4 2

1

ORIFICE SIDE

8

TO TANK

13

9

3

TO TANK

13

ID0037447

147

AUXILIARY BACKUP WRENCH HYDRAULICS REF PART NO. NUMBER

QTY

DESCRIPTION

1.

1

SOLENOID VALVE (SINGLE) O-RING (012 D70) O-RING (012 D90) O-RING (018 D70) O-RING (008 D90) SOLENOID TUBE COIL, 12VDC CONNECTOR (04O-06S) HOSE (04OFX90S-18"-3000) HOSE (04OFX90-20"-3000) HOSE TRACK STAND BK CONNECTOR (04O-04O90BK) ABRASION SLEEVE (1.00" X 164") BRANCH TEE (06S-04O-04O, ORF) CONNECTOR (04OFX-16"-3000) CONNECTOR (06S-08O) CONNECTOR (06S-08O45) CYL (1" x 2") W/EYE UNION (04O-04OFX90) HOSE (04OFX-150"-3000) HOSE (04OFX-160"-3000) ABRASION SLEEVE (1.59" X 145") CONNECTOR (04S-04O90)

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

516-098 157-208 157-209 157-210 157-212 159-505 217-948 154-220 154-715 515-041 322-612 154-355 117-841 514-431 154-401 154-246 154-283 150-723 154-255 154-950 515-161 117-741 154-252

1 1 1 3 1 1 1 1 1 1 1 2 1 1 2

REMARKS

NOT SHOWN:

FOOTNOTES:

1. THIS SYSTEM BEGINS WITH S/N 2R0582.

NOTE:

REFER TO O-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS.

13

ID0037447

148

MUD MOTOR HYDRAULICS

52

DRIVE CONTROL VALVE

53

41 2 RETURN 33

26

14

23

42

15 16 35 36 19

17 18

39

34

TO OIL COOLER

1

40 3

38 FROM CASE DRAIN ON THRUST MOTOR

PRESSURE PILOT LINE 12

4 13

5 11 7 10 MOUNTS TO FRAME 28

27

RETURN

48

23 20

43

45 46 44

6

29

8

30

32 31

TO GAUGE ON FRONT WRENCH 49

22

24 25

9

50 45 21

31

29 32

RETURN 31 37

47

51

ID0025455

149

MUD MOTOR HYDRAULICS REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20 21 22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

158-403 190-725 158-469 154-711 117-679 156-973 157-784 155-748 106-602 154-264 154-293 153-675 153-219 154-680 106-386 515-170 217-864 154-273 154-368 515-242 515-230 154-249 154-271 154-266 156-500 353-396 115-963 154-322 158-420 154-318 158-937 158-687 190-760 159-581 514-079 154-317 154-310 154-312 154-711

QTY

-

1 3 1 1 1 2 1 1 1 1 2 1 1 1 1 1 1 1 1 2 1 1 1 2 1 1 1 1 2 1 2 2 1

DESCRIPTION

REMARKS

GEAR MOTOR (3.0 CUI/REV) SEAL REPAIR KIT GEAR MOTOR(3.0 CUI/REV) HOSE (08OFX-30"-3000) ABRASION SLEEVE (1.59" X 32") BRANCH TEE (08O-04O-10S) PROPORTIONAL HYD FLOW VALVE O-RING (916 D90) SCREW (M8-1.25 X 80MM) CONNECTOR (08O-10S45) BRANCH TEE (045-04O-040) HYDRALIC CONTROL VALVE WH-A RELIEF CARTRIDGE HOSE (08OFX-74"-3000)) FLG LOCKNUT (M8-1.25) HOSE (04OFX-86"-3000)) COIL (12V) CONNECTOR (10S-12090) UN RUN TEE (12OFX-12O-12O) HOSE (12OFX90-95"-3000) HOSE (12OFX-54"-4000) REDUCER STEM (080) REDUCER NUT (12OF) UNION RUN TEE (08OFX-08O-08O) HYD LINE (-08) DIVIDER PLATE ABRASION SLEEVE (1.59" X 75") CONNECTOR (08O-10S90) HYDRAULIC PUMP BRANCH TEE (10S-10O-10O) HYDRAULIC CONTROL VALVE (_ sPOOL) PRIORITY VALVE SEAL REPAIR KIT HOSE (08OFX45-114"-3000) UNION (10S-10OFX) RUN TEE (10S-10O-10O) REDUCER NUT (10OF) REDUCER STEM (08O) HOSE (08FX-30"-3000)

EARLY STYLE JT920 BEGINS WITH S/N 2N2090.USE WITH JT920 & JT921.

USE WITH JT921

BEGINS WITH S/N 2V0571

USE WITH JT920 AND JT921 USE WITH JT921S

NOT SHOWN:

FOOTNOTES:

NOTE:

REFER TO O-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS.

31

ID0025455

150

MUD MOTOR HYDRAULICS REF PART NO. NUMBER

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

47.

48.

49.

50.

51.

52.

53.

QTY

154-708 1 154-272 1 154-248 1 154-828 1 154-921 1 154-924 1 154-255 1 514-378 1 158-842 1 500-756 117-679 1 115-924 1 154-662 1 154-396 2 105-460 2 154-288 1 514-968 1 117-713 1 154-315 1 159-159 1 154-233 1 150-1064 1

DESCRIPTION

HOSE (08OFX-34"-3000) REDUCER NUT (08OF) REDUCER STEM (04O) HOSE (08OFX-17"-3000) HOSE (04OFX-54"-3000-AR) HOSE (040FX-38"-3000-AR) UNION (04O-04OFX90) BRANCH TEE (080-10S-08S) RELIEF VALVE (2000PSI) SEAL REPAIR KIT ABRASION SLEEVE (1.59" X 32") ABRASION SLEEVE (1.59" X 88") HOSE (08OFX-98"-3000) BK CONNECTOR (08O90BK) WASHER (13/16") CONNECTOR (10S-10O90, XL) HOSE (040FX90-122"-3000) ABRASION SLEEVE (1.00" X 76") UNION (10O-10OFX90) QDC ADAPTER (02-10OFX) CONNECTOR (08S-080) PILOT OPERATED RELIEF (ADJ. 1850 PSI)

REMARKS

WITH TANK WITH OUT TANK

BEGINS WITH S/N: 2z1825

NOT SHOWN:

FOOTNOTES:

NOTE:

31

ID0025455

151

152

ANCHOR CONTROL

2

ENDS WITH S/N

1

28 26

3

5

4

6 8 TO A PORT LEFT MOTOR TO B PORT LEFT MOTOR

7 11 29

5 TO A PORT LEFT CYLINDER TO B PORT LEFT CYLINDER

6

10

23

27

25

TO A PORT RIGHT MOTOR TO B PORT RIGHT MOTOR

9

7 12

TO A PORT RIGHT CYLINDER TO B PORT RIGHT CYLINDER

24

14 13

15 16

22 17

19 20 BACK-UP WRENCH VALVE SUPPLY

18 21

M

805-527

153

ANCHOR CONTROL ENDS WITH S/N REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

QTY

154-235 1 154-716 1 350-470 1 156-174 2 117-686 2 515-015 4 154-220 4 117-761 1 515-174 2 154-221 2 154-883 2 106-570 3 106-386 3 158-944 1 499-443 190-641 499-143 365-414 154-284 1 155-492 1 115-925 1 154-396 2 105-460 2 154-778 154-662 353-296 350-466 1 106-991 4 106-551 4 117-566 1 115-963 1 215-2727 1 216-026 1 214-103 1 214-104 2 157-645 2 500-908 4

DESCRIPTION

CONNECTOR (08S-08O90) HOSE (08OFX90-48"-3000) COVER CONNECTOR (06S-06O) ABRASION SLEEVE (1.75" X 43") HOSE (060FX90M-44"-3000) CONNECTOR (04O-06S) ABRASION SLEEVE (1.59" X 70") HOSE (04OFX90-74"-3000) CONNECTOR (06S-06O) HOSE (04OFX90L-66"-3000) SCREW (M8-1.25 X 60MM) FLG LOCKNUT (M8-1.25) HYD CONTROL VALVE VP RELIEF SEAL REPAIR KIT LEVER CONTROL AND BOOT M10 THREAD LEVER CONNECTOR (08S-08O45) HOSE (08OFX-39"-3000) ABRASION SLEEVE (2.38" X 40") BK CONNECTOR (080-08O90BK) WASHER (13/16") HOSE (08OFX-120"-3000) HOSE (08OFX-98"-3000) DRILL FRAME VALVE SUPPORT FLG LK SCREW (M8-1.25 X 20MM) CLIP NUT (M8-1.25) ABRASION SLEEVE (1.25" X 11") ABRASION SLEEVE (1.59" X 75") STROBE LIGHT, GREEN (LED) FLEX-GUARD (.25")(SOLD PER IN) (2-WAY) MALE CONNECTOR PACKARD MALE TERMINAL WEATHER-PAC SEAL (2.80MM) LEVER (M8-1.25, BLACK)

REMARKS

BEGINS WITH S/N________________ USE 1 @ 15"

FOOTNOTES

NOTE:

REFER TO O-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS.

M

805-527

154

ANCHORING HYDRAULICS

1

8

4 3 4 9 13 11

10

3

2

12

5 6

5 7

01

ID0147003

155

ACHORING HYDRAULICS REF PART NO. NUMBER

QTY

100-955 158-738 500-746 355-496 155-481 154-421 154-222 159-030 159-029 105-247 106-354 106-621 105-894 110-030 115-900

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

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

DESCRIPTION

REMARKS

2-PT ANCHOR SYSTEM HYDRAULIC MOTOR SEAL REPAIR KIT ANCHOR DRIVER HOSE (06OFX-185"-3000) CONNECTOR (060-10S90) CONNECTOR (06O-08S) QDC ADAPTER (08-08SF) QDC BODY (08-08SF) SCREW (M12-1.75 X 35MM) FLANGE NUT (M12-1.75) SCREW (M10-1.5 X 55MM) LOCKNUT (M10-1.5, PRV TRQ, 10.9) CABLE TIE (1/16" TO 4") ABRASION SLEEVE (2.54 x 190")

NOT SHOWN:

FOOTNOTES:

NOTE:

REFER TO O-RING CHART (800-301) IN BACK FOR REPLACEMENT OF SAE AND ORS O-RINGS.

01

ID0147003

156

ANCHOR HYDRAULICS JT921 & JT921S

39

5

10 14

38

4 4 2

32

3

18

2

33

6

35

36

37

LEFT MOTOR LEFT CYLINDER RIGHT MOTOR RIGHT CYLINDER

40

1 41 7 8 34

9 19 19 42 13 BACK-UP WRENCH VALVE

26

SUPPLY

25

15

12 22 20

11

17

23

22

21

27 23

16

20 23

23 16 25 29 28

24

24 31

31 30

28

07

ID0036556

157

ANCHOR HYDRAULICS JT921 & JT921S REF PART NO. NUMBER

QTY

DESCRIPTION

1.

1

HYD CONTROL VALVE VP RELIEF SEAL REPAIR KIT LEVER CONTROL & BOOT M10 THREAD LEVER CONNECTOR (04O-06S) CONNECTOR (06S-06O) CONNECTOR (06S-06O45) CONNECTOR (08S-08O90) LEVER (M8-1.25, BLACK) CONNECTOR (08S-08O45) HOSE (08OFX-39"-3000) ABRASION SLEEVE (2.38" X 40") HOSE (08OFX90-48"-3000) BK CONNECTOR (08O-08O90BK) HOSE (08OFX-98"-3000) HOSE (08OFX-120"-3000) ABRASION SLEEVE (1.25" X 11") HOSE (06OFX90M-44"-3000) BK CONNECTOR (06O-06O90BK) HOSE (06OFX90M-34"-3000) ABRASION SLEEVE (1.59" X 38") ABRASION SLEEVE (1.00" X 30") HOSE (06OFX90-32"-3000) HOSE (06OFX90-30"-3000) ABRASION SLEEVE (1.59" X 32") CONNECTOR (06O-10S) HYDRAULIC MOTOR CONNECTOR (04O-06S45) HOSE (04OFX90S-40"-3000) HOSE (04OFX90L-28"-3000) CONNECTOR (04O-06S90)

158-944 499-443 190-641 499-143 365-414 2. 154-220 3. 154-221 4. 154-224 5. 154-235 6. 500-908 7. 154-284 8. 155-492 9. 115-925 10. 154-716 11. 154-396 12. 154-662 13. 154-778 14. 117-566 15. 515-015 16. 154-229 17. 159-843 18. 117-655 19. 117-676 20. 515-707 21. 157-822 22. 117-679 23. 154-369 24. 158-700 25. 154-250 26. 154-706 27. 515-210 28. 154-226

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

REMARKS

SEE FOOTNOTE #2

NOT SHOWN:

FOOTNOTES:

1. YOU WILL NEED TO NOTCH SLEEVE TO ALLOW SHORT HOSE TO COME THROUGH. 2. KEYWAY 165-909 COMES WITH THE 158-700 MOTOR.

NOTE:

07

ID0036556

158

ANCHOR HYDRAULICS JT921 & JT921S REF PART NO. NUMBER

QTY

DESCRIPTION

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

1 1 1 1 1 4 4 1 1 3 3 1

HOSE (04OFX90S-66"-3000) HOSE (04OFX90L-54"-3000) HYDRAULIC CYLINDER ABRASION SLEEVE (1.25" X 58") ABRASION SLEEVE (1.25" X 68") DRILL FRAME VALVE SUPPORT CLIP NUT (M8-1.25) FLG LK SCREW (M8-1.25 X 20mm) COVER STROBE LIGHT-GREEN MEDIUM SCREW (M8-1.25 X 60mm) FLG LOCKNUT (M8-1.25) ABRASION SLEEVE (1.59" X 88")

154-840 149-064 151-214 117-690 117-691 325-629 350-466 106-551 106-991 350-470 217-297 106-570 106-386 115-924

REMARKS

SEE FOOTNOTE 1 SEE FOOTNOTE 1

NOT SHOWN:

FOOTNOTES:

NOTE:

07

ID0036556

159

160

ANCHOR SYSTEM 5

18 7

10 2

6

17

11 8 16

3 9 15

14 12 20 13

4

1

19 22

08

21

ID0036676

161

ANCHOR SYSTEM REF PART NO. NUMBER

1.

2.

3.

4.

5.

QTY

329-299 1 316-767 2 316-801 2 166-605 2 158-700 2 500-658 166-278 6. 165-909 7. 106-707 4 8. 106-771 2 9. 105-052 2 10. 115-503 8 11. 179-736 4 12. 106-685 4 13. 107-336 4 14. 106-355 4 15. 151-214 2 500-1542 16. 318-631 2 17. 318-658 2 18. 107-196 4 19. 327-457 131-259 20. 158-238 2 21. 107-331 2 22. 327-460 -

DESCRIPTION

ANCHOR FRAME UPPER TUBE ANCHOR DRIVER SHAFT HYD MOTOR SEAL REPAIR KIT SHAFT ASSEMBLY KEY (5/16" X 1-1/8") SCREW (M12-1.75 X 45MM, SOC) SCREW (M12-1.75 X 60MM, SOC) BOLT (3/8-NC X 1-1/4") KLIP RING (.750") PIN LOCKNUT(M12-1.75,PRV TRQ,10.9) FLG SCREW (M16-2.00X45MM,10.9) FLG NUT (M16-2.00, 10.9) HYD CYL SEAL KIT BOLT-ON CLAMP (1.88") BULKHEAD BRACKET BOLT (1/4-NC X 3") ROCK ANCHOR INSERT BIT - CARBIDE TIPPED CENTERING CAP ROLL PIN (M12 X 50MM) AUGER (4")

REMARKS

INCL. REF #6

NOT SHOWN:

FOOTNOTES:

NOTE:

08

ID0036676

162

ANCHOR HYDRAULICS

HEAVY DUTY ANCHOR SYSTEM

1

2 10

19 13 3 14

11

4 15 16

12

5 1 6 17

7 18

8

9

9 8

05

ID0085722

163

ANCHOR HYDRAULICS

HEAVY DUTY ANCHOR SYSTEM REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

QTY

150-6055 1 154-369 2 154-228 2 155-481 2 115-900 1 110-030 4 154-222 2 159-030 2 159-029 2 106-477 2 355-759 1 106-354 2 355-497 3 106-332 3 110-013 2 182-092 1 180-723 1 115-010 1 180-760 4 160-1059 1 106-266 3

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 (M12-1.75 X 45MM, 10.9) MOTOR TROLLEY FLANGE NUT (M12-1.75) TROLLEY SPACER SCREW (M10-1.5 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 (M10-1.50)

SEE FOOTNOTES 1 & 2

OBSOLETE

NOT SHOWN:

FOOTNOTES:

1. FOR OLD STYLE HYD MOTOR 155-579, USE SEAL KIT 500-347 FOR MOTOR VERSION 002, 003, 004 & 005.

SEAL KIT 500-658 IS TO BE USED WITH VERSION 006 MOTORS. 2. HYD. MOTOR 150-6055 BEGINS WITH S/N: CMW_______, USE SEAL KIT 500-3733

NOTE:

05

ID0085722

164

165

166

HYDRAULIC MOTOR

TAPERED KEYED SHAFT 1-1/4"

1

3

4 2

1

5

1

6

09

ID0051772

167

HYDRAULIC MOTOR

TAPERED KEYED SHAFT 1-1/4" REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

QTY

150-6055 155-580 153-280 500-347 1 155-771 3 155-760 1 165-915 1 105-418 1 105-501 1

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 2 THRU 6, SEE FOOTNOTES 1, 4 & 5 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- 500-1469 4. FOR OLD STYLE HYD MOTOR 155-579, USE SEAL KIT 500-347 FOR MOTOR VERSION 002, 003, 004 & 005.

SEAL KIT 500-658 IS TO BE USED WITH VERSION 006 MOTORS. 5. HYD. MOTOR 150-6055 BEGINS WITH S/N: CMW_______, USE SEAL KIT 500-3733 NOTE:

09

ID0051772

168

HYDRAULIC CYLINDERS (2.0" X 1.0")

1

6 11

13

12 5

7

4 8

9 3 10 2

04

ID0015823

169

HYDRAULIC CYLINDERS (2.0" X 1.0") REF PART NO. NUMBER

QTY

DESCRIPTION

1 2

151-094 152-029 153-007 149-667 149-761 149-728 151-027 150-282 150-414 151-038 150-290 150-421 151-039 150-291 150-422 151-044 150-294 150-424 151-031 150-285 150-417 151-076 152-017 150-444 149-668 150-286 149-729

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

CYL (2.0 X 1.0 X 2.0) CYLINDER BARREL (2.0 X 2.0) CYLINDER ROD (1.00 X 2.0) CYL (2.0 X 1.0 X 2.5) CYLINDER BARREL (2.0 X 2.5) CYLINDER ROD (1.00 X 2.5) CYL (2.0 X 1.0 X 3.0) CYLINDER BARREL (2.0 X 3.0) CYLINDER ROD (1.00 X 3.0) CYL (2.0 X 1.0 X 4.0) CYLINDER BARREL (2.0 X 4.0) CYLINDER ROD (1.00 X 4.0) CYL (2.0 X 1.0 X 5.0) CYLINDER BARREL (2.0 X 5.0) CYLINDER ROD (1.00 X 5.0) CYL (2.0 X 1.0 X 6.0) CYLINDER BARREL (2.0 X 6.0) CYLINDER ROD (1.00 X 6.0) CYL (2.0 X 1.0 X 8.0) CYLINDER BARREL (2.0 X 8.0) CYLINDER ROD (1.00 X 8.0) CYL (2.0 X 1.0 X 10.0) CYLINDER BARREL (2.0 X 10.0) CYLINDER ROD (1.00 X 10.0) CYL (2.0 X 1.0 X 12.0) CYLINDER BARREL (2.0 X 12.0) CYLINDER ROD (1.00 X 12.0)

3 4 5 6 7 8 9 10 11 12 13

150-772 150-778 150-775 106-096 157-022 155-732 157-540 157-537 125-774 157-534 157-018

1 1 1 1 1 1 1 1 1 1 1

CYLINDER HEAD (2.0 X 1.00) LOCK RING (2.0) CYLINDER PISTON (2.0 X 1.00) FLG BOLT (1/2-NC X 1-3/4",GD8) O-RING (224 D90) BACKUP RING (224 D90) U-SEAL (1.000") WIPER SEAL (1.000") WEAR RING BACKUP RING (131 D90) O-RING (131 D90)

1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2

REMARKS

SEE FOOTNOTES 1 & 2

SEE FOOTNOTES 1 & 2

SEE FOOTNOTES 1 & 2

SEE FOOTNOTES 1 & 2

SEE FOOTNOTES 1 & 2

SEE FOOTNOTES 1 & 2

SEE FOOTNOTES 1 & 2

SEE FOOTNOTES 1 & 2

SEE FOOTNOTES 1 & 2

.

SEE FOOTNOTE 3

NOT SHOWN:

259-100 259-235 259-239 259-241 259-188

U-SEAL INSTALLER (1" - 1.499") 1.00 ROD WIPER TOOL WIPER/SEAL INSTALLER (2") PISTON INSTALLER (2") CYL HEAD SPANNER - TWO PIN

FOOTNOTES:

1. REF. #1 & #2 ARE SPECIFIC TO EACH CYLINDER, REF. #3 THRU #13 ARE COMMON FOR ALL THE ABOVE LISTED CYLINDERS 2. SEAL REPAIR KIT P/N: 190-165 3. APPLY LOCTITE 277 OR EQUIVALENT, TORQUE TO 90-100 FT-LBS

NOTE:

04

ID0015823

170

HYDRAULIC CYLINDERS (3.0" X 1.5")

1

6 11 13

12

5

7 8 4 9 10

3

2

02

ID0015860

171

HYDRAULIC CYLINDERS (3.0" X 1.5") REF PART NO. NUMBER

QTY

1 2

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

CYL (3.0 X 1.5 X 2.5) CYLINDER BARREL (3.0 X 2.5) CYLINDER ROD (1.50 X 2.5) CYL (3.0 X 1.5 X 3.0) CYLINDER BARREL (3.0 X 3.0) CYLINDER ROD (1.50 X 3.0) CYL (3.0 X 1.5 X 4.0) CYLINDER BARREL (3.0 X 4.0) CYLINDER ROD (1.50 X 4.0) CYL (3.0 X 1.5 X 5.0) CYLINDER BARREL (3.0 X 5.0) CYLINDER ROD (1.50 X 5.0) CYL (3.0 X 1.5 X 6.0) CYLINDER BARREL (3.0 X 6.0) CYLINDER ROD (1.50 X 6.0) CYL (3.0 X 1.5 X 8.0) CYLINDER BARREL (3.0 X 8.0) CYLINDER ROD (1.50 X 8.0) CYL (3.0 X 1.5 X 10.0) CYLINDER BARREL (3.0 X 10.0) CYLINDER ROD (1.50 X 10.0) CYL (3.0 X 1.5 X 12.0) CYLINDER BARREL (3.0 X 12.0) CYLINDER ROD (1.50 X 12.0) CYL (3.0 X 1.5 X 16.0) CYLINDER BARREL (3.0 X 16.0) CYLINDER ROD (1.50 X 16.0) CYL (3.0 X 1.5 X 20.0) CYLINDER BARREL (3.0 X 20.0) CYLINDER ROD (1.50 X 20.0)

3 4 5 6 7 8 9 10 11 12 13

150-774 150-911 150-777 106-098 155-734 155-733 157-542 157-539 125-776 157-536 157-020

1 1 1 1 1 1 1 1 1 1 1

CYLINDER HEAD (3.0 X 1.50) LOCK RING (3.0) CYLINDER PISTON (3.0 X 1.50) FLG BOLT (3/4-NC X 2", GD8) O-RING (334 D90) BACKUP RING (334 D90) U-SEAL (1.500") WIPER SEAL (1.500") WEAR RING BACKUP RING (230 D90) O-RING (230 D90)

1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2

REMARKS

DESCRIPTION

149-682 149-804 149-731 151-049 150-299 150-431 151-054 152-004 150-434 151-179 152-068 153-038 151-086 152-008 153-003 151-136 152-014 153-027 151-029 150-284 150-416 151-043 150-293 150-426 151-034 150-288 150-419 151-117 152-054 150-669

SEE FOOTNOTES 1 & 2

SEE FOOTNOTES 1 & 2

SEE FOOTNOTES 1 & 2

SEE FOOTNOTES 1 & 2

SEE FOOTNOTES 1 & 2

SEE FOOTNOTES 1 & 2

SEE FOOTNOTES 1 & 2

SEE FOOTNOTES 1 & 2

SEE FOOTNOTES 1 & 2

SEE FOOTNOTES 1 & 2

.

SEE FOOTNOTE 3

NOT SHOWN:

259-040 259-237 259-065 259-066 259-188

U-SEAL INSTALLER (1.5" - UP) ROD WIPER INSTALLER (1.5") PISTON SEAL INSTALLER (3") PISTON INSTALLER (3") CYL HEAD SPANNER - TWO PIN

FOOTNOTES:

1. REF. #1 & #2 ARE SPECIFIC TO EACH CYLINDER, REF. #3 THRU #13 ARE COMMON FOR ALL THE ABOVE LISTED CYLINDERS. 2. SEAL REPAIR KIT P/N: 190-167 3. APPLY LOCTITE 277 OR EQIVALENT, TORQUE TO 290-325 FT-LBS NOTE:

02

ID0015860

172

NOTES:

ID0134963

173

ELECTRICAL

174

See loose-leaf schematic included with this manual.

175

ELECTRICAL SCHEMATIC JT920 TIER 2

REF. # B1 B2 BT1 BT2 D1-D7 DS1 DS2 DS3 DS4 DS5 E1 F1 F2 F3 F4 F5 F6 F7 F8 F9 G1 HR1 HR2 HR3 HR4 J1 J2 J3 K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14 K15

04

215-231

211-293 211-295 211-295 211-293 211-311 211-310

211-296

211-298 211-296 211-297 211-298 211-296 217-701

COMPONENT NOTES Starter motor Linear actuator CMW# 215-231 Battery 12V Battery Dual battery option Diodes 1N5402 Engine low oil pressure indicator Hydraulic oil filter restricted light Hydraulic oil high temperature light E.S.I.D. Strobe light Tracker control strobe Acc socket Accessory fuse 20A Mini-ATC Accessory socket fuse Auxillary light fuse 30A Mini-ATC Main fuse 30A Mini-ATC Start fuse 20A Mini-ATC Ignition fuse Primary Power Fuse 100A BK/AMI Glow plug fuse 60A BK/AMI Drill fluid controller fuse 3A ATC Alternator 55A 12V Glow plug Glow plug Glow plug Glow plug Auxillary light connector Umbilical connector Download connector Fluid shutoff relay Wiper relay Tracker control relay Bussmann Component (Micro) Throttle up relay Throttle down relay Fluid max relay 5V relay Rotation enable relay Bussmann Component (Mini) Engine stop relay Bussmann Component (Micro) Shutdown relay Bussmann Component (4-Pin Micro) Strobe relay Light test relay Start relay Bussmann Component (Mini) Engine oil pressure relay Bussmann Component (Micro) Glow plug relay (60 AMP, SPST 12V DC

ID0029556

176

ELECTRICAL SCHEMATIC JT920 TIER 2 REF. # L1 L2 L3 L4 L5 L6 L7 L8 LS1 LS2 M1 M2 M3 M4 Q1 R1 R2 R3 R4 S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 S13 S14 S15 S16 S17 U1 U2 U3 U4 U5 W1

04

Part #

306-602 215-133 215-128 214-449 217-549 217-940

217-736

306-607 214-467

217-762 217-935 214-466

217-937 215-914 214-502 217-232

COMPONENT

NOTES

Starter solenoid Fuel shutoff solenoid Rotation solenoid Rotation solenoid Drill fluid control solenoid Autobore shutoff solenoid Aux. Wrench down solenoid Aux. Wrench up solenoid Warning alarm (status) ESID alarm Voltmeter Fuel gauge Engine Water temperature gauge Engine Hourmeter Fluid shutoff proximity switch Alternator Diode Resistor Fuel level sender Engine water temperature sender Fluid flow adjust potentiometer Battery disconnect switch Ignition switch Engine stop switch Cold start switch Engine low oil pressure switch Hydraulic oil filter restricted switch Hydraulic oil high temperature switch Fluid Pac Remote start switch With 306-608 cover Operator's Throttle Switch "Joystick" Mobile Position Throttle Switch @ Rear Aux. Wrench up/down switch Fluid Pac remote throttle switch Seat switch (Operator Presence) With 215-939 harness Tracker control switch Fluid on-off-(maximum) switch "Joystick" Fluid Pump select switch Autobore shutoff switch Start Bypass Delay Timer Drill fluid controller Delay timer (1min) ESID module Remote display Glow plug buss bar

ID0029556

177

ELECTRICAL SCHEMATIC JT920 TIER 2

CIRCUIT WIRE COLOR FUNCTION NUMBER 1 blk High current ground 1A blk/red Medium current ground 1B blk/blu Low current ground 2 red Protected Battery circuit (100 amp primary power fuse) 2A red Battery cable (Battery to starter motor) un-fused 3 red/blu Individually Fused battery circuit 4 org/brn Accessory circuit 5 wht/blk Start circuit 6 org/blu Ignition circuit 7 org/yel Fused accessory socket circuit 8 org Fused accessory circuit 9 org/grn Fused ignition circuit 10 pur/blk Fused start circuit 11 pur Start relay to starter solenoid 12 gra Fused glow plug circuit 13 yel Fused auxillary light connector 14 gra Glow plug relay to glow plugs 15 pur/wht Glow plug switch to glow plug relay 16 brn Fuel sender to fuel gauge 17 grn Water temperature sender to water temperature gauge 18 yel/red Engine stop switch to diode anode & umbilical connector 19 yel/gra Diode cathode to engine stop relay 20 blu Engine stop relay to engine oil pressure relay 21 org/gra Engine oil pressure relay to diode anode & hourmeter 22 org/blk Diode cathodes to fuel shutoff solenoid 23 wht/blu Engine oil pressure switch to EOP relay & EOP indicator 24 wht/org Start bypass delay to EOP relay 25 blk/yel Light test relay to diode cathodes 26 gra/yel Hydraulic filter switch to diode anode & hydraulic filter light 27 gra/blk Hydraulic oil termperature switch to diode anode & HOT light 28 red/blk Remote start switch to umbilical connector 29 pur/org Throttle switches to throttle up relay 30 blu/org Throttle switches to throttle down relay 31 grn/org Throttle down relay to linear actuator 32 wht/org Throttle up relay to linear actuator 33 yel/blk FP throttle switch to umbilical connector

04

ID0029556

178

ELECTRICAL SCHEMATIC JT920 TIER 2

CIRCUIT WIRE COLOR FUNCTION NUMBER 34 gra/grn Seat switch to rotation enable relay 35 gra/red Rotation enable relay to rotation solenoids 36 red/yel ESID module to delay timer, strobe relay, shutdown relay, & diode 37 tan/blk Delay timer to shutdown relay 38 wht/pur ESID module to strobe relay, delay timer, & umbilical connector 39 wht/yel Strobe relay to strobe 40 wht/grn ESID module to alarm 41 ******* Voltage limiter cable 42 ******* Current transformer cable 43 wht Fluid shutoff switch to fluid shutoff relay 44 grn Fluid shutoff relay to wiper relay 45 grn/blu Fluid flow adjust potentiometer to fluid shutoff relay 46 blu/grn Fluid flow adjust potentiometer 5V 47 blk/yel Fluid switch to fluid flow adjust potentiometer 48 blk/wht Fluid switch to fluid max relay 49 yel/blu Water select switch to wiper relay, fluid max relay, & 5V relay 50 blk/wht Fluid max relay to drill fluid solenoid & drill fluid controller 51 blu/wht Fluid max relay to umbilical connector 52 gra/grn Wiper relay to umbilical connector 53 gra/blu 5V relay to umbilical connector 54 tan/grn Wiper relay to drill fluid controller 55 tan/blu 5V relay to drill fluid controller 56 org/blu Diode pack to alternator exciter circuit 57 yel/blk Autobore switch to autobore solenoid 58 tan/red Tracker control switch to remote display & Tracker control relay 59 gra/pur Tracker control relay to strobe 60 tan/pur Tracker control relay to seat switch 61 blk Remote display to download connector "A" 62 wht Remote display to download connector "B" 63 yel Remote display to download connector "C" 64 yel/grn Auxillary wrench switch to Aux. Wrench up solenoid 65 pur/grn Auxillary wrench switch to Aux. Wrench down solenoid 66 red/grn Primary power & glow plug fuse supply power

04

ID0029556

179

ELECTRICAL SCHEMATIC JT920 TIER 2

04

Ref. No.

Part No.

Qty.

Description

1 2 3 4 5 6

214-175 214-293 214-295 214-296 215-939 213-171

1 1 1 1 1 1

STROBE PIGTAIL HARNESS GAUGE HARNESS RELAY HARNESS BORING CONSOLE HARNESS SEAT SWITCH HARNESS ENGINE FRAME HARNESS old # 214-294

ID0029556

180

181

182

183

184

ELECTRICAL SCHEMATIC

JT921 w/AUTOBORE SHUTOFF BEGINS w/2Z0259 POWER CIRCUIT FUSED BAT BATTERY

PRIMARY FUSE

1

F4

100A

BT1

F2 20A

5 4 3 2

BAT

30A

ACC ST

4 ST

28 REMOTE START SWITCH S1

6

9

5

S2

2

IGN

F6

TO UMB CONN

START FUSE 10

F5

MASTER DISCONNECT SWITCH

1

-

I

G

1B

TO ACC

31

3

29

20A STARTER SOLENOID

B1

START RELAY K13 87a 30 87

8

FUEL GAUGE

I S G

8

8

1A

THROTTLE DOWN RELAY 4 K5

OPERATOR SWITCH

STARTER M MOTOR

11 5

8

3

1B

16

5

S6

FUEL SENDER 30

MOBILE POSITION SWITCH

9 GLOW PLUG RELAY K15 30 87

GLOW PLUG FUSE 12 60A

1B

8

1A 8 WATER TEMP GAUGE

S7 33

14

COLD START SWITCH

1A

I S G

TO UMB CONN

FP THROTTLE SWITCH

15

AUTOBORE SHUTOFF SOLENOID

8

17

L1

S3

AUX LIGHTS FUSE

GLOW PLUG BUSS BAR

30A

1A

57

S8

TO AUX LIGHTS

13

TO IGN STROBE

9 TO REMOTE START SWITCH TO FLUID ADJUST POT "A" TO FLUID ADJUST POT "B" TO FLUID SWITCH "MAX" TO "ESS ALARM/STROBE" TO "PP THROTTLE" TO "ENGINE STOP SWITCH"

DS1 40

R2

ALARM

1A

LS2

D6

G1 1A 38

38

IND

ELECTRICAL STRIKE SYSTEM ALARM BOX

BAT FUSED

3 36 CURRENT COIL

1A

FLUID CONTROL POT

46

FLUID SHUTOFF SWITCH TO Q1 ACC

U3 CURRENT COIL VOLTAGE STAKE

FLUID SHUTOFF RELAY 4 K1

VOLTAGE STAKE

41

28 53 52 51 38 33 18 1A

TO BAT

2 VOLTAGE LIMITER

3

42

56

+V +V

1

1 5 4 2

UMBILICAL CABLE PIN #

UMBILICAL CONNECTION

ALTERNATOR ELECTRICAL STRIKE SYSTEM

WATER TEMP SENDER

AUTOBORE SHUTOFF SWITCH

HR1-4

TO UMB CONN ESS ALARM/STROBE

TO ACC

5

IGN

1A

F3

+ 21

VOLTMETER

S5

20A

66

F8

1

UP RELAY 4 K4

32

2A

BT2

TO FUEL SOLENOID

1A 3

F1

ACC SOCKET

HOURMETER

B2

VARIABLE LINEAR ACTUATOR

ACC

7

IGNITION SWITCH

MAIN FUSE

8

F7 20A

GAUGES

VARIABLE THROTTLE CONTROL & AUTOBORE SHUTOFF

8

3

A FLUID FLOW ADJUST POT

B

45

5

7 10 9 6 14 8 4 1

R3 43

STATUS INDICATOR

TO IGN

EOP SWITCH

9

ENGINE OIL PRESSURE

SP1

44

1B VAR

DS2 1B

23 HOT SWITCH TO IGN

MAX FLUID SWITCH

DS3

ST1

WARNING LIGHT ALARM

3

HYDRAULIC FILTER

26 27

9

JT920

D4 2

27

LIGHT TEST RELAY 4 K12

5

26 3 TO UMB CONN

6

3

25

D3

5

4

TO ACC

3

5

23

EOP RELAY 4 K14 3

20

5

IN5402 21

TO HOURMETER

IN5402

1A

9

1A

K7

4

3

5

+5V E

55 54

TRACKER CONTROL

SW

START BYPASS DELAY

OUT

U1

ACC

GND 5

24

50 DRILL FLUID CONTROL SOLENOID L2

8

F9 3A

1B FUSE

TRACKER STROBE

DS5

TO ACC

AUXILLARY WRENCH SWITCH UP/DOWN 64 8 65

WRENCH UP

BATT

U2

WRENCH DOWN

L7

REMOTE DISPLAY

1A

1

8 58

63 62

TRACKER CONTROL RELAY

K3

4

K8

3

5

A B C DOWNLOAD CONNECTION

30

1A

SEAT SWITCH 34

35

L4

60

S11 58

L3

87a 87

59

64

ROTATION SOLENOID

ROTATION ENABLE RELAY 3

8

L6

TO UMB CONN

50

1A AUXILLARY WRENCH

53 55

POT D DRILL FLUID CONTROLLER +12V C U4 PWMB

+12V

1B

TO UMB CONN

8

GND A TO IGN

52

5VOLT RELAY

WATER SELECT SWITCH

1A

L5

ENGINE STOP RELAY

TO UMB CONN

54

49 49

D5

4

5

FP

D2

K9

3

9

FUEL SOLENOID

19 9

50 51

S10

TO IGN

5

TO ST

S13 1

5

WIPER RELAY 4 K2

49

DS4 SP2

LS1

ENGINE STOP SWITCH

FLUID MAX RELAY 4 K6

48

1A HYD FILTER SWITCH

18

C

47

OFF

S9

HYDRAULIC OIL HI TEMP

27

1A

TRACKER CONTROL KEY

1A

S14

05

ID0044163

185

ELECTRICAL SCHEMATIC

JT921 w/AUTOBORE SHUTOFF BEGINS w/2Z0259

COMPONENT DESCRIPTIONS Ref. No. B1 B2 BT1 BT2 D1 D2 D3 D4 D5 D6 DS1 DS2 DS3 DS4 DS5 F1 F4 F7 F2 F6 F5 F8 F3 F9 G1 HR1 HR2 HR3 HR4 K1 K2 K3 K4 K5 K6 K7 K8 K9 K12 K13 K14 K15

05

Part No. 215-231 213-104

217-296

217-297 211-311 211-295

211-293 211-293 211-310 211-295 211-289 215-189

211-296 211-296 211-296 211-296 211-296 211-296 211-296 211-298 211-296 211-297 211-298 211-296 217-701

Component

Notes

STARTER VARIABLE LINEAR ACTUATOR BATTERY BATTERY DIODE DIODE DIODE DIODE DIODE DIODE ESID STROBE ENGINE OIL PRESSURE HYDRAULIC OIL HI TEMPERTURE HYDRAULIC FILTER TRACKER CONTROLLER STROBE PRIMARY FUSE MAIN FUSE ACC FUSE ACC SOCKET IGNITION FUSE STATRER FUSE GLOW PLUG FUSE AUX LIGHTS FUSE DRILL FLUID CONTROLLER FUSE ALTERNATOR GLOW PLUG GLOW PLUG GLOW PLUG GLOW PLUG FLUID SHUTOFF RELAY WIPERE RELAY TRACKER CONTROL RELAY UP RELAY THROTTLE DOWN RELAY FLUID MAX RELAY 5V RELAY ROTATION ENABLE RELAY ENGINE STOP RELAY LIGHT TEST RELAY STARTER RELAY EOP RELAY GLOW PLUG RELAY

INCLUDES SOLENOID CMW# 215-231 12V,875CCA 1N5402 1N5402

AMBER

GREEN 100A 30A 20A 20A 20A 20A 60A 30A 3A 12V, 60A

ID0044163

186

ELECTRICAL SCHEMATIC

JT921 w/AUTOBORE SHUTOFF BEGINS w/2Z0259

COMPONENT DESCRIPTIONS L1 L2 L3 L4 L5 L6 L7 LS1 LS2 M1 M2 M3 M4 Q1 Q2 R1 R2 R3 R4 S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 S13 S14 SP1 SP2 ST1 U1 U2 U3 U4

05

306-602 215-2594 215-133

214-449 217-940 217-549 214-852 217-849 214-647 217-762 214-467 217-935

see notes 214-854 217-937 SUBSITE 220-1024

AUTOBORE SHUTOFF SOLENOID DRILL FLUID CONTROL SOLENOID ROTATION SOLENOID ROTATION SOLENOID FUEL SOLENOID WRENCH UP SOLENOID WRENCH DOWN SOLENOID WARNING LIGHT ALARM ESID ALARM HOURMETER FUEL GAUGE WATER TEMP GAUGE VOLT METER FLUID SHUTOFF SWITCH ENGINE WATER TEMERTURE SENDER ALTERNATOR DIODE RESISTOR FLIUD FLOW ADJUST POTENTIONMETER FUEL LEVEL SENDER REMOTE START SWITCH IGNITION SWITCH COLD START SWITCH MASTER DISCONNECT SWITCH OPERATOR SWITCH MOBILE POSITION SWITCH FP THROTTLE SWITCH AUTOBORE SHUTOFF SWITCH FLUID SWITCH WATER SELECT SWITCH SEAT SWITCH (OPERATOR PRESENCE) AUXILLARY WRENCH SWITCH UP/DOWN ENGINE STOP SWITCH TRACKER CONTROL KEY EOP SWITCH HYD. FILTER SWITCH HOT SWITCH START BYPASS DELAY REMOTE DISPLAY ESID MODULE DRILL FLUID CONTROLLER

WITH 215-939 HARNESS

SP1/217-721 OIL PRESSURE SWITCH component of 157-458

ID0044163

187

ELECTRICAL SCHEMATIC

JT921 w/AUTOBORE SHUTOFF BEGINS w/2Z0259

CIRCUIT DESCRIPTIONS Circuit Number 1 1A 1B 2 2A 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

05

Wire Color Function blk blk/red blk/blu red red red/blu org/blu wht/blk org/blu org/yel org org/grn pur/blk pur gra yel gra pur/wht brn grn yel/red yel/gra blu org/gra org/blk wht/blu wht/org blk/yel gra/yel gra/blk red/blk pur/org blu/org grn/org wht/org yel/blk gra/grn gra/red

System Ground Medium Ground Low Ground Battery Positive (100 Amp Primary Power Fuse) Fused Alternator (Battery to starter)Un-fused Individually Fused Battery Circuit Accessory circuit Start Circuit Ignition Circuit Fused Accessory Socket Circuit Fused Accessory Circuit Ignition Circuit Fused Start Circuit Start Relay to Starter Solenoid Fused Glow Plug Circuit Fused Auxiliary Light Connector Glow Plug Relay to Glow Plugs Glow Plug Switch to Glow Plug Relay Fuel Sender to Fuel Gauge Water Temperature Sender to Water Temperature Gauge Engine Stop Switch to Diode Anode & Umbilical Connector Diode Cathode to Engine Stop Relay Engine Stop Relay to Engine Oil Pressure Relay Engine Oil Pressure Relay to Diode Anode & Hourmeter Diode Cathode to Fuel Shutoff Solenoid Engine Oil Pressure Switch toEOP Relay & EOP Indicator Start Bypass Delay to EOP Relay Light Test Relay toDiode Cathodes Hydraulic Fliter Switch to Diode Anode & Hydraulic Filter Light Hydraulic Oil Temperature Switch to Doide Anode & Hot light Remote Start Switch to Umbilical Connector Throttle Switches toThrottle Up Relay Throttle Switches toThrottle Down Relay Throttle Down Relay to Linear Actuator Throttle Up Relay to Linear Actuator FP Throttle Switch to Umbilical Connector Seat Switch to Rotation Enable relay Rotation Enable Relay to Rotation Solenoids

ID0044163

188

ELECTRICAL SCHEMATIC

JT921 w/AUTOBORE SHUTOFF BEGINS w/2Z0259

CIRCUIT DESCRIPTIONS Circuit Number 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66

Wire Color Function red/yel ESID module to Delay Timer,Strobe Relay, Shutdown Relay & Diode tan/blk delay Timer to Shutdown Relay wht/pur ESID module to Strobe Relay, Delay Timer& Umbilical Connector wht/yel Strobe Relay to Strobe wht/grn ESID Module to Alarm ******* Voltage Limiter Cable ******* Current Transformer Cable wht Fluid Shutoff Switch to Fuild Relay grn Fluid Shutoff Relay to Wiper Relay grn/blu Fluid Flow Adjust Potentiometer To Fluid Shutoff Relay blu/grn Fluid Flow Adjust Potentiometer 5V blk/yel Fliud Switch to Fluid Flow Adjust Potentiometer blk/wht Fliud Switch to Fluid Max Relay yel/blu Water Select Switch to wiper Relay, Fluid Max Relay, & 5V Relay blk/wht Fluid Max Relay to Drill Fluid Solenoid & Drill Fluid Controller blu/wht Fluid Max Relay to Umbilical Connector gra/grn Wiper Relay to Umbilical Connector gra/blu 5v Relay to Umbilical Connector tan/grn Wiper Relay to Drill Fluid Controller tan/blu 5v Relay to Drill Fluid Controller org/blu Diode Pack to Alternator Exciter Circuit yel/blk Autobore Switch to Autobore Solenoid tan/red Tracker Control Switch to Remote Display & Tracker Control Relay gra/pur Tracker Control Relay to Strobe tan/pur Tracker Control Relay to Seat Switch blk Remote Display to Download Connector "A" wht Remote Display to Download Connector "B" yel Remote Display to Download Connector "C" yel/grn Auxillary Wrench Switch to Aux. Wrench Up Solenoid pur/grn Auxillary Wrench Switch to Aux. Wrench Down Solenoid red Primary Power & Glow Plug Fuse Supply Power

WIRING HARNESSES Ref. No. 1 2 3 4 5 6 7 8 9

05

Part No. Quantity Description 215-1177 1 JT922 ENGINE FRAME HARNESS 215-1178 1 JT922 DRILL FRAME HARNESS 215-1164 1 DUAL ELEMENT COLD START HARNESS 215-310 1 BATTERY CABLE (RED) 215-1029 1 BATTERY CABLE (BLACK) 215-1035 1 BATTERY CABLE (BLACK) 213-002 1 BATTERY CABLE (BLACK) 215-333 1 BATTERY CABLE (RED) 215-1566 1 HOME SWITCH HARNESS

ID0044163

189

190

ELEC DIA ENG/FR HARNESS

ENGINE/FRAME HARNESS

SPARE FUSES

TO RELAY HARNESS

11

10

THROTTLE

60

60

20

20

20

20

BLU/GRN (30) YEL/RED (11) ORG/BLK (12) WHT/BLK (14)

COLD START

RED (2)

6

GRA/GRN (33) GRN (46)

RED (2)

ORG/BLU (5) ORG (3) WHT/BLU (15)

GRA/BLU (32)

MAIN

FUEL SOLENOID

CAVITY PLUG

WHT/BLK (8)

4

3

2

1

12 11 10

5

9

8

7

18 17 16

15 14 13

24 23 22

21 20

GRA (17) GRA/WHT (34)

19

RED (2)

RED (2)

BLU (45)

BLK/WHT (47) CAVITY PLUGS

6

5

4

3

2

RED (4) BRN/ORG (40)

WHT (36) BLK/WHT (44) YEL/BLU (48) WHT/PUR (38) ORG/RED (49)

1

GRA/WHT GRA/ORG RED/WHT (37)

YEL/BRN YEL/BLK

D C B A

1

CLIP REF SERVICE P/N 105-660

TO RELAY HARNESS THROTTLE ACTUATOR

WHT/BLK (23) BRN/ORG (40) BRN (41) BLK (1) RED (4) AB

A B C

BLK WHT

RED GRN BLK

AUX. LIGHT FUSE

ACC. SOCKET FUSE

9 3 2 WHT GRN BLK

GRA/WHT (53) GRA/ORG (54) BLK (1)

4

GRA (19) GRA (19) G BK BLK (1) BLK (1)

W R

WATER TEMP SENDER

8

AUX. LIGHT SOCKET

ORG/WHT (20) GRA (19) ORG (3) RED (2)

GRN (31)

7 FUEL SOL. BRN (41) BLK (1)

RED (2)

6

BLK (1) ENGINE OIL PRESS.

16

ACC. SOCKET WHT/BLU (15)

-A-

5

ORG/WHT {20}

-B-

ID0051890

191

ELEC DIA ENG/FR HARNESS

ENGINE/FRAME HARNESS

-A-

-B-

TO GAUGE HARNESS TO UMBILICAL CABLE

YEL/BLU (48)

WHT/BLK (14)

ORG (3)

GRN (31) 12 11 10 9 8 7

RED/BLK (25) GRA (17) WHT/BLU (15) BLU/GRN (30)

1 2 3 4 5 6

ORG/BLU (5)

BLK (1)

RED (4)

YEL/BRN

BLK (1) YEL/RED 1 (11) 2 3 YEL/BLK 4 (22)

YEL/BLK {52} B A {51}

BRN/ORG (6)

A B

WHT/BLK (8) ORG/BLK (12)

WHT/PUR CAVITY PLUGS (38)

WHT/PUR (36) 8 7 6 5

GRA/WHT (34) GRA/GRN (33) GRA/BLU (32)

RED/BLK (25)

CAVITY PLUG

YEL/RED (11) BLK CAVITY (1) PLUG CAVITY GRA/WHT PLUG (34) GRA/BLU RED/BLK (32) GRA/GRN YEL/BLK (25) (22) (33)

14

13

12

BLK (1)

15

GRA {17} MANIFOLD HEATER RELAY

WHT/BLK (14)

RED/WHT (37) BRN/ORG (6)

28 30 85

HYDRAULIC FILTER

87A

86

87

BLK (1) BRN/YEL (7)

HYDRAULIC TEMPERATURE SWITCH TO BORING CONSOLE

YEL/RED (11)

6 5 4

7 8 9

WHT/PUR (38)

ORG/BLU (5)

3 2

10 11 12

ORG/RED (49)

16

WHT/BLK (23) RED (2)

BLU (45) GRN (46) BLK/WHT (47) YEL/BLK (22)

STARTER

HEATER ELEMENT

1

ORG (3) YEL/BLK (51) BLK (1) YEL/BRN (52)

BRN/YEL (7)

17 TO BORING CONSOLE

27

A B

RED (4)

BLK (1)

26

18

WHT (36) BLK (1)

ORG (3)

STROBE LIGHT RED (2)

RED

VARIABLE THROTTLE MOBILE SWITCH BLK (1)

22 25

YEL/BRN (52) ORG (3)

YEL/BLK (51) FLUID CONTROL SOLENOID

21

8 7 1 4 2 5 3 6

20

RED

23 BLK

BLK

19

BLK/WHT ORG (44) (3) TO ENGINE

24

16

ID0051890

192

ELEC DIA ENG/FR HARNESS

ENGINE/FRAME HARNESS REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

214-294 217-813 217-812 217-017 105-185 106-048 214-301 106-888 106-557 217-760 217-862 217-565 215-231 214-299 196-331 501-358 217-805 217-793

QTY

DESCRIPTION

1 1 2 2 1 2 2 1 1 1 1 1 -

ENGINE FRAME HARNESS FUSE (ATC, 3O AMP) FUSE (ATC, 20 AMP) CONNECTOR (4-WAY, FM) BOLT (#10-24 X 1/2", RD SLT) LOCKNUT (#10-24) ACCESSORY SOCKET SCREW (M4-.70 X 16MM) NUT (M4-.70) LOW OIL PRESSURE SWITCH FUEL SOLENOID TEMPERATURE SENDER 100 - 280 F LINEAR ACTUATOR ACTUATOR PIGTAIL CABLE (LINEAR ACTUATOR) ROLL PIN (3/32" X 3/4") FUSE (MAXI, 20 AMP) FUSE (MAXI, 60 AMP)

1 1 3

FLG LK SCREW (M8-1.25 X 25MM) FLG LOCKNUT (M8-1.25) BOLT-ON CLAMP (1-5/8")

REMARKS

NOT SHOWN:

106-381 106-386 110-332

ALL CONNECTORS ARE SHOWN WITH REAR VIEWS

FOOTNOTES:

NOTE:

16

ID0051890

193

ELEC DIA ENG/FR HARNESS

ENGINE/FRAME HARNESS REF PART NO. NUMBER

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

217-765 214-172 106-216 106-454 106-220 217-099 217-826 105-185 106-048 194-407 217-910 215-159 215-275 215-244 215-370 215-337 217-819 215-375 217-864 217-764 214-175 217-041 217-720 217-310 217-311 121-055 215-148 214-819

QTY

1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

DESCRIPTION

INDICATOR SWITCH UMBILICAL HARNESS BOLT (3/8-NC X 1", SIL BRZ) LOCKNUT (3/8-NC, SIL BRZ) INT STAR WASHER (3/8", SIL BRZ) UMB CONNECTOR DUST CAP (LARGE) MINI RELAY (SPDT) BOLT (#10-24 X 1/2, RD SLT) LOCKNUT (#10-24) STARTER HEATER ELEMENT ALTERNATOR (12V, 61 AMP) BATTERY BATTERY BAT CABLE (1/0 GA X 46", RED) BAT CABLE (2/0 GA X 19", BLK) BAT DISCONNECT SWITCH BAT CABLE (1/0 GA X 24", BLK) PROPORTIONAL SOLENOID COIL ROCKER SWITCH (SPDT) STROBE PIGTAIL HARNESS STROBE LIGHT (12V DC) BULB (12V DC) STROBE LIGHT (12V DC) BULB (12V DC) LENS (AMBER) TEMPERATURE SWITCH TEMPERATURE SWITCH

REMARKS

OBSOLETE

MOMENTARY ON-OFF-MOMENTARY ON OBSOLETE ENDS WITH S/N _______________

BEGINS WITH S/N ______________

NOT SHOWN:

ALL CONNECTORS ARE SHOWN WITH REAR VIEWS

FOOTNOTES:

NOTE:

16

ID0051890

194

195

196

197

198

ELECTRICAL DIAGRAM GAUGE HARNESS JT920_JT920C

TO ENGINE/FRAME HARNESS

YEL/BLK {51}

YEL/BRN {52}

RED {4}

BLK {1}

RED/BLK GRN

A B

B A

WHT/BLK {14}

GRA WHT/BLU {17} {15}

{25}

{31}

12 11 10 9

8

7

4

5

6

1

2

3

BLU/GRN {30} ORG/BLK {12}

YEL/BLU {48} ORG {3}

WHT/BLK ORG/BLU {8} {5} BRN/ORG {6}

16

FUEL SENDER

HYDRAULIC TEMP LIGHT

10 ENGINE OIL

11

PSI LIGHT

HYDRAULIC FILTER LIGHT

9

17

12

8 ORG/BLU {5}

ORG/BLU {5} WHT/BLK {14}

BRN {29} GRA {17}

HOUR METER

WHT/BLU {15}

3

WARNING LIGHT ALARM BLU/GRN {30}

FUEL GAUGE

BLK {1} ORG/BLK {12}

FLUID SELECT SWITCH

1

2

7 8 4 5 2 6 3 1

I

PUR {3A}

G

ORG {3}

S BLK {1}

6

15

YEL/BLU {48}

GRA {29}

VOLT METER GAUGE

VARIABLE THROTTLE

PUR {3A}

I G

BLK {1}

18

YEL/BRN {52}

7 8 4 1 5 2 6 3

ORG (3) YEL/BLK {51}

WATER GAUGE

7

I G S

PUR {3A}

COLD START SWITCH

4

BLK {1} GRA {33}

2 3

ORG/BLU {5} BRN/ORG {6}

REMOTE START SWITCH

5 ORG {3} RED/BLK {25}

IGN

RED {4}

ST

WHT/BLK {8}

14 13

06

ORG/BLU {5}

BAT ACC

ORG {3}

ID0112778

199

ELECTRICAL DIAGRAM GAUGE HARNESS JT920_JT920C REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

QTY

215-133 1 215-415 306-603 1 215-2594 1 217-789 1 165-817 1 214-852 1 214-961 214-962 215-129 1 215-415 217-512 1 215-415 217-020 2 217-046 1 217-028 1 217-021 1 217-027 1 217-036 1 306-607 1 306-608 1 217-762 1 165-817 1 217-549 214-293 1 217-764 1 165-817 1

DESCRIPTION

FUEL GAUGE NITE-LIGHT KIT (12V DC) AUDIO ALARM HOUR METER ROCKER SWITCH SWITCH GASKET IGNITION SWITCH KEY, PAIR (BASE CODE) SWITCH MOUNTING NUT VOLT METER NITE-LIGHT KIT (12V DC) WATER TEMPERATURE GAUGE NITE-LIGHT KIT (12V DC) PILOT LIGHT BULB (12V DC) INSERT (BLACK) BLANK INSERT (RED) ENG OIL PSI INSERT (RED) HYD OIL HI TEMP INSERT (YEL) HYD OIL PSI HORN BUTTON BUTTON COVER ROCKER SWITCH (SPDT) SWITCH GASKET FUEL SENDER GAUGE HARNESS ROCKER SWITCH (SPDT) SWITCH GASKET

REMARKS

OFF-MOMENTARY ON INCL KEYS & NUT

ON-ON

MOMENTARY ON-OFF-MOMENTARY ON

NOT SHOWN:

FOOTNOTES:

NOTE:

06

ID0112778

200

ELECTRICAL DIAGRAM

GAUGE HARNESS W/AUTOBORE SELECT JT920 / JT920C / JT920L / JT921

TO ENGINE/FRAME HARNESS RED {4}

BLK {1}

RED/BLK GRN

A B WHT/BLK

12 11 10 9

{14}

1

YEL/BLU {48} YEL/BLK {51}

WHT A B

CAVITY PLUG

A B

GRA WHT/BLU {17} {15}

{25}

{31}

2

3

4

8

7

5

6

BLU/GRN {30} ORG/BLK {12}

ORG {3}

WHT/BLK ORG/BLU {8} {5} BRN/ORG {6}

16

FUEL SENDER

YEL/BRN {52} BLK

HYDRAULIC TEMP LIGHT

10 ENGINE OIL

11

PSI LIGHT

HYDRAULIC FILTER LIGHT

9

17

12

8 ORG/BLU {5}

18

ORG/BLU {5} WHT/BLK {14}

WHT

BRN {29}

GRA {17}

HOUR METER

WHT/BLU {15}

3

WARNING LIGHT ALARM BLU/GRN {30}

BLK {1}

ORG/BLK {12}

BLK

FUEL GAUGE

FLUID SELECT SWITCH

2

7 8 4 5 2 6 3

15

1

1

I PUR {3A}

G

ORG {3}

S BLK {1}

YEL/BLU {48}

GRA

6

VOLT METER GAUGE

{29}

AUTOBORE SELECT

I G

BLK {1}

15

YEL/BRN {52}

7 8 4 1 5 2 6 3

PUR {3A}

ORG (3) YEL/BLK {51}

PUR {3A}

WATER GAUGE

7

I G S

COLD START SWITCH

4

BLK {1} GRA {33}

2 3

ORG/BLU {5}

BRN/ORG {6}

REMOTE START SWITCH ORG {3} RED/BLK {25}

14

06

5

ORG/BLU {5} IGN

RED {4}

ST

WHT/BLK {8}

13

BAT ACC

ORG {3}

ID0043895

201

ELECTRICAL DIAGRAM

GAUGE HARNESS W/AUTOBORE SELECT JT920 / JT920C / JT920L / JT921 REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

QTY

215-133 1 215-415 1 306-603 1 215-2594 1 217-789 1 165-817 1 214-852 1 214-961 214-962 215-129 1 215-415 1 217-512 1 215-415 1 217-020 2 217-046 1 217-028 1 217-021 1 217-027 1 217-036 1 306-607 1 306-608 1 217-762 2 165-817 2 217-549 214-293 1 214-495 1

DESCRIPTION

FUEL GUAGE NITE-LIGHT KIT (12V DC) AUDIO ALARM HOUR METER ROCKER SWITCH SWITCH GASKET IGNITION SWITCH KEY, PAIR SWITCH MOUNTING NUT VOLT METER NITE-LIGHT KIT (12V DC) WATER TEMPERATURE GUAGE NITE-LIGHT KIT (12V DC) PILOT LIGHT BULB (12V DC) INSERT (BLK) BLANK INSERT (RED) ENG OIL PSI INSERT (RED) HYD OIL HI TEMP INSERT (YEL) HYD OIL PSI HORN BUTTON BUTTON COVER ROCKER SWITCH (SPDT) SWITCH GASKET FUEL SENDER GUAGE HARNESS AUTO BORE JUMPER

REMARKS

OFF-MOMENTARY ON

ON-ON

NOT SHOWN:

FOOTNOTES:

NOTE:

ALL CONNECTORS ARE SHOWN WITH REAR VIEWS

06

ID0043895

202

ELECTRICAL STRIKE SYSTEM

1

11

2

23

12

3

14

4

24

13

16

15

10 7

19

9

8 6 18

17 5

21

20

N

22

806-095

203

ELECTRICAL STRIKE SYSTEM REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

362-620 105-836 105-832 217-041 217-720 217-310 217-311 121-055 353-289 353-290 115-671 363-507 105-825 259-210 259-234 260-223 215-799 216-032 211-042 217-232 274-483 274-727 217-241 197-232 197-079 214-173 214-554 214-175 106-386 305-997 217-331 216-023 216-064 211-083 355-478 105-843 106-640 106-670

QTY

1 3 3 1 1 1 1 1 1 4 8 8 1 1 1 1 1 1 1 1 4 1 1 1 1 1 4 4 4

REMARKS

DESCRIPTION

LIGHT COVER FLG LOCK BOLT (1/4-NC X 1/2") FLG LOCKNUT (1/4-NC) STROBE LIGHT (12V DC) BULB (12 V DC) STROBE LIGHT (12V DC) BULB (12V DC) LENS (AMBER) UPPER STABILIZER TUBE UPPER STABILIZER TUBE - WET BULK EDGE (1/16" SOLD PER 1") LIGHT POST WELDM'T FLG LK BOLT (3/8-NC X 3/4") TRAFFIC CONE - ORANGE CONE CLIP BARRIER TAPE (3" X 1000') VOLTAGE STAKE VOLT LIMITER (EL STR SYSTM) VOLTAGE LIMITER CABLE CONTROL MODULE ESID GRAPHIC OVERLAY "Z" FCC LABEL W/ (CE) MARK ESID MODULE ESID MODULE REBUILT ESID MODULE - REBUILT ELEC STR SYS CABLE (3.7M) CURRENT COIL CABLE STROBE PIGTAIL HARNESS FLG LOCKNUT (M8-1.25) BACK COIL COVER SMALL FERRITE CLAMP-ON CURRENT TRANSFORMER CURRENT TRANSFORMER CURRENT TRANSFORMER COIL COVER SCREW (M6-1.00 X 80MM) SCREW (M6-1.00 X 20MM, BUT SOC) NUTSERT (M6-1.00)

OBSOLETE

OBSOLETE, W/O WATER TANK WITH WATER TANK

OBSOLETE OBSOLETE OBSOLETE SEE FOOTNOTE 2.

SEE FOOTNOTE 1.

SEE FOOTNOTE 2.

SEE FOOTNOTE 1.

REPLACEMENT FOR 217-232 REBUILT 217-241 SEE FOOTNOTE 2.

SEE FOOTNOTE 1.

OBSOLETE, SEE FOOTNOTE 2, & SEE FOOTNOTE 3.

OBSOLETE, SEE FOOTNOTE 1.

SEE FOOTNOTE 1.

FOOTNOTES

1.

2.

3.

BEGINS WITH S/N 2T2624 - JT920, & S/N 2T2639 - JT920L. ENDS WITH S/N 2T2623 - JT920, & S/N 2T2638 - JT920L. REF 20 OBSOLETED, 216-023 REPLACED WITH 101-143.

NOTE:

N

806-095

204

205

206

207

208

209

210

RELAY PANEL (CATERPILLAR DIESEL) 10

10

10 8

7

5 12

9

14 3 13

5 2

4

13

6

11 11

6

1

03

ID0028289

211

RELAY PANEL (CATERPILLAR DIESEL) REF PART NO. NUMBER

QTY

1. 350-503 2. 320-825 1 3. 105-826 4. 516-098 5. 106-379 8 6. 106-385 8 7. 217-937 1 8. 214-502 2 9. 215-914 1 10. 106-049 6 11. 106-048 6 12. 213-105 1 13. 214-908 2 14. 273-198 1

DESCRIPTION

MOBILING STATION ELECTRICAL BRACKET FLG LK BOLT (3/8"-NC X 3/4") SOLENOID VALVE (SINGLE) FLG LK SCREW (M6-1.00 X 20 MM) FLG LOCKNUT (M6-1.00) START BYPASS DELAY TIMER DELAY TIMER DRILL FLUID CONTROLLER BOLT (#10-24 X 3/4" PLPS) LOCKNUT (#10-24) BUSSMAN (JT920 T2 D.V.E.C.) ON-OFF KEY SWITCH TRACKER CONTROL

REMARKS

SEE NOT SHOWN FOR REPLACEMENT KEYS.

NOT SHOWN:

215-1818 215-1819

KEY, TRACKER CONTROL SWITCH, SINGLE KEY, TRACKER CONTROL SWITCH, DOUBLE

FOOTNOTES:

NOTE:

03

ID0028289

212

NOTES:

ID0134963

213

LUBRICATOR SYSTEMS

214

THREAD LUBRICATOR

2

4

27 25

20

6 9 23

8

5

24 11

1

26

19 21 7 2

27

15

11

3

18 34 10

32 7 3

8

30

16

29

14 PIP E

31

LU BE

13 28

12

17 33 12

22

08

ID0042993

215

THREAD LUBRICATOR REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

QTY

105-818 1 106-070 2 110-573 2 117-257 1 307-879 1 303-371 1 125-301 2 105-085 5 105-890 1 125-136 1 130-331 1 307-873 1 329-298 1 359-925 1 157-716 1 359-869 1 359-871 1 256-663 1 256-026 1 256-1003 1 154-342 1 149-879 1 514-163 1 322-289 2 106-386 2 149-221 1 307-874 1 110-095 1 105-106 4 105-047 2 106-382 2 106-162 2 307-414 1 118-461 1 106-327 2 106-386 2 117-162 1

DESCRIPTION

REMARKS

BOLT (1/4-NC X 1-1/2") SHLD BLT (1/2" X 3/8", 3/8-NC) BOLT-ON CLAMP (1",SOLD PER SET) TORSION SPRING SHAFT PEDAL COMPOSITION BUSHING (.750") LOCKNUT (1/4-NC) SEAL WASHER (7/16") DETENT BALL (.187", CHROME) CONNECTOR LINK (1-1/4") BEFORE S/N PIVOT BRACKET AFTER S/N PIVOT BRACKET LUBER BASE GREASE SEAL GREASE BARREL PLUNGER GREASE (14 OZ CARTRIDGE) GREASE (14 OZ CART, ARTIC GD) TOOL JT LUBE, 14OZ CART,ENVTL FRIENDLY METAL FREE, ALL WEATHER CONNECTOR (06S-06O90) HYD LINE (-06) BK CONNECTOR (06O-06OBK) BACKUP (BOLT-ON) LOCKNUT (M8-1.25,PRV TRQ,10.9) NOZZLE PLUNGER MACHINERY BUSHING (3/4", 18GA) BOLT (1/4-NC X 2") LOCKNUT (3/8-NC) FLG LK SCREW (M10-1.5 X 20mm) FLG SCREW (M8-1.25 X 20mm) POLY GUIDE BLOCK SHIM (.135) SCREW (M8-1.25 X 30mm) FLG LOCKNUT (M8-1.25) COMPRESSION SPRING (.438")

NOT SHOWN:

FOOTNOTES:

NOTE:

08

ID0042993

216

NOTES:

ID0134963

217

ANCHOR SYSTEMS

218

219

220

4 POINT ANCHOR SYSTEM

16 15 17

15

9

10 23

8

16

7 24

18 25 4 10 1

22 15 5

13

12 11

3 2 19 14 6 21 20

01

ID0139777

221

4 POINT ANCHOR SYTEM REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

QTY

355-597 2 355-514 4 355-503 1 355-566 4 355-499 4 355-575 AR 355-498 1 355-510 1 110-013 2 110-032 2 106-540 8 106-355 8 106-334 1 106-089 1 106-266 8 106-332 4 355-497 3 355-505 1 106-564 4 355-582 4 355-519 AR 355-515 4 351-234 AR 115-618 AR 105-535 AR 190-137 AR

DESCRIPTION

REMARKS

DOUBLE ANCHOR BRACKET NUT HOUSING NUT RETAINER ANCHOR SHAFT ANCHOR NUT 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 (M16-2.00) SCREW (M12-1.75 X 50MM) HEX NUT (M12-1.75) FLG NUT (M10-1.5) SCREW (M10-1.5 X 70MM) TROLLEY SPACER NUT DRIVER SCREW (M10-1.5 X 100MM) STAKE BIT (INCL. REF. NO'S 23, 24, AND 25) 6" AUGER ASSEMBLY TUBE SOCKET COUPLING SEAR COMPRESSION SPRING ROLL PIN (1/8 IN. X † IN.) SLIP-LATCH REPAIR KIT (INCL. REF. NO'S. 23, 24, AND 25)

NOT SHOWN:

FOOTNOTES:

NOTE:

01

ID0139777

222

AUTO-ANCHOR SYSTEM ENDS WITH S/N:

39

21 22 40

19

20

18

41 7 38

17

38 16

25

37 8 23 41 7

A PORT B PORT

24 27 12 36

13 16

26 25

31 28

32

6 10

15

25 9 7

29 11 6

30

31

7

14 2 3

B PORT

34 35

1

4

A PORT

5

33 1

17

ID0035732

223

AUTO-ANCHOR SYSTEM ENDS WITH S/N: REF PART NO. NUMBER

1.

2.

3.

4.

5.

348-315 105-833 105-256 348-550 347-125 310-119 347-128 310-120 347-806 310-118 105-828 105-884 179-228 350-290 305-643 354-451 348-965 106-799 107-331 348-963 178-598 154-369 179-227 154-255 107-308 105-052 350-289 165-909 106-574 106-379 350-375 158-700 500-347 166-278 500-658 106-707 106-685

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

QTY

2 4 4 2 2 2 2 2 2 4 8 2 2 2 2 2 2 2 2 2 2 2 4 2 2 2 4 4 2 2 4 8

DESCRIPTION

ANCHOR PLATE FLG LOCKNUT (1/2-NC) CARRIAGE BOLT (1/2-NC X 3-1/2") DRILL FRAME AUGER (150MM) 150MM AUG WELD AUGER (100MM) 100MM AUG WELD ANCHOR SHAFT BIT ANCHOR SHAFT BIT FLG LK BOLT (1/2-NC X 3/4") WASHER (.531") CYL PIN (1") CENTERING CAP CENTERING CAP STOP TUBE STOP TUBE ROLL PIN (M12 X 45MM) ROLL PIN ANCHOR SHAFT BAR, ANCHOR SHAFT CONNECTOR (06O-10S) CYL PIN (1.25") UNION (04O-04OFX90) SCREW (M12-1.75 X 75MM) BOLT (3/8-NC X 1-1/4") ANCHOR DRIVER KEY (5/16" X 1-1/8") CLIP NUT (M6-1.00) FLG LK SCREW (M6-1.00 X 20MM) COVER HYD MOTOR SEAL REPAIR KIT SHAFT/ASSEMBLY BEARING SEAL REPAIR KIT SCREW (M12-1.75 X 45MM, SOC) LOCKNUT (M12-1.75, PRV TRQ, 10.9)

REMARKS

ENDS WITH S/N______ BEGINS WITH S/N______, ENDS WITH S/N______ BEGINS WITH S/N______, ENDS WITH S/N______ BEGINS WITH S/N______,

SEE FOOTNOTE 1 SEE FOOTNOTE 1 SEE FOOTNOTE 1

OLD STYLE NEW STYLE OLD STYLE NEW STYLE, SEE FOOTNOTE 3 ENDS WITH S/N______ BEGINS WITH S/N______, SEE FOOTNOTE 1

NOT SHOWN:

FOOTNOTES:

1. IF REPLACING ITEM 5 OR 12 WITH NEW STYLE, THE OTHER MUST ALSO BE REPLACED. 2. 105-762 AND 106-685 MOUNTING HARDWARE OPTIONAL IN PLACE OF ROLL PIN

NOTE:

1.

17

REFER TO O-RING CHART (800-301) IN BACK OF BOOK FOR REPLACEMENT OF O-RINGS.

ID0035732

224

AUTO-ANCHOR SYSTEM ENDS WITH S/N: REF PART NO. NUMBER

QTY

DESCRIPTION

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

2 2 2 2 2 4 2 2 4 4 4 2 4 2 2 4

ANCHOR MOTOR MOUNT SPRING LOADED PIN COMPOSITION BUSHING (1") CYL (2" X 1" X 24") COMPOSITION BUSHING (1.25") CONNECTOR (04S-04O90) HOSE (04OFX90-32"-3000) HOSE (04OFX90-8.5"-3000) BK CONNECTOR (04O-04O90BK) BK CONNECTOR (04O-04OBK) SCREW (M4-.70 X 30MM) CYL SLIDE TUBE BUSHING LEVER EXTENSION SPRING (4.062") FLG LK BOLT (1/2-NC X 1-1/2")

350-282 347-888 125-770 151-096 125-771 154-252 515-011 515-085 154-355 154-275 106-796 350-301 348-333 348-331 115-601 105-831

REMARKS

REFER TO 052-283 FOR PROPER INSTALLATION

NOT SHOWN:

FOOTNOTES:

NOTE:

17

ID0035732

225

226

227

228

229

230

231

232

233

234

235

236

237

238

NOTES:

ID0134963

239

FLUID SYSTEMS

240

TANK SUPPORT

3 1

2 10

1

11

6

5

4

7

8 9 12 13

K

805-030

241

TANK SUPPORT REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

QTY

106-992 12 353-864 1 344-760 1 106-098 2 105-340 4 353-822 1 364-276 1 157-488 157-490 157-189 190-053 353-168 1 105-248 4 106-551 12 106-188 2 105-834 3 105-825 3

DESCRIPTION

FLG LK SCREW (M8-1.25 X 25mm) VALVE COVER VALVE COVER FLG BOLT (3/4-NC X 2", GD8) FLG LOCKNUT (3/4-NC) WATER TANK SUPPORT WATER TANK (63.0 GAL) CAP/LID (WATER TANK) BK CONNECTOR (16NF, POLY) O-RING (325 D70) POLY PATCH TANK REPAIR KIT SIDE PLATE SCREW (M12-1.75 X 25mm, SOC) CLIP NUT (M8-1.25) BOLT (3/4-NC X 10") FLG LOCKNUT (3/8-NC) FLG LK BOLT (3/8-NC X 3/4")

REMARKS

BEGINS WITH S/N 2N2402

BEGINS WITH S/N 2W0228 SEE FOOTNOTE 2

SEE FOOTNOTE 1

FOOTNOTES

1. TORQUE BOLT TO 271 N-M (200FT-LBS) 2. HOLES MAY REQUIRE MODIFICATION FOR NEW FITTINGS.

NOTE:

REFER TO O-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS.

K

805-030

242

243

244

2 22

FLUID PUMP 9 GPM

4 A

1 2

2

3 1

07

ID0042991

245

FLUID PUMP 9 GPM

REF PART NO. NUMBER

QTY

158-465

DESCRIPTION

-

500-2416 500-2417 2

FLUID PUMP

REMARKS

BEGINS WITH S/N 2N2090

OIL SLINGER KIT CRANKSHAFT SEAL

1. 190-933 1 PACKING REPAIR KIT (MUD PUMP) 2. 190-815 2 VALVE REPAIR KIT 3. 500-903 2 CERAMIC CYLINDER 4. 499-015 1 FLUID CYLINDER (HEAD)

NOT SHOWN:

499-086

2

VALVE COVER

FOOTNOTES:

NOTE:

07

ID0042991

246

247

248

FLUID PUMP PLUMBING

25 5

7 6

9

12 11 10

13 24 17

14

23

19

15

17 16 21

2

3

8 1

18 22

20

17 4 17

10

ID0035751

249

FLUID PUMP PLUMBING REF PART NO. NUMBER

1.

159-240 153-242 515-003 154-490 149-324 190-963 154-747 154-829 154-296 117-672 154-396 158-465 514-145 154-248 154-272 156-732 154-466 159-088 190-186 155-936 154-971 154-349 515-073 155-706 116-632 117-713 115-754 158-579 110-538 156-590 154-352

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

QTY

DESCRIPTION

REMARKS

1 AR 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 4 1 1 1 1 1 1 1 1

WATER SWIVEL WATER SWIVEL HOSE (08OFX90-31"-3000) CONNECTOR (12N-08O90) FLOW CHECK (08NF-08NF/64PSI) REPAIR KIT (CHECK VALVE) HOSE (08OFX45-21"-3000) HOSE (08OFX45-19"-3000) CAP (040F) ABRASION SLEEVE (1.00" X 20") BK CONNECTOR (08O-08O90BK) FLUID PUMP CROSS (08O) REDUCER STEM (04O) REDUCER NUT (08OF) CONNECTOR (08J-08O) CONNECTOR (08S-08S) QDC BODY (08-08SF) SEAL REPAIR KIT DUST PLUG (1/2"-3/4") HOSE (08OFX90-78"-3000) CONNECTOR (08N-08O) HOSE (08OFX-127"-3000) O-RING (908 D90) ABRASION SLEEVE (1.59" X 130") ABRASION SLEEVE (1.00" X 76") ABRASION SLEEVE (1.59" X 30") SHUTOFF (08NF-08NF) VALVE LEVER HYD LINE (-08) CONNECTOR (08N-08O90)

OBSOLETE SEE FOOTNOTE 1

2 1 2

OIL SLINGER KIT CRANKSHAFT SEAL PACKING REPAIR KIT VALVE REPAIR KIT VALVE CHAMBER/FLUID CYLINDER CLINDER, CERAMIC

USE WITH JT921S

SEE NOT SHOWN FOR SERVICE PARTS

NOT SHOWN:

500-2416 500-2417 190-933 190-815 499-015 500-903 FOOTNOTES:

1. INSTALL USING NICKLE THREAD SEALING TAPE (117-555) AND (500-1948) THREAD COMPOUND OVER THE NICKLE TAPE ON MALE THREADS.

NOTE:

REFER TO O-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS.

10

ID0035751

250

MUD PUMP PLUMBING ENDS WITH S/N 2S2778

5 4

22 3 1

6

10

37 16 14

7 8

2 24 13

11 12

13 15

12 29

36

27

21

35

30

17 23

27

18

30 28

19 20

9 33

25

34

26 26

31 32 4 32

11

ID0111324

251

MUD PUMP PLUMBING ENDS WITH S/N 2S2778 REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

115-130 154-968 154-354 159-247 115-442 114-010 115-161 115-115 154-396 154-748 514-145 154-248 154-272 154-802 156-732 154-339 154-466 159-088 190-186 154-708 154-971 154-354 155-203 217-543 155-706 115-811 117-679 115-754 158-579 115-115 156-590 154-349 515-102 515-073 154-354 154-838 515-003 159-240 158-411 197-171 158-465 197-172 105-460 154-482

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

QTY

1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 2 1 1 2 1 1 -

DESCRIPTION

1 1

PIPE TEE HOSE (100FX-26"-2750) CONNECTOR (08O-12N) FLOW CHECK (12NF-12NF) ELBOW (08N-12N90) ELBOW (08NF-08NF90) NIPPLE (08N-3.5") STREET ELBOW (08N-08NF90) BK CONNECTOR (08O-08O90 BK) HOSE (08OFX45-23"-3000) CROSS (08O-080-080-08O) REDUCER STEM (04O) REDUCER NUT (08OF) HOSE (04OFX90-26"-3000) CONNECTOR (08J-08O) CONNECTOR (04N-04O) CONNECTOR (08S-08S) QDC BODY (08-08SF) SEAL REPAIR KIT HOSE (08OFX-34"-3000) HOSE (08OFX90-78"-3000) CONNECTOR (08O-12N) BK CONNECTOR (08N-08O90) PRESSURE GAUGE (3000 PSI) O-RING (908 D90) ABRASION SLEEVE (1.59" X 20") ABRASION SLEEVE (1.59" X 32") ABRASION SLEEVE (1.59" X 30") SHUT-OFF (08NF-08NF) STREET ELBOW (08N-08NF90) HYD LINE (-08) CONNECTOR (08N-08O) HOSE (08OFX-110"-3000) HOSE (08OFX-127"-3000) CONNECTOR (08O-12N) HOSE (08OFX90-44"-3000) HOSE (08OFX90-31"-3000) WATER SWIVEL MUD PUMP MUD PUMP - REBUILT MUD PUMP MUD PUMP - REBUILT WASHER (13/16") CONNECTOR (04N-04O90)

2 1 2

OIL SLINGER KIT CRANKSHAFT SEAL PACKING REPAIR KIT VALVE REPAIR KIT VALVE CHAMBER/FLUID CYLINDER CLINDER, CERAMIC

-

REMARKS

ENDS WITH S/N 2N2089 REBUILT 158-411 BEGINS WITH S/N 2N2090, SEE NOT SHOWN FOR SERVICE PTS REBUILT 158-465

NOT SHOWN:

500-2416 500-2417 190-933 190-815 499-015 500-903 FOOTNOTES:

NOTE:

REFER TO O-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS.

11

ID0111324

252

FLUID PUMP PLUMBING W/OUT TANK TO PRIORITY VALVE

2 24

3

22

TO DRIVE CONTROL VALVE

9

TO TANK

29

1

5

12

12

4 10 11

8

23 6

7

14

25 15 26 20 28

30

13 27

TO DRILL CARRIAGE

16 19 21

17

18 14

ID0035754

253

FLUID PUMP PLUMBING W/OUT TANK REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

158-465 115-924 154-972 154-322 106-386 157-784 106-602 154-255 154-694 154-473 117-679 115-811 515-197 154-711 154-233 158-469 190-725 350-622 105-826 105-971 105-340 105-265 117-189 154-747 154-352 154-674 158-842 154-322 514-378 154-256 117-672

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

QTY

DESCRIPTION

REMARKS

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

FLUID PUMP ABRASION SLEEVE (1.59" X 88") HOSE (08OFX-94"-3000) CONNECTOR (08O-10S90) FLG LOCKNUT (M8-1.25) HYD FLOW VALVE SCREW (M8-1.25 X 80mm) UNION (04O-04OFX90) HOSE (04OFX-98"-3000) RUN TEE (10S-08O-04O) ABRASION SLEEVE (1.59" X 32") ABRASION SLEEVE (1.59 X 20") HOSE (08OFX90-23"-3000) HOSE (08OFX-30"-3000) CONNECTOR (08S-08O) GEAR MOTOR (3.0 CUI/REV) SEAL REPAIR KIT FLUID PUMP / WEIGHT SUPPORT FLG LK BOLT (3/8-NC X 1") BOLT (3/4-NC X 10-1/2") FLG LOCKNUT (3/4-NC) FLG BOLT(1/2-NC X 2") ABRASION SLEEVE (1.25" X 44") HOSE (08OFX45-21"-3000) CONNECTOR (08N-08O90) HOSE (08OFX-24"-3000) RELIEF VALVE (2000PSI) CONNECTOR (08O-10S90) BRANCH TEE (080-10S-08S) UNION (080-08OFX90) ABRASION SLEEVE (1.00" X 20")

SEE NOT SHOWN FOR SERVICE PARTS

2 1 2

OIL SLINGER KIT CRANKSHAFT SEAL PACKING REPAIR KIT VALVE REPAIR KIT VALVE CHAMBER/FLUID CYLINDER CLINDER, CERAMIC

BEGINS WITH S/N 2N2090 BEGINS WITH S/N 2N2090

NOT SHOWN:

500-2416 500-2417 190-933 190-815 499-015 500-903 FOOTNOTES:

NOTE:

14

ID0035754

254

FLUID TANK PLUMBING

11

6

11

5 4

12 3 18

13

1

5 16

2

19

9 14 10 7 8

15

10 14 7 17 TO MUD PUMP

16

ID0042829

255

FLUID TANK PLUMBING REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

QTY

115-206 1 115-208 1 155-232 1 155-233 1 110-353 2 116-460 AR 115-440 2 149-137 1 149-113 1 115-163 2 115-174 2 364-276 157-488 157-490 157-189 190-053 158-579 1 514-024 1 115-151 2 153-133 1 153-198 155-137 1 105-003 2 157-490 1 107-563 1

DESCRIPTION

NIPPLE (16N-2-1/2") ELBOW (16NF-16NF90) FHC ADAPTER (16-16N) FHC BODY (16-16H) WORM CLAMP (3/4" - 1-1/5") BULK HOSE (1", SOLD PER 1') STREET ELBOW (16N-16NF90) FHC BODY (16FM-16N) 3-WAY SHUT-OFF (16NF) VALVE ALL THREAD (12N) SCH 80 NIPPLE (12N-1.500" LG) SCH 40 WATER TANK CAP/LID 5" (NEW THREAD) BK CONNECTOR (16NF, POLY) O-RING (325 D70) POLY PATCH TANK REPAIR KIT SHUT-OFF (08NF-08NF) BRANCH TEE (08N-16N-16NF) REDUCER (16N-12NF) STRAINER (12NF) SCREEN (20-MESH) S/O COUPLER (16N-16H90) FLG LOCKNUT (5/16-NC) BK CONNECTOR (16NF POLY) U-BOLT (5/16-NC X 1 7/8")

REMARKS

USE 1@ 42"

STEEL

BEGINS WITH S/N 2W0228 SEE FOOTNOTE 2

USE 150-2416 TRANSPARENT FILTER BOWL, FOR BOWL REPLACEMENT.

NOT SHOWN:

FOOTNOTES:

1. REFER TO O-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS. 2. HOLES MAY REQUIRE MODIFICATION FOR NEW FITTINGS.

NOTE:

16

ID0042829

256

WASH WAND

1 2

3

4

5

6

7 8

08

ID0133890

257

WASH WAND REF PART NO. NUMBER

1.

2.

3.

4.

5.

6.

7.

8.

QTY

259-374 150-2121 1 115-170 1 259-353 1 259-197 1 190-179 1 514-141 1 154-804 1 154-233 1 159-089 1 190-186 1

DESCRIPTION

REMARKS

WATER SPRAY GUN (PARTS ASS'Y) NOZZLE (#05, 04N, 15 DEG, SS) 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 (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS.

08

ID0133890

258

NOTES:

ID0134963

259

PIPE LOADER SYSTEMS

260

261

262

NOTES:

ID0134963

263

ACCESSORIES

264

FLUID MIXING ACCESSORIES

1 3 2

4

8 6

5

7

9

10

11

10

ID0109085

265

FLUID MIXING ACCESSORIES REF PART NO. NUMBER

QTY

DESCRIPTION

1. 259-195 2. 259-196 3. 259-804 4. 259-805 5. 259-807 6. 259-808 7. 259-809 8. 259-810 9. 259-821 10. 259-822 11. 259-832

1 1 AR AR AR AR AR AR AR AR AR

VISCOSITY FUNNEL VISCOSITY CUP BENTONITE, QUIK-GEL (50 LB) LIQUID POLYMER, EZ-MUD (5 GAL) BENTONITE, BORE-GEL (50 LB) VISCOSIFIER, LIQUI-TROL (5 GAL) POWDER POLYMER, QUIK-TROL (20 LB) WET AGENT, CON-DET (5 GAL) 'PAC-R' FILTRATION CONTROL 'BARAZAN D+' VISCOSIFIER 'NO SAG' (20# BOX/10-2#BAGS)

1 1

DRILLING FLUID TEST KIT SHEAROMETER

REMARKS

NOT SHOWN:

191-158 259-487

FOOTNOTES:

NOTE:

10

ID0109085

266

GROUNDING CABLES

8

1

7

2

6 3

4 5

05

ID0132451

267

GROUNDING CABLES REF PART NO. NUMBER

1 2 3 4 5 6 7 8

215-769 215-813 215-768 106-462 106-220 215-773 106-454 215-775 215-776

QTY

DESCRIPTION

1 1 AR 1 1 1 1 1 1

GROUND CLAMP GROUND CABLE (1/0 GA X 25') GROUND CABLE (1/0 GA) BOLT (3/8-NC X 1-1/4", SIL BRZ) INT STAR WASHER (3/8", SIL BRZ) RING LUG TERMINAL (27/64") LOCKNUT (3/8-NC, SIL BRZ) GROUND ROD SLIDE DRIVER

REMARKS

INCL REF USE 25 FT

NO.'S 1 AND 5

NOT SHOWN:

FOOTNOTES:

NOTE:

05

ID0132451

268

269

270

271

272

GARDEN HOSE ADAPTER

1 2 3

4

02

ID0091310

273

GARDEN HOSE ADAPTER REF PART NO. NUMBER

1 2 3 4

159-891 114-038 115-271 115-134 159-500

QTY

1 1 1 1

DESCRIPTION

GARDEN HOSE ADAPTER NIPPLE (12N-12NH) REDUCER (24N-12NF) COLLAR (24NF) FHC BODY (24-24N)

REMARKS

INCL. REF No's 1 - 4

NOT SHOWN:

FOOTNOTES:

NOTE:

02

ID0091310

274

NOTES:

ID0134963

275

MISCELLANEOUS

276

Torque Information Tightening Guidelines Values given on the following pages are a guide. Do not use these values if a different torque value or tightening procedure is given for specific application. 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, tighten only to torque value of original fastener.

Make sure fastener threads are clean and that the threads are properly started. This will prevent them from cross threading or galling when tightened.

Lubed means cleaned, dry bolts lubricated with a standard, medium-viscosity machine oil. Lubricate all contact areas of the bolts and washers. Lubricating the bolts is the suggested torque method.

V01

ID0493104

277

SAE Bolt Torque Torque estimates based on clamp load (75% of proof strength) as specified in SAE J429 and ASME 574.

Diameter and Thread Pitch

SAE Grade 5

SAE Grade 8

Socket Head Cap Screw

Dry

Lubed

Dry

Lubed

Dry

Lubed

1/4-20

101 in•lb 11.4 N•m

76 in•lb 8.6 N•m

143 in•lb 16.2 N•m

107 in•lb 12.1 N•m

168 in•lb 19 N•m

120 in•lb 13.6 N•m

1/4-28

116 in•lb 13.1 N•m

87 in•lb 9.8 N•m

147 in•lb 16.6 N•m

123 in•lb 13.9 N•m

192 in•lb 21.7 N•m

144 in•lb 16.3 N•m

5/16-18

209 in•lb 23.6 N•m

157 in•lb 17.7 N•m

295 in•lb 33.3 N•m

221 in•lb 25 N•m

348 in•lb 39.3 N•m

264 in•lb 29.8 N•m

5/16-24

231 in•lb 26.1 N•m

174 in•lb 19.7 N•m

327 in•lb 36.9 N•m

245 in•lb 27.7 N•m

384 in•lb 43.4 N•m

288 in•lb 32.5 N•m

3/8-16

372 in•lb 42 N•m

276 in•lb 31.2 N•m

44 ft•lb 59.7 N•m

33 ft•lb 44.7 N•m

51 ft•lb 69.1 N•m

38 ft•lb 51.5 N•m

3/8-24

420 in•lb 47.5 N•m

312 in•lb 35.3 N•m

49 ft•lb 66.4 N•m

37 ft•lb 50.2 N•m

58 ft•lb 78.6 N•m

43 ft•lb 58.3 N•m

7/16-14

49 ft•lb 66.4 N•m

37 ft•lb 50.2 N•m

70 ft•lb 94.9 N•m

52 ft•lb 70.5 N•m

81 ft•lb 109.8 N•m

61 ft•lb 82.7 N•m

7/16-20

55 ft•lb 74.6 N•m

41 ft•lb 55.6 N•m

78 ft•lb 105.8 N•m

58 N•m 78.6 N•m

91 ft•lb 123.4 N•m

68 ft•lb 92.2 N•m

1/2-13

75 ft•lb 101.7 N•m

57 ft•lb 77.3 N•m

106 ft•lb 143.7 N•m

80 ft•lb 108.5 N•m

124 ft•lb 168.1 N•m

93 ft•lb 126.1 N•m

1/2-20

85 ft•lb 115.2 N•m

64 ft•lb 86.8 N•m

120 ft•lb 162.7 N•m

90 ft•lb 122 N•m

140 ft•lb 189.8 N•m

105 ft•lb 142.4 N•m

5/8-11

150 ft•lb 203.4 N•m

113 ft•lb 153.2 N•m

212 ft•lb 287.4 N•m

159 ft•lb 215.6 N•m

238 ft•lb 322.7 N•m

179 ft•lb 242.7 N•m

5/8-18

170 ft•lb 230.5 N•m

127 ft•lb 172.2 N•m

240 ft•lb 325.4 N•m

180 ft•lb 224 N•m

270 ft•lb 366.1 N•m

202 ft•lb 273.9 N•m

3/4-10

267 ft•lb 362 N•m

200 ft•lb 271.2 N•m

376 ft•lb 509.8 N•m

282 ft•lb 382.3 N•m

423 ft•lb 573.5 N•m

317 ft•lb 429.8 N•m

3/4-16

297 ft•lb 402.7 N•m

223 ft•lb 302.3 N•m

420 ft•lb 569.4 N•m

315 ft•lb 427.1 N•m

472 ft•lb 640 N•m

354 ft•lb 480 N•m

7/8-9

429 ft•lb 581.6 N•m

322 ft•lb 436.6 N•m

606 ft•lb 821.6 N•m

455 ft•lb 616.9 N•m

682 ft•lb 924.7 N•m

511 ft•lb 692.8 N•m

7/8-14

474 ft•lb 642.7 N•m

355 ft•lb 481.3 N•m

669 ft•lb 907 N•m

502 ft•lb 680.6 N•m

752 ft•lb 1019.6 N•m

564 ft•lb 791.8 N•m

1-8

644 ft•lb 873.1 N•m

483 ft•lb 654.9 N•m

909 ft•lb 1232.4 N•m

681 ft•lb 923.3 N•m

1022 ft•lb 1385.6 N•m

767 ft•lb 1039.9 N•m

1-12

722 ft•lb 978.9 N•m

542 ft•lb 734.9 N•m

1020 ft•lb 1382.9 N•m

765 ft•lb 1037.2 N•m

1147 ft•lb 1551.1 N•m

860 ft•lb 1166 N•m

V01

ID0493104

278

Metric Bolt Torque Torque estimates based on clamp load (75% of proof strength) as specified in ISO 898-1.

Class 8.8

Class 10.9

12.9 Socket Head Cap Screw 12.9

Size and Thread Pitch

Dry

Lubed

Dry

Lubed

Dry

Lubed

M5 X 0.80

54 in•lb 6.1 N•m

41 in•lb 4.6 N•m

78 in•lb 8.8 N•m

59 in•lb 6.7 N•m

91 in•lb 10.3 N•m

68 in•lb 7.7 N•m

M6 X 1.00

92 in•lb 10.4 N•m

69 in•lb 7.8 N•m

133 in•lb 15 N•m

99 in•lb 11.2 N•m

156 in•lb 17.6 N•m

116 in•lb 13.1 N•m

M7 X 1.00

156 in•lb 17.6 N•m

116 in•lb 13.1 N•m

222 in•lb 25.1 N•m

167 in•lb 18.9 N•m

260 in•lb 29.4 N•m

195 in•lb 22 N•m

M8 X 1.25

225 in•lb 25.4 N•m

169 in•lb 19.1 N•m

333 in•lb 37.6 N•m

242 in•lb 31.3 N•m

377 in•lb 42.6 N•m

284 in•lb 32.1 N•m

M10 X 1.50

37 ft•lb 50.2 N•m

28 ft•lb 38 N•m

53 ft•lb 71.9 N•m

40 ft•lb 54.2 N•m

62 ft•lb 84.1 N•m

47 ft•lb 63.7 N•m

M12 X 1.75

65 ft•lb 88.1 N•m

49 ft•lb 66.4 N•m

93 ft•lb 126.1 N•m

69 ft•lb 93.6 N•m

108 ft•lb 146.4 N•m

81 ft•lb 109.8 N•m

M14 X 2.00

104 ft•lb 141 N•m

78 ft•lb 105.8 N•m

148 ft•lb 200.7 N•m

111 ft•lb 150.5 N•m

173 ft•lb 234.6 N•m

130 ft•lb 176.3 N•m

M16 X 2.00

161 ft•lb 218.3 N•m

121 ft•lb 164.1 N•m

230 ft•lb 311.8 N•m

172 ft•lb 233.2 N•m

269 ft•lb 364.7 N•m

202 ft•lb 273.9 N•m

M18 X 2.50

222 ft•lb 301 N•m

167 ft•lb 226.4 N•m

318 ft•lb 431.2 N•m

238 ft•lb 322.7 N•m

372 ft•lb 504.4 N•m

279 ft•lb 378.3 N•m

M20 X 2.50

314 ft•lb 425.7 N•m

235 ft•lb 318.6 N•m

449 ft•lb 608.8 N•m

337 ft•lb 456.9 N•m

525 ft•lb 711.8 N•m

394 ft•lb 534.2 N•m

M22 X 2.50

428 ft•lb 580.3 N•m

321 ft•lb 435.2 N•m

613 ft•lb 831.1 N•m

460 ft•lb 623.7 N•m

716 ft•lb 970.8 N•m

537 ft•lb 728.1 N•m

M24 X 3.00

543 ft•lb 736.2 N•m

407 ft•lb 551.8 N•m

776 ft•lb 1052.1 N•m

582 ft•lb 789.1 N•m

908 ft•lb 1231.1 N•m

681 ft•lb 923.3 N•m

M27 X 3.00

796 ft•lb 1079.2 N•m

597 ft•lb 809.4 N•m

1139 ft•lb 1544.3 N•m

854 ft•lb 1157.9 N•m

1331 ft•lb 1804.6 N•m

998 ft•lb 1353.1 N•m

M30 X 3.50

1079 ft•lb 1462.9 N•m

809 ft•lb 1096.9 N•m

1543 ft•lb 2092 N•m

1158 ft•lb 1570 N•m

1804 ft•lb 2445.9 N•m

1353 ft•lb 1834.4 N•m

M33 X 3.50

1468 ft•lb 1990.3 N•m

1101 ft•lb 1492.8 N•m

2101 ft•lb 2848.6 N•m

1576 ft•lb 2136.8 N•m

2455 ft•lb 3328.5 N•m

1842 ft•lb 2497.4 N•m

M36 X 4.00

1886 ft•lb 2557.1 N•m

1415 ft•lb 1918.5 N•m

2699 ft•lb 3659.4 N•m

2024 ft•lb 2744.2 N•m

3154 ft•lb 4276.3 N•m

2366 ft•lb 3207.9 N•m

V01

ID0493104

279

Prevailing Torque Locknut Torque Torque relationships for electrodeposited zinc and lubricated all-metal prevailing torque locknuts.

Torque minimum and maximum estimates based on clamp load (75% of proof strength) for appropriate grade of bolt.

Locknut

Grade B Hex

Grade C Hex

Grade F Hex Flange

Grade G Hex Flange

US

Metric

US

Metric

US

Metric

US

Metric

1/4-20

7-10 ft•lb

9-13 N•m

8-12 ft•lb

11-16 N•m

6-8 ft•lb

8-11 N•m

9-11 ft•lb

12-15 N•m

1/4-28

8-11 ft•lb

11-15 N•m

9-12 ft•lb

12-16 N•m

7-9 ft•lb

9-12 N•m

10-13 ft•lb

13-17 N•m

5/16-18

13-18 ft•lb

17-24 N•m

16-21 ft•lb

21-28 N•m

13-17 ft•lb

17-23 N•m

18-23 ft•lb

24-43 N•m

5/16-24

14-19 ft•lb

19-25 N•m

18-23 ft•lb

24-31 N•m

14-18 ft•lb

19-24 N•m

20-26 ft•lb

27-35 N•m

3/8-16

16-20 ft•lb

21-27 N•m

28-37 ft•lb

38-50 N•m

23-29 ft•lb

31-39 N•m

33-41 ft•lb

44-50 N•m

3/8-24

16-22 ft•lb

21-30 N•m

32-42 ft•lb

43-57 N•m

26-33 ft•lb

35-44 N•m

37-47 ft•lb

50-63 N•m

7/16-14

23-32 ft•lb

31-43 N•m

45-59 ft•lb

61-80 N•m

37-47 ft•lb

50-63 N•m

52-66 ft•lb

70-89 N•m

7/16-20

24-34 ft•lb

32-46 N•m

51-66 ft•lb

69-89 N•m

41-52 ft•lb

55-70 N•m

58-74 ft•lb

78-100 N•m

1/2-13

37-50 ft•lb

50-67 N•m

69-90 ft•lb

93-122 N•m

57-72 ft•lb

77-97 N•m

80-101 ft•lb

108-137 N•m

1/2-20

38-53 ft•lb

51-72 N•m

78-102 ft•lb

105-138 N•m

64-81 ft•lb

87-110 N•m

90-114 ft•lb

122-154 N•m

9/16-12

50-70 ft•lb

67-95 N•m

100-130 ft•lb

135-176 N•m

82-103 ft•lb

111-139 N•m

115-146 ft•lb 156-198 N•m

9/16-18

58-78 ft•lb

78-105 N•m

111-146 ft•lb

150-198 N•m

91-115 ft•lb

123-156 N•m 128-163 ft•lb 173-221 N•m

5/8-11

70-95 ft•lb

95-129 N•m

138-180 ft•lb

187-224 N•m

113-143 ft•lb 153-194 N•m 159-201 ft•lb 215-272 N•m

5/8-18

73-98 ft•lb

99-133 N•m

156-204 ft•lb

211-276 N•m

127-161 ft•lb 172-218 N•m 180-228 ft•lb 224-309 N•m

3/4-10

125-165 ft•lb 169-223 N•m 245-320 ft•lb

332-434 N•m

200-253 ft•lb 271-343 N•m 282-357 ft•lb 382-484 N•m

3/4-16

120-165 ft•lb 162-223 N•m 273-357 ft•lb

370-484 N•m

223-282 ft•lb 302-382 N•m 315-399 ft•lb 427-541 N•m

7/8-9

185-250 ft•lb 251-339 N•m 394-515 ft•lb

534-698 N•m

7/8-14

200-270 ft•lb 271-366 N•m 435-568 ft•lb

589-770 N•m

1-8

275-375 ft•lb 373-508 N•m 591-772 ft•lb

801-1046 N•m

1-12

290-395 ft•lb 393-535 N•m 663-867 ft•lb

899-1175 N•m

1 1/8-7

294-404 ft•lb 398-547 N•m 837-1095 ft•lb

1135-1484 N•m

1 1/8-12

412-549 ft•lb 558-744 N•m 939-1227 ft•lb

1273-1663 N•m

1 1/4-7

375-513 ft•lb 508-695 N•m 1181-1545 ft•lb 1601-2094 N•m

1 1/4-12

412-549 ft•lb 558-744 N•m 1308-1710 ft•lb 1773-2318 N•m

V01

Grades B and F: SAE J429 Grade 5 bolts Grades C and G: SAE J429 Grade 8 bolts

ID0493104

280

Torque Values for Other Types of Fasteners Find the torque for the same size and grade/class of hex nut and multiply that value by the conversion factor listed below to determine recommended torque values for other types of fasteners.

Type

Factor

Example

hex top deformed locknuts

.75

3/8”, grade 5: 31 ft•lb X .75 = 23.25 ft•lb

smooth flange nuts and bolts

1.5

M10, class 8.8: 52 N•m X 1.5 = 78 N•m

serrated flange nuts and bolts

2.0

1/2”, grade 8: 145 N•m X 2.0 = 290 N•m

Lug Nut Torque Size

Type

Torque (ft•lb)

Torque (N•m)

7/16-NF

cone

75-85

102-115

1/2-NF

cone

90-100

120-135

5/8-NF

flange

275-325

373-440

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.

Torque values are for non-lubricated threads.

Hydraulic Cylinder Bolt Torque Bolt Size

Bolt PN

Cylinder Repair Kit PN

Torque

1/2”

106-096

190-165

90-100 ft•lb

120-135 N•m

5/8”

106-097

190-166 & 190-169

180-200 ft•lb

245-270 N•m

3/4”

106-098

190-167 & 190-170

290-325 ft•lb

395-440 N•m

7/8”

106-122

190-172 & 190-174

410-460 ft•lb

550-625 N•m

1”

106-145

190-175 & 190-189

630-700 ft•lb

855-950 N•m

1-1/8”

106-146

190-177

770-850 ft•lb

1045-1170 N•m

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 tighten to value shown on chart.

V01

ID0493104

Replacement O-Rings Fitting

SAE (Port Seal)

ORFS (Face Seal)

Code 61, Code 62 4-Bolt Flange

Thread

O-Ring

Dash

O-Ring

Size

Dash

Thread

O-Ring

(Inch)

Size

Size

Dash Size

P/N

Size

Dash Size

P/N

Size

P/N

1/16

1

NA

NA

NA

NA

NA

NA

NA

NA

1/8

2

5/16 - 24

-902

NA

NA

NA

NA

NA

NA

3/16

3

3/8 - 24

-903

NA

NA

NA

NA

NA

NA

1/4

4

7/16 - 20

-904

155-760

9/16 - 18

-011

157-037

NA

NA

5/16

5

1/2 - 20

-905

NA

5/8 - 18

NA

NA

NA

NA

3/8

6

9/16 - 18

-906

155-705

11/16 - 16

-012

157-038

NA

NA

1/2

8

3/4 -16

-908

155-706

13/16 - 16

-014

157-039

-210

155-759 #

5/8

10

7/8 - 14

-910

155-707

1 - 14

-016

157-040

NA

NA

3/4

12

1-1/16 - 12

-912

155-709

1-3/16 - 12

-018

157-017

-214

155-723

7/8

14

1-3/16 - 12

-914

155-747

1-5/16 - 12

-020

157-042

NA

NA

1

16

1-5/16 - 12

-916

155-748

1-7/16 - 12

-021

155-714

-219

157-029

1-1/4

20

1-5/8 - 12

-920

155-702

1-11/16 - 12

-025

157-129

-222

157-078

1-1/2

24

1-7/8 - 12

-924

157-001

2 -12

-029

157-130

-225

157-128

2

32

2-1/2 - 12

-932

NA

2-1/2 - 12

-135

NA

-228

500-031

2-1/2

40

3 - 12

NA

NA

NA

NA

NA

-232

157-015 #

3

48

3-1/2 - 12

NA

NA

NA

NA

NA

-237

157-006 #

All part numbers listed above are D90 except for # which are D70.

Thread size indicates the diameter of the threaded area in fractions of an inch and number of threads per inch.

NA = not a current Ditch Witch® part numbered o-ring, or dash size does not occur in current Ditch Witch applications.

SAE = straight thread fitting that seals by compressing a hard o-ring between a shoulder on the male part and an angular surface at the mouth of the female port.

ORFS = o-ring seal; a 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.

V01

ID0493104

281

282

JT920 Related Publications Component

Ass’y

P/N

Model: JT920 ................. Parts Manual ......................................................... ............ 053-467 JT920 ................. Operators Manual .................................................. ............ 054-509 JT920 ................. Repair Guide (Service Manual) .............................. ............ 055-498 Engine: Lister-Petter ........ Parts Manual - LPWT4 ................................... 194-417 ........ N/A Lister-Petter ........ Operators Manual - LPWT4 ................................... ................ N/A Lister-Petter ........ Service (Shop) Manual - LPWT4 ........................... ................ N/A Lister-Petter ........ Service (Shop) Video - LPWT4 .............................. ................ N/A Caterpillar ……….. CAT 3024C Parts Manual ………………………………....... 053-144 Caterpillar ……….. CAT 3024C Oper / Maint Manual …………………………… 054-128 Caterpillar ……….. CAT 3024C Service Manual ………………………………… 055-076 Caterpillar ……….. CAT 3024C User Handbook ………………………………… 056-005 WATER TRANSFER SYSTEM OPTION: Honda 5.5hp ....... Parts Manual - GX160K1TX ........................... 195-028 .... 053-042 Honda 5.5hp ....... Operators Manual - GX160K1TX ........................... ................ N/A Honda 5.5hp ....... Service (Shop) Manual - GX160K1TX ................... ................ N/A

Filters Engine: Lister-Petter LPWT4 Air Filter Parts Ass’y ......................................................................................... 194-812 Element (primary) .............................................................................. 195-817 Air Filter Parts Ass’y - Early Model ................................................................... 195-816 Element (primary) - Early Model ......................................................... 195-817 Element (secondary) - Early Model .................................................... 195-818 Air Stack Cap (2.500”) ...................................................................................... 195-692 Oil Filter Element (spin-on) - Lister-Petter ........................................................ 159-141 Fuel Filter Element (spin-on) - Lister-Petter ...................................................... 194-420 Caterpillar 3024C Air Filter Parts Ass’y …………………………………………………………………. 194-297 Element (Safety) ………………………………………………………….. 194-758 Element (Primary) ………………………………………………………… 194-757 Oil Filter Element …………………………………………………………………….. 153-113 Fuel Filter Element (30 Micron) …………………………………………………….. 194-491 Fuel Filter Element (2 Micron) ………………………………………………………. 194-551

VER.03

ID0117422

283

JT920 Related Publications WATER TRANSFER SYSTEM OPTION: Air Filter Parts Ass’y - Honda 5.5hp (GX160K1TX) .............................................. N/A Element Set (primary, paper) - Honda (GX160K1TX) ........................ 194-001 (secondary, foam) - Honda (GX160K1TX) ..................... 194-001 Fuel Filter (04H-04H, in-line) - Honda 5.5hp (GX160K1TX) .............................. 194-002 Hydraulic: Oil Filter Element (1-1/2-UNF, spin-on, Replacement) ...................................... 159-079 Element (1-1/2-UNF, spin-on, Break-In) ............................................. 149-840 Oil Strainer (24S-20SF) .................................................................................... 110-336

Optional Kits O-ring Repair Kit - FLG, ORS & SAE (15 different O-rings) .............................. 190-051 O-ring Repair Kit - Field Service (46 different O-rings) ..................................... 190-052

VER.03

ID0117422

284

285

ID0040564

286

ID0135281