1867227645
Uploaded by
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Uploaded by
Mohamed Rashed1
JT4020
ISSUE NO. 09PL-08/11
For Replacement Copy Order P/N 053-470
This product is covered by one or more of the following patents:
US B1 4,858,704; 4,953,638; 5,148,880; 5,242,026; 5,341,887; 5,490,569; 5,684,466; 5,713,423,
5,794,719; 5,880,680; 5,941,322; 6,085,852; 6,109,371; 6,179,065; 6,216,803; 6,250,403;
6,250,404; 6,290,606; 6,311,790; 6,411,094; 6,543,551; 6,550,547; 6,672,409; 6,739,413;
6,776,246; 6,808,210; 6,827,158; RE37,450; RE37,923; RE37,975; RE38,418
AU 689,533; 706,544; 718,034, 755,862
CA 2,156,398
FR 674,093
DE 694 17 019; 695 29 634; 297 01 406
EP 0683845; 0674093; 0817901; 0846841
GB 2,209,239; 2,312,006; EP674,093; EP846,841
JP 3,458,247
Other U.S. and foreign patents pending
This manual contains information concerning the following models:
JT4020 Directional Drilling System
Copyright 1998, 2000, 2003, 2004, 2005, 2006, 2007, 2011 by The Charles Machine Works, Inc.
, Ditch Witch, CMW, AutoCrowd, Modularmatic, Jet Trac, Roto Witch, Subsite, Fluid
Miser, Perma-Soil, Power Pipe, Super Witch, Super Witch II, Pierce Arrow, The Underground, and The
Underground Authority Worldwide are registered trademarks of The Charles Machine Works, Inc.
ID0135012
2
3
FOREWORD___________
This manual contains illustrated parts lists to help you select quality ProTech
Replacement parts for your Ditch Witch equipment. Using other replacement parts will
lessen the productivity of your equipment.
Part numbers enclosed in a box are no longer available from The Charles Machine
Works, Inc. Your local Ditch Witch dealer may be able to locate the part for you.
Footnotes provide more information to help you identify parts shown in the manual.
Assembly instructions and Tech Bits articles referenced in footnotes are available
through your local Ditch Witch dealer.
Description and specifications in this book were current at publication. However,
The Charles Machine Works, Inc. reserves the right to improve equipment, so this
manual might not reflect the most current improvements.
Instructions on recommended equipment use and maintenance are in the Operators
Manual that was shipped with your equipment.
Keep the following in mind when ordering ProTech replacement parts:
Specify parts you need by part number and description, not by illustration reference
numbers.
Have equipment model and serial number on hand to help ensure you get the right
parts for your machine whether its old or new.
Thank you for buying and using Ditch Witch equipment and ProTech replacement parts.
8/6/2010, Rev-B 800-001
4
WARRANTY__________________________
DW WARRANTY Policy
July, 2005
POLICY 1: DITCH WITCH EQUIPMENT AND REPLACEMENT PARTS
LIMITED WARRANTY POLICY
Subject to the limitation and exclusions herein, free replacement parts will be provided at any authorized Ditch
Witch dealership for any Ditch Witch equipment or parts manufactured by The Charles Machine Works, Inc.
(CMW) that fail due to a defect in material or workmanship within one (1) year of first commercial use
(Exception: 2 years for all SK500 Attachments). Free labor will be provided at any authorized Ditch Witch
dealership for installation of parts under this warranty during the first year following initial commercial use of
the serial numbered Ditch Witch equipment on which it is installed. The customer is responsible for
transporting their equipment to an authorized Ditch Witch dealership for all warranty work.
EXCLUSIONS FROM PRODUCT WARRANTY
All incidental or consequential damages.
All defects, damages, or injuries caused by misuse, abuse, improper installation, alteration,
neglect, or uses other than those for which products were intended.
All defects, damages, or injuries caused by improper training, operation, or servicing of products
in a manner inconsistent with manufacturers recommendations.
All engines and engine accessories (these are covered by original manufacturers warranty).
Tires, belts, and other parts which are subject to another manufacturers warranty. (Such
warranty will be available to purchaser.)
ALL IMPLIED WARRANTIES NOT EXPRESSLY STATED HEREIN, INCLUDING ANY
WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY.
IF THE PRODUCTS ARE PURCHASED FOR COMMERCIAL PURPOSES, AS DEFINED BY THE
UNIFORM COMMERCIAL CODE, THEN THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE
FACE HEREOF AND THERE ARE NO IMPLIED WARRANTIES OF ANY KIND WHICH EXTEND TO A
COMMERCIAL BUYER. ALL OTHER PROVISIONS OF THIS LIMITED WARRANTY APPLY INCLUDING
THE DUTIES IMPOSED.
Ditch Witch products have been tested to deliver acceptable performance in most conditions. This does not
imply they will deliver acceptable performance in all conditions. Therefore, to assure suitability, products
should be operated under anticipated working conditions prior to purchase.
Defects will be determined by an inspection within thirty (30) days of the date of failure of the product or part
by CMW or its authorized dealer. CMW will provide the location of its inspection facilities or its nearest
authorized dealer upon inquiry. CMW reserves the right to supply remanufactured replacement parts under
this warranty as it deems appropriate.
Extended warranties are available upon request from your local Ditch Witch dealer or CMW.
Some states do not allow exclusion or limitation of incidental or consequential damages, so the above
limitation or exclusion may not apply. Further, some states do not allow exclusion of or limitation of how long
an implied warranty lasts, so the above limitation may not apply. This limited warranty gives product owner
specific legal rights and the product owner may also have other rights which vary from state to state.
For information regarding this limited warranty, contact CMWs Product Support Department, P.O. Box 66,
Perry, OK 73077-0066, or contact your local Ditch Witch dealer.
Ver. 03 ID0134872
5
CONTENTS______________________
Decals Hydraulic Cylinder (2x1x3)................................ 194
Decal Location - JT4020 ..................................... 8 Hydraulic Cylinder (3x1.75)............................... 202
Hydraulic Cylinder (4x2)................................... 204
Engine Components Hydraulic Cylinder (4x2x10) .............................. 196
2-Post ROPS ................................................... 22 Hydraulic Diagram - Begins ............................. 110
Air Filter System .............................................. 30 Hydraulic Reservoir ........................................ 112
Cold Start Kit .................................................... 34 Hydraulic Schematic .................................... 106
Covers - Battery.................................................. 42 Load Sense Hydraulics - Begins ..................... 144
Covers - Engine ............................................... 36 Load Sense Hydraulics - Ends ....................... 142
Deaeration Tank ............................................... 28 Main Frame Bulkhead .................................. 120
Dual Battery Option ......................................... 24 Oil Cooler Hydraulics ..................................... 114
Engine - John Deere Diesel .................................. 14 Pipe Loader - Gripper Hydraulics - Begins ............ 174
Engine Mounts ................................................ 18 Pipe Loader - Gripper Hydraulics - Ends .............. 172
Engine Oil Drain .............................................. 32 Pipe Loader - Lifter Hydraulics ........................... 178
Engine Skid ...................................................... 20 Pipe Loader - Shuttle Hydraulics ........................ 176
Radiator ............................................................ 26 Pipe Loader - Supply/Return - Begins .................. 160
Sound Insulation - Engine .................................. 38 Pipe Loader - Supply/Return - Ends .................... 158
Valve Covers & Cylinder Locks ........................ 40 Rotation - Thrust/Mud Gauges ............................ 118
Rotation Motor Hydraulics .............................. 126
Frame Components Rotation Motor/Case Drain Hydraulics .......... 128
Carriage - Begins ............................................... 50 Rotation Pump Hydraulics ............................. 122
Carriage - Prior to S/N ......................................... 46 Rotation Test Ports ....................................... 124
Center Pipe Support ......................................... 84 Row Select ..................................................... 180
Fuel Tank ......................................................... 68 Row Select Hydraulics ................................... 184
Gear Box - Rotation Drive..................................... 54 Row Select Indicator ...................................... 182
Grease Cylinder ............................................... 76 Seat Rotation Hydraulics .............................. 192
Grease Cylinder ............................................... 78 Spindle Brake ................................................. 130
Idler .................................................................. 72 Spindle Brake Hydraulics ............................... 132
Pipe Guide - Front .............................................. 64 Stabilizer Hydraulics ...................................... 188
Pivot ................................................................. 82 Supply/Return Hydraulics ............................. 186
Roller ................................................................ 74 Thrust Drive Hydraulics ................................. 148
Stabilizer - Rear ................................................ 80 Thrust Hydraulics ......................................... 146
Thrust Drive ...................................................... 60 Thrust/Track Drive Pump Hydraulics ............ 140
Thrust Idler ....................................................... 62 Track Brake ................................................... 138
Track Group - Rubber......................................... 70 Track Case Drain Hydraulics ........................ 152
Wrench - Backup ................................................ 56 Track Drive Hydraulics .................................. 150
Wrench - Breakout ............................................. 58 Track Shift Hydraulics ................................... 136
Wrench - Front ................................................... 66 Wrench Hydraulics - Backup ........................... 166
Wrench Hydraulics - Breakout - Begins ............. 170
Operators Station Wrench Hydraulics - Breakout - Ends ................ 168
Console ........................................................... 96 Wrench Hydraulics - Front .............................. 164
Console Gauges - Begins ................................ 100
Console Gauges - Ends ..................................... 98 Continued
Covers - Vandal .................................................. 92
Gauge Panel .................................................. 102
Operator Station .............................................. 88
Seat - Belts - Cover ......................................... 94
Hydraulics
2-Speed Track/Thrust Hydraulics .................. 134
Anchor Control Hydraulics ............................. 156
Anchor Supply Hydraulics ............................. 154
Auto-Luber Hydraulic .................................... 198
Auxiliary Valve Hydraulics ............................. 162
Frame Tilt Hydraulics ................................... 190
Hydraulic Cylinder (2x1x2) ................................ 200
ID0135081
6
CONTENTS______________________
Electrical Accessories
Alarm/Strobe Light ........................................ 242 Mud Mixing Accessories ............................... 324
Battery .......................................................... 246 Pipe Box ......................................................... 330
Electrical Diagram - Drill Frame ......................... 234 Wireline Kit ..................................................... 326
Electrical Diagram - Engine ............................. 216 Working Light Kit ............................................ 328
Electrical Diagram - Horn/Switch ...................... 228
Electrical Diagram - Joystick ............................ 226 Miscellaneous
Electrical Diagram - Main Frame ...................... 232 Bolt/Nut Torque Chart .................................... 334
Electrical Diagram - Operator Station ................. 224 Filters ............................................................ 338
Electrical Diagram - Relay Panel ....................... 220 Optional Kits .................................................. 338
Electrical Diagram - Rotation ........................... 244 Parts Manual Change Request ..................... 339
Electrical Diagram - Work Light ........................ 222 Related Publications ..................................... 338
Electrical Schematic ...................................... 208 Replacement O-Ring Chart............................ 337
Electrical Strike System - Begins ...................... 240 Warranty Registration ................................... 342
Electrical Strike System - Ends ........................ 238
Photo-Electric Eye .......................................... 248
Thrust Control Kit ........................................... 230
Anchor Systems
Anchor Base ................................................... 252
Anchor Drive - Left........................................... 256
Anchor Drive - Right......................................... 262
Anchor Drive Hydraulics - Left ........................ 260
Anchor Drive Hydraulics - Right ...................... 266
Anchor Motor - Left ......................................... 258
Anchor Motor - Right ....................................... 264
Anchor Shaft................................................... 274
Anchor Stake Coupler ................................... 272
Anchor Valve ................................................. 254
Hex Coupler .................................................. 270
Hydraulic Cylinder .......................................... 268
Fluid System
Antifreeze Kit .................................................. 278
Fluid Pump - Fluid End ..................................... 286
Fluid Pump - Power End ................................... 288
Mud Check Valve ........................................... 292
Mud Motor Hydraulics ................................... 284
On-Board Mud Supply Hydraulics ................. 280
Wash Wand ................................................... 290
Pipe Loader Systems
Applicator ....................................................... 304
Auto-Lubricator .............................................. 300
Grease Pump ................................................. 302
Grease Pump Mounting ................................ 296
Guard Lock Pin............................................... 320
Pipe Loader - Gripper ....................................... 316
Pipe Loader - Lifter .......................................... 314
Pipe Loader - Shuttle - Front .............................. 310
Pipe Loader - Shuttle - Rear ............................... 312
Pipe Loader - Shuttle Drive ................................ 308
Selector Valve ................................................ 298
Shuttle Guard ................................................. 318
Thread Lubricator - Ends ................................. 306
ID0135081
7
DECALS
ID0135069
8
DECAL LOCATION
JT4020
VIEW
ROTATED 90
1 42
34
33
41
12
14 9
2
10
18
26
3 29
28 16
38 46
15 13
36 25
6
8
3
5
24 28
37 11
32
13 3
4
23
30
22
21
G 804-935
9
DECAL LOCATION
JT4020
40
19
20
7
16
39
28
3
27
45
29
31 37
31
VIEW 17
ROTATED 180
43
1
31
3
5
31
1
31 35 28
3 5
G 804-935
10
DECAL LOCATION
JT4020
G 804-935
11
DECAL LOCATION
JT4020
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
275-727 DECAL KIT - 4020
1 274-049 3 DANGER ELECTROCUTION
2 274-050 1 WARNING JOBSITE HAZARD
3 274-318 6 TIE DOWN LOCATION
4 274-375 1 MASTER DISCONNECT SWITCH
5 274-442 4 LIFT LOCATION
6 274-678 1 JT4020 MODEL - ID
7 274-724 1 ONE CALL NOTIFICATION
8 274-780 1 JET TRAC PATENT (S)
9 274-826 1 INSTRUMENT PANEL JT4020
10 700-827 1 LEFT INSTRUMENTS JT4020
11 700-828 1 RIGHT CONSOLE PANEL JT4020
12 274-875 1 JET TRAC LOGOTYPE
13 274-877 AR GRAPHIC STRIPE (SOLD PER INCH) USE 80
14 274-883 1 DITCH GRAPHIC STRIPE
15 274-884 4 WITCH GRAPHIC STRIPE
16 274-885 2 JET TRAC LOGO TYPE
17 274-909 1 AUTOMATION REFLECTOR PANEL SEE FOOTNOTE 3
18 274-936 1 ANCHOR DRIVER CONTROL PANEL
19 274-948 1 AUTO-LOAD SWITCH PANEL SUPERSEDED BY 274-827
20 274-949 1 FLUID PRESSURE GAUGE 1193 PSI 75 GPM MUD PUMP
21 274-988 1 JOYSTICK CONTROLLER
22 274-989 1 AUTOMATION CONTROLLER
23 275-033 1 NOTICE ELECTRICAL SYSTEM
24 275-048 1 IMPORTANT SAFETY RULES
25 275-120 1 RESERVOIR (THF)
274-672 1 ENVIRO HYDRAULIC RESERVOIR SEE FOOT NOTE 2
26 275-148 1 FUEL TANK (DIESEL)
27 273-146 1 NOTICE ADD COOLANT
28 275-184 28 WARNING MOVING PARTS 4 PER PIPE BOX
29 275-197 2 DANGER ROTATING SHAFT
30 275-203 1 BATTERY
31 275-230 6 DANGER STRIPE 1.75 X 18
32 275-307 1 DITCH WITCH EMBLEM
33 275-341 1 WARNING SLIDING PARTS
34 275-355 1 CAUTION HOT PARTS
35 275-372 1 IMPORTANT CYLINDER LOCK
36 275-400 1 NOTICE OIL LEVEL
37 275-449 2 DITCH WITCH LOGO PLACARD
38 275-497 1 OIL DRAIN - ID
39 274-198 1 NOTICE OIL LEVEL
40 274-951 1 LEFT RELAY PANEL JT4020
41 274-291 1 SOUND POWER 10 SEE FOOT NOTE 1
42 273-006 1 RELAY PANEL
43 273-005 1 SOLENOID VALVE
44 275-326 24 WARNING CRUSHING WEIGHT 4 PER PIPE BOX
45 273-138 1 NOTICE COOLANT
46 273-278 1 DANGER WRENCH
FOOTNOTES
1. NOT PART OF KIT. FOR EUROPEAN UNITS ONLY
2. NOT PART OF KIT. SEE 256-030 ENVIRONMENTAL HYDRAULIC OIL.
3. NOT PART OF KIT. USED ON MACHINES WITH PHOTO-ELECTRIC EYES.
G 804-935
12
NOTES:
ID0134963
13
ENGINE
COMPONENTS
ID0134845
14
15
16
17
18
19
20
21
22
23
24
DUAL BATTERY OPTION
2 10
5
1
6
1
7
8
9
4
04 ID0112194
25
DUAL BATTERY OPTION
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
101-072 DUAL BATTERY KIT FOOTNOTE 1
1. 215-244 2 BATTERY
273-267 2 BATTERY WARRANTY DECAL FOOTNOTE 2
2. 215-381 - BATTERY CABLE (1 GA X 12", BLK)
3. 347-857 - DUAL BATTERY STRAP
4. 105-832 - FLG LOCKNUT (1/4-NC)
5. 215-339 - BATTERY CABLE (2/0 GA X 96", RED)
6. 215-360 1 BATTERY CABLE (2 GA X 23.6", BLK)
7. 215-361 1 BATTERY CABLE (2 GA X 23.6", RED)
8. 356-491 - TIE-DOWN ROD (1/4-NC X 9.3")
9. 362-784 - BATTERY TRAY
10. 106-384 2 FLG LK BOLT (3/8-NC X 3/8")
NOT SHOWN:
FOOTNOTES:
1. REFER TO INSTRUCTION 051-253
2. LOCATE DECAL ON BATTERY SO THAT DECAL IS VISIBLE WHEN VIEWING BATTERY.
NOTE:
04 ID0112194
26
RADIATOR
11
JT4020 12
10
9
4
14 13
3
20 5
7
1
TO AUX.
TANK
19
8
FROM AUX.
TANK 16
21
17
7 15
17 18
6 3
2
T 805-434
27
RADIATOR
JT4020
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
1. 306-822 1 RADIATOR SEE FOOTNOTE 1
111-091 1 RADIATOR CAP
2. 106-142 3 SCREW (M10-1.50 X 65MM)
3. 116-727 3 SHOCK MOUNT
4. 105-223 3 WASHER (3/8")
5. 106-387 3 FLG LOCKNUT (M10-1.50)
6. 350-506 - FRONT ENGINE MOUNT
7. 110-134 4 WORM CLAMP (2.062" TO 2.750")
8. 116-706 1 LOWER COOLANT HOSE
9. 116-705 1 UPPER COOLANT HOSE
10. 194-737 1 FAN GUARD (24")
11. 106-561 4 LOCKNUT (M8-1.25, PRV TRQ, 10.9)
12. 105-118 4 WASHER (3/8")
13. 354-436 1 RADIATOR BRACKET
14. 106-632 2 FLG LK SCREW (M12-1.75 X 35MM,SER)
15. 364-229 1 OVERFLOW TANK (3 QT)
110-765 1 CAP (2-1/4")
190-053 - POLY-PATCH TANK REPAIR KIT
16. 107-334 2 SCREW (M8-1.25 X 25MM,BUT SOC)
17. 105-117 4 WASHER (5/16") SEE FOOTNOTE 2
18. 106-561 2 LOCKNUT (M8-1.25, PRV TRQ, 10.9)
19. 115-349 1 GROMMET (1/2") SEE FOOTNOTE 1
20. 105-940 2 WASHER (5/8")
21. 115-381 AR BULK HOSE (1/4", SOLD PER 1") USE 1 @ 39"
FOOTNOTES
1. FAN MUST BE CENTERED IN DIAMETER OF RADIATOR SHROUD OPENING. ROUTE OVERFLOW HOSE THROUGH HOLE AND
GROMMET (115-349) IN TOP HOOD.
2. ONE OF THESE WASHER (106-916) SHOULD BE PLACED BETWEEN NUT (106-561) AND OVERFLOW TANK (364-229),
TWO PLACES. ONE OF THE WASHERS SHOULD BE PLACED BETWEEN OVERFLOW TANK AND HOOD STIFFENER PLATE,
TWO PLACES.
NOTE:
T 805-434
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
NOTES:
ID0134963
45
FRAME
COMPONENTS
ID0135068
46
CARRIAGE
PRIOR TO S/N 2T1167
51
3
2
50 28
49
38
37 34
41 39
28
10 46
9
11 8 52
48
53
5
18
17
47
16
32
7
22 6
14
54 1
35 13
25 4
17
12
36 18
26
24 15
23 16
17
33 19
27 20
40
21
30
42
45
31
44
43
32
44
29
29
14 ID0114269
47
CARRIAGE
PRIOR TO S/N 2T1167
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
1. 166-423 1 ROTATION DRIVE GEARBOX SEE FOOTNOTE 5. INCLUDES PLANETARY (166-152).
197-060 REBUILT ROTATION GEARBOX SEE FOOTNOTE 5.
2. 158-012 1 HYD MOTOR
190-906 SEAL REPAIR KIT
157-750 SHAFT SEAL
217-745 CONTROL SOLENOID
499-176 CONNECTOR PLUG
197-075 REBUILT 158-012 HYD. MOTOR
3. 105-997 2 BOLT (5/8-NC X 1-3/4", SOC) USE 242 LOCTITE. TORQUE TO 175 LB-FT.
4. 350-752 1 RIGHT CARRIAGE SIDE
5. 350-753 1 LEFT CARRIAGE SIDE
6. 350-768 1 SLIDING OUTPUT SHAFT APPLY 256-666 OPEN GEAR COMPOUND TO SPLINED AREA.
7. 171-112 1 SPACER
8. 184-946 1 SPACER
9. 107-104 1 NUT -2.933 NS
10. 106-532 1 THRUST LOCK WASHER (2.937")
11. 106-531 1 THRUST LOCKNUT (2.937-NS)
12. 307-538 1 SAVER SUB (3.12 SLOD) SEE FOOTNOTE 7.
13. 107-354 9 SCREW (M16-2.00 X 55mm, SOC) USE 242 LOCTITE. TORQUE TO 225 LB-FT.
14. 500-818 3 DOWEL PIN (16mm X 40mm)
15. 157-151 1 O-RING (226 D90)
16. 350-759 2 CHAIN ANCHOR USE WITH 130-604 CHAIN.
17. 106-399 4 WASHER (M20, HARDENED)
18. 107-204 2 SCREW (M20-2.5 X 300mm, 10.9)
19. 106-665 2 LOCKNUT (M20-2.50, 10.9)
20. 130-604 1 ROLLER CHAIN (#140-2, .500" 297P) SEE FOOTNOTE 3.
178-246 - EXTENDED PIN (#140-2, .500") SEE FOOTNOTE 4.
21. 130-606 2 CONNECTOR LINK (#140-2, .500") USE WITH 130-604 CHAIN.
130-607 AR ROLLER LINK (#140-2, .500") USE WITH 130-604 CHAIN.
22. 107-144 10 SCREW (M16-2.0 X 100mm)
23. 106-545 10 LOCKNUT (M16-2.00, PRV TRQ, 10.9)
24. 350-932 2 BOTTOM SLIDE BAR
25. 350-931 2 THICK SLIDE SPACER
26. 350-933 2 SLIDE SHIM
27. 350-930 2 SLIDE BAR
28. 106-398 14 WASHER (M16, HARDENED)
29. 350-767 1 HOSE TRACK (5" X 150") INCL REF NO. 30, SEE FOOTNOTE 1 & 8.
306-620 AR REPAIR SECTION (5.00"W X 20"L)
308-831 AR EASY-OUT BAR (1/2" X 5")
308-832 AR EASY-OUT BAR (1/2" X 5")
308-833 AR 5" ALUMINUM FLAT BAR
308-834 AR WINDOW EXTENDER
307-337 AR L1 BRACKET (LEFT)
307-338 AR L1 BRACKET (RIGHT)
NOT SHOWN:
FOOTNOTES:
NOTE:
14 ID0114269
48
CARRIAGE
PRIOR TO S/N 2T1167
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
30. 354-368 - HOSE BAG (150") SEE FOOTNOTE 8.
31. 105-249 4 CARRIAGE BOLT (3/8-NC X 1-1/4")
32. 105-047 8 LOCKNUT (3/8-NC)
33. 130-601 4 ROLLER BUSHING (#140) USE WITH 130-604 CHAIN
34. 157-084 1 O-RING (159 D70)
35. 354-515 2 TOP SLIDE BAR
36. 354-509 2 THIN SLIDE SPACER
37. 159-382 1 WATER SWIVEL (16N-16NF)
190-905 SWIVEL REPAIR KIT
38. 350-475 1 WATER SWIVEL PAD
39. 106-666 12 SCREW (M16-2.00 X 65MM, 10.9) USE 277 LOCTITE, TORQUE TO 225 LB-FT. SEE FOOTNOTE 6.
40. 105-600 4 CARRIAGE BOLT (3/8-NC X 1")
41. 115-261 1 REDUCER (24N-16NF)
42. 350-432 1 TARGET SEE FOOTNOTE 2.
43. 106-640 1 SCREW (M6-1.00 X 20mm, BUT SOC)
44. 106-389 4 WASHER (M8)
45. 106-538 1 LOCKNUT (M6-1.00,PRV TRQ,10.9)
46. 166-152 1 ROTATION GEARBOX PLANETARY
47. 105-894 2 LOCKNUT (M10-1.50, PRV TRQ, 10.9)
48. 354-476 1 SWIVEL BAR
49. 354-909 1 CLAMP
50. 106-390 2 WASHER (M10)
51. 105-245 2 SCREW (M10-1.50 X 25MM)
52. 514-106 1 CAP (08NF)
53. 115-161 1 NIPPLE (08N, 3-1/2")
54. 116-882 1 SHIM USED PRIOR TO SN 2S0795
NOT SHOWN:
FOOTNOTES:
1. INSTALL HOSE TRACK SO THAT THE POINT ATTACHING TO CARRIAGE IS THE END W/ EXTENDER BAR NEAREST THE END.
2. INSTALL TARGET ON HOSE TRACK ON THE NINTH EXTENDER BAR FROM THE CARRIAGE END.
3. THE END THE EXTENDED PIN IS CLOSEST TO WILL ATTACH TO THE FRONT OF THE CARRIAGE.
4. REFER TO SERVICE BULLETIN 052-098 FOR INSTALLATION INSTRUCTIONS
5. HOLDS 10.5 PINTS OF MPL, SEE GEAR BOX PAGE FOR SERVICE PARTS.
6. EARLY MACHINES USE 8 WASHERS & 8 SCREWS.
7. 350-756 SAVER SUB IS SUPERSEDED BY 307-538. USE 307-538 SAVER SUB FOR ALL REPLACEMENTS.
8. INSTALL ELECTRIC CABLE THAT ATTACHES TO ROTATION MOTOR INSIDE ACCESSORY FLAP ON HOSE BAG.
NOTE:
14 ID0114269
49
50
51
52
53
54
ROTATION GEAR BOX
41 29 44 2 3 5
1
11 4
21
22
10 30
23
9 12
32
43 25
37 18 26
36 19
20
6
35
33
24
14 7
13 15
27 16
17
28
40
8
38
39
42
34
31
08 ID0111795
55
ROTATION GEAR BOX
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
166-423 ROTATION DRIVE GEARBOX INCL REF NO'S 1-12, 14-26, 29-37, 41 & 43.
197-060 REBUILT ROTATION GEARBOX INCL REF NO'S 1-12, 14-26, 29-37. SEE FOOTNOTE 2
1. 169-074 1 COVER
2. 169-075 1 COVER
3. 500-818 5 DOWEL PIN (16mm X 40mm)
4. 106-700 11 SCREW (M12-1.75 X 80mm)
5. 168-034 1 INPUT PINION GEAR
6. 168-035 1 IDLER GEAR
7. 168-036 1 OUTPUT GEAR
8. 167-309 1 OUTPUT SHAFT
9. 125-308 1 TAPERED BEARING (3")
10. 125-309 1 TAPERED RACE (5")
11. 125-359 1 TAPERED RACE (4.781")
12. 125-360 1 TAPERED BEARING (3")
13. 184-946 1 SPACER (75mm X 88.9mm)
14. 125-1009 2 TAPERED BRNG/RACE (110mm)
15. 165-810 3 SHIM (.002")
16. 165-811 3 SHIM (.003")
17. 165-812 3 SHIM (.007")
18. 165-842 3 SHIM (.051mm)
19. 165-843 3 SHIM (.076mm)
20. 165-844 3 SHIM (.178mm)
21. 165-869 3 SHIM (.051mm)
22. 165-868 3 SHIM (.076mm)
23. 165-870 3 SHIM (.178mm)
24. 157-631 2 INTERNAL SEAL (4.250")
25. 159-003 1 AIR VENT (02N)
26. 514-123 1 PICKUP TUBE (02N-02NF90-2")
27. 107-104 1 NUT - 2.933 NS
28. 171-112 1 SPACER
29. 105-534 3 DOWEL PIN (.375" X .875")
30. 105-245 10 SCREW (M10-1.50 X 25mm)
31. 106-117 2 SCREW (M12-1.75 X 80mm)
32. 350-828 1 CAP USED PRIOR TO SN/2T1161 AND AFTER SN/2T1180
308-890 1 CAP USED SN/2T1161 TO SN/2T1180
33. 350-829 1 CAP
34. 115-211 1 PLUG (08N, SQ, MAG) SEE FOOTNOTE 1
35. 115-167 1 PLUG (12N, SQ)
36. 126-170 2 TAPERED BEARING (2.250")
37. 126-171 2 TAPERED RACE (3.740")
38. 106-531 1 THRUST LOCKNUT (2.937-NS)
39. 106-532 1 THRUST LOCK WASHER (2.937")
40. 157-151 1 O-RING (226 D90)
41. 105-179 12 BOLT (3/8-NC X 3-1/2") TORQUE TO 40 FT LB
42. 350-768 1 SLIDING OUTPUT SHAFT USE COMPOUND GREASE 256-666 ON INITIAL INSTALLATION
43. 166-152 1 ROTATION GEARBOX PLANETARY SEE FOOTNOTE 2
44. 107-530 1 SHIM USED SN/2T1161 TO SN/2T1180
FOOTNOTES:
1. NOT SHOWN: 1X 514-106 AND 1X 115-161 REPLACE ITEM 34
2. APPLY A 3/16" MIN. BEAD OF LOCTITE SUPERFLEX RED HIGH TEMP RTV (OR EQUIVALENT) ON BOTH SIDES
OF PLANETARY. BE SURE THAT DOWELS (ITEM 29) ARE INSTALLED BEFORE ATTACHING PLANETARY.
3. 126-172 SUPERSEDED BY 125-1009. TIMKEN 32222M WILL NOT WORK IN THIS APPLICATION.
NOTE:
179-297 & 179-298 - ASSEMBLY TOOLS REQUIRED WHEN REBUILDING GEARBOX
08 ID0111795
56
57
58
59
60
THRUST DRIVE
16
17
18
13
5
15
2 4
14
3 7
19 1
12
20
21
11
21
10
20
5 7
15
4
13
14
05 ID0114257
61
THRUST DRIVE
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
1. 106-334 8 SCREW (M12-1.75 X 50mm)
2. 106-685 8 LOCKNUT (M12-1.75, PRV TRQ, 10.9)
3. 106-397 16 WASHER (M12, HARDENED)
4. 125-314 2 ROLLER BEARING (2.952")
5. 157-084 2 O-RING (159 D70)
6. 105-066 8 BOLT (1/2-NC X 1-3/4")
7. 155-883 2 INTERNAL SEAL (3.750")
8. 350-726 1 THRUST DRIVE COVER
9. 106-991 4 FLG LK SCREW (M8-1.25 X 20MM)
10. 175-740 1 SPROCKET (D140B15)
11. 167-318 1 THRUST DRIVE SHAFT
12. 350-725 1 THRUST DRIVE HOUSING
13. 118-031 2 INTERNAL SNAP RING (6.250")
14. 166-151 2 GEARBOX PLANETARY SEE FOOTNOTE 1
501-861 PRIMARY CARRIER (8")
501-862 SECONDARY CARRIER (8")
501-863 COVER
501-864 RING GEAR, 8" OBSOLETE
501-865 SUN GEAR, 8"
15. 158-026 2 HYDRAULIC MOTOR (15 CU/IN)
500-711 SEAL REPAIR KIT - REAR
500-758 SEAL REPAIR KIT - SHAFT
16. 105-808 24 BOLT (3/8-NC X 7")
17. 106-390 48 WASHER (M10)
18. 105-047 24 LOCKNUT (3/8-NC)
19. 106-551 4 CLIP NUT (M8-1.25)
20. 118-044 2 EXTERNAL SNAP RING (4.250")
21. 126-127 AR THRUST WASHER RACE (1.750")
NOT SHOWN:
FOOTNOTES:
1. APPLY RED GASKET MAKER TO BOTH SIDES OF PLANETARY.
NOTE:
05 ID0114257
62
63
64
65
66
67
68
69
70
TRACK GROUP
10
11
12
4
30
21
24 21
23 13 2 30
22 8
30
33
22 30
30 1
35 3
30 9
34 20 30
22
5
17
26
27
28 14
21
30
22
32 19
25
6 30 22 18 16
31 15
30
29
21
04 ID0145188
71
TRACK GROUP
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
1. 106-066 18 LUG NUT (5/8-NF)
2. 107-010 4 FLG LOCK SCREW (M12-1.75 X 30mm)
3. 106-685 4 LOCKNUT (M12-1.75, PRV TRQ, 10.9)
4. 354-480 2 RUBBER TRACK (400MM 82P)
5. 166-218 2 PLANETARY GEARBOX (22.04:1) TRACK PLANETARY
6. 354-861 14 ROLLER
7. 350-757 1 LEFT ROLLER FRAME
8. 349-314 2 SLIDE PAD
9. 175-293 2 SPROCKET (2.755"A22)
10. 354-517 2 YOKE
11. 354-860 2 IDLER PARTS ASS'Y
12. 117-164 2 COMPRESSION SPRING COMPRESSED LENGTH 18" +0 -1/4" TO KEEP TRACKS TIGHT
13. 354-531 1 RIGHT GREASE CYLINDER
354-530 1 LEFT GREASE CYLINDER
14. 105-303 16 FLG BOLT (5/8-NC X 2-1/2")
15. 107-773 4 SCREW (1/2-NC X 4.25, GD8) USE 242 LOCTITE; TORQUE TO 130 FT LB
16. 158-949 1 HYDRAULIC MOTOR
158-951 1 HYDRAULIC MOTOR
17. 105-994 16 FLG LOCKNUT (5/8-NC)
18. 105-070 4 LOCK WASHER (.500")
19. 155-768 2 O-RING (155 D70)
20. 350-758 1 RIGHT ROLLER FRAME
21. 106-616 20 SCREW (M16-2.00 X 55mm, 10.9) QTY OF 36 BEFORE S/N
22. 106-545 27 LOCKNUT (M16-2.00,PRV TRQ, 10.9)
23. 354-529 2 SPRING GUIDE
24. 350-831 1 ROPS SUPPORT PLATE
25. 159-453 2 COUNTERBALANCE MANIFOLD OBSOLETE
158-020 HYDRAULIC VALVE
26. 105-599 8 BOLT (3/8-NF X 4.000")
27. 105-072 8 LOCK WASHER (3/8")
28. 106-390 8 WASHER (M10)
29. 354-569 1 LEFT TRACK GUARD
30. 106-398 56 WASHER (M16, HARDENED)
31. 105-597 14 BOLT (1-NC X 7.50", GD8)
32. 105-919 14 FLG NUT (1-NC)
33. 354-570 1 RIGHT TRACK GUARD
34. 107-598 16 SCREW (M16 X 60MM 10.9) BEGINS WITH S/N 2T3577
35. 106-442 16 FLG LKNUT (M16-2.00, PRV TRQ, 10.9) USE LOCTITE 242; TORQUE EVENLY TO 250 FT-LB
NOT SHOWN:
FOOTNOTES:
NOTE:
04 ID0145188
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
NOTES:
ID0134963
87
OPERATORS
STATION
88
OPERATOR STATION
53
58 60 54
22
61 1
2
3
59 4
5
44
61
11 11
39 12
6 25
14 15
7 13
29 8 16
31 17
10
13
30
41
33 48 28
43 47 45 34
27 42 20 29
48 57 40
55 49
49 47 56 32
26 19
47
25
56
57 9 48
46
24 8
30
36 20
23 51
18
35
21
38 47
37 6 52
50
R 805-629
89
OPERATOR STATION
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
1. 350-746 1 OPERATOR FRAME
2. 117-156 1 TORSION SPRING
3. 354-454 1 HANDLE SPACER
4. 125-813 2 COMPOSITION BUSHING (1")
5. 354-390 1 HANDLE
6. 106-345 2 SCREW (M20-2.50 X 50mm)
7. 105-423 1 WASHER (3/4")
8. 111-001 2 WASHER (M51.2)
9. 125-754 1 COMPOSITION BUSHING (2")
10. 179-226 1 TAPERED PIN (50.8mm X 272mm)
11. 105-245 3 SCREW (M10-1.50 X 25mm)
12. 106-396 1 WASHER (M10, HARDENED)
13. 110-084 2 BRASS BUSHING (1-5/32")
14. 125-771 1 COMPOSITION BUSHING (1.25")
15. 181-981 1 TAPERED INSERT (1")
16. 151-031 1 CYL (2" X 1" X 8")
17. 125-770 1 COMPOSITION BUSHING (1")
18. 184-064 1 TAPERED INSERT (2")
19. 350-989 2 FLOOR TREADS
20. 106-561 5 LOCKNUT (M8-1.25, PRV TRQ, 10.9)
21. 106-399 1 WASHER (M20, HARDENED)
22. 106-336 1 SCREW (M12-1.75 X 90mm)
23. 350-750 - MAIN FRAME
24. 105-503 1 ROLL PIN (1/4" X 2")
25. 110-093 2 MACHINERY BUSHING (1-1/4", 18GA)
26. 179-225 1 PIN (31.75mm X 60mm)
27. 350-988 1 CHANNEL COVER
28. 183-767 1 TAPERED PIN (25.4mm X 60mm)
29. 106-991 7 FLG LK SCREW (M8-1.25 X 20mm)
30. 106-551 10 CLIP NUT (M8-1.25)
31. 106-685 1 LOCKNUT (M12-1.75, PRV TRQ, 10.9)
32. 106-381 4 FLG LK SCREW (M8-1.25 X 25MM)
33. 106-992 4 FLG LK SCREW (M8-1.25 X 25MM)
34. 354-488 1 STEP
35. 354-500 1 WIRE COVER
36. 354-502 1 WIRE COVER
37. 106-595 4 SCREW (M6-1.00 X 60mm)
38. 106-388 4 WASHER (M6)
39. 105-223 1 WASHER (3/8")
40. 306-609 1 HIGH FREQUENCY HORN------------------ OBSOLETE
192-006 1 HIGH FREQUENCY HORN
192-005 1 HORN BRACKET
41. 214-416 1 HORN (ELECTRIC)
42. 106-538 2 LOCKNUT (M6-1.00, PRV TRQ, 10.9)
FOOTNOTES
NOTE:
R 805-629
90
OPERATOR STATION
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
43. 106-389 2 WASHER (M8)
44. 106-988 2 FLG LK SCREW (M6-1.00 X 20mm)
45. 354-586 1 BRACKET (PROX SWITCH) ENDS WITH S/N 2S4081
307-773 1 BRACKET, SWITCH BEGINS WITH S/N 2S4081
46. 359-951 1 BRACKET (PROX SWITCH) ENDS WITH S/N 2S4081
307-771 1 TARGET PLATE BEGINS WITH S/N 2S4081
47. 106-048 4 LOCKNUT (#10-24) ENDS WITH S/N 2S4081
106-850 10 LOCKNUT (M5-.80) BEGINS WITH S/N 2S4081
48. 106-049 4 BOLT (#10-24 X 3/4", PHLPS) ENDS WITH S/N 2S4081
107-430 6 SCREW (M5-.80 X 14MM) BEGINS WITH S/N 2S4081
49. 217-227 2 PROXIMITY SWITCH ENDS WITH S/N 2S4081
214-692 2 PROXIMITY SWITCH BEGINS WITH S/N 2S4081
50. 214-088 1 CABLE ASS'Y (6GA X 200 MM)
51. 106-217 1 BOLT (1/4-NC X 1", SIL BRZ)
52. 106-455 1 LOCKNUT (1/4-NC, SIL BRZ)
53. 354-905 1 CUP HOLDER
54. 110-560 3 POP RIVET (3/16" X 1/2", ALUM)
55. 307-772 1 BRACKET, SWITCH
56. 106-426 4 SCREW (M5-.80 X 25MM, SOC)
57. 214-683 2 PROX SWITCH HARNESS
58. 216-032 1 VOLT LIMITER (EL STR SYSTEM)
59. 215-799 1 VOLTAGE STAKE
60. 106-205 3 WASHER (.191")
61. 115-355 2 GROMMET (1-3/8)
FOOTNOTES
NOTE:
R 805-629
91
92
93
94
95
96
97
98
CONSOLE GAUGES
JT4020
ENDS WITH S/N 2T4301
22 21
26
16
23
17 28
24
5
4 1
3
2 25
15
34 20
12 6 18
5
22
7
19
32
14
23 8
30
35
26
13
29 11
31
10
27
33
16 ID0121248
99
CONSOLE GAUGES
JT4020
ENDS WITH S/N 2T4301
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
1. 350-996 - LEFT CONSOLE COVER
2. 306-608 1 BUTTON COVER
3. 217-907 1 ROCKER SWITCH (DPDT) ON-ON
4. 217-911 6 ROCKER SWITCH (SPDT) ON-OFF(ON)
5. 217-940 2 FLUID FLOW POTENTIOMETER
6. 306-607 1 HORN BUTTON
7. 217-221 1 FLOW METER DISPLAY
8. 350-998 - RIGHT CONSOLE
9. 217-917 1 ROCKER SWTCH (DPDT) OFF-(ON)
10. 214-852 1 IGNITION SWITCH
214-961 KEY, PAIR (BASE CODE) (OLD STYLE)
214-962 SWITCH MOUNTING NUT
11. 191-078 1 JOYSTICK AND HARNESS KIT INCLUDES JOYSTICK & HARNESS
307-288 1 BOOT (RUBBER) OLD STYLE
214-473 1 JOYSTICK 'HANDLE' {GRAY} OLD STYLE
499-108 - PUSH BUTTON OLD STYLE
499-109 - 3 POSITION SWITCH OLD STYLE
599-285 1 JT420 JOYSTICK CONVERSION KIT INCLUDES JOYSTICK & HARNESS. SEE FOOTNOTE 2
107-414 4 SCREW (M4-.70 X 30mm, BUT SOC) NEW REPLACEMENT
107-514 4 CLIP NUT (M4-.70) NEW REPLACEMENT
214-703 1 DUAL AXIS JOYSTICK NEW REPLACEMENT
217-279 1 JOYSTICK HARNESS NEW REPLACEMENT
12. 348-896 1 COVER PLATE
13. 217-552 1 PRESSURE GAUGE (6000 PSI) FOR UNITS WITHOUT 90D ANTENNA
14. 191-048 1 PRESSURE GAUGE KIT
15. 214-413 1 RIG RF CABLE (2130mm)
16. 217-156 2 DIFFUSION LENS (GREEN)
17. 217-923 1 ROCKER SWITCH (DPDT) ON-OFF-ON
217-925 1 ROCKER SWITCH (ACTUATOR)
18. 106-205 4 WASHER (.191")
19. 217-079 1 PRESSURE GAUGE (10,000 PSI)
20. 110-560 4 POP RIVET (3/16" X 1/2", ALUM)
21. 217-232 1 EL STR SYS CONTROL MODULE ELECTRIC STRIKE SYSTEM
197-232 (ESID) CONTROL MODULE REBUILT REPLACEMENT FOR 217-232
22. 106-640 8 SCREW (M6-1.00 X 20mm, BUT SOC)
23. 106-670 8 NUTSERT (M6-1.00)
24. 217-912 1 ROCKER SWITCH (DPDT) ON-ON-ON
25. 214-489 2 ROCKER SWITCH (DPDT) (ON) OFF (ON)
26. 221-177 1 ANTENNA UHF US-UK EXR450TN CEN USA
219-948 - ANTENNA 420-450MHZ RT ANG TNC INTERNATIONAL
27. 106-049 4 BOLT (#10 - 24 X 3/4", PHLPS)
28. 275-089 1 STEERING WHEEL PLAQUE
29. 216-009 1 COVER (13/16", NYLON)
30. 106-049 2 BOLT (#10-24 X 3/4", PLPS)
31. 106-048 2 LOCKNUT (#10-24)
32. 274-949 - FLUID PRESSURE GAUGE 1193 PSI SEE FOOTNOTE 1
33. 116-789 - RUBBER EDGE TRIM 1/8" (12 GA) 1 @ 93", USE 401 LOCTITE
34. 116-789 - RUBBER EDGE TRIM 1/8" (12 GA) 1 @ 83", USE 401 LOCTITE
116-789 - RUBBER EDGE TRIM 1/8" (12 GA)
35. 315-878 1 ADAPTOR PLATE
NOT SHOWN:
FOOTNOTES:
1. REFER TO SERVICE BULLETIN 052-317
2. REFER TO SERVICE BULLETIN 052-321
NOTE:
16 ID0121248
100
ELECTRICAL STRIKE SYSTEM
JT4020
BEGINS WITH S/N 2T4302
22 21
26
16
23
17
28
24
4 1
3
2 25
15
33 20
12 6 18
5
22 35
19 7
14 31
23
8
27
34
26
13
29 11
30
10
27
32
07 ID0052002
101
ELECTRICAL STRIKE SYSTEM
JT4020
BEGINS WITH S/N 2T4302
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
1. 350-996 - LEFT CONSOLE COVER
2. 306-608 1 BUTTON COVER
3. 217-907 1 ROCKER SWITCH (DPDT) ON-ON
4. 217-911 6 ROCKER SWITCH (SPDT) ON-OFF(ON)
5. 217-940 2 FLUID FLOW POTENTIOMETER
6. 306-607 1 HORN BUTTON
7. 217-221 1 FLOW METER DISPLAY
8. 350-998 - RIGHT CONSOLE
9. 217-917 1 ROCKER SWTCH (DPDT) OFF-(ON)
10. 214-852 1 IGNITION SWITCH
214-961 KEY, PAIR (BASE CODE)
214-962 SWITCH MOUNTING NUT
11. 191-078 1 JOYSTICK AND HARNESS KIT OBSOLETE INCLUDES JOYSTICK & HARNESS (OLD STYLE)
307-288 1 BOOT (RUBBER) OLD STYLE
214-473 1 JOYSTICK 'HANDLE' {GRAY} OLD STYLE
499-108 - PUSH BUTTON OLD STYLE
499-109 - 3 POSITION SWITCH OLD STYLE
599-285 1 JT4020 JOYSTICK CONVERSION KIT INCLUDES JOYSTICK AND HARNESS. SEE FOOTNOTE 2
107-414 4 SCREW (M4-.70 X 30mm, BUT SOC) NEW REPLACEMENT
107-516 4 CLIP NUT (M4-.70) NEW REPLACEMENT
214-703 1 DUAL AXIS JOYSTICK NEW REPLACEMENT
217-279 1 JOYSTICK HARNESS NEW REPLACEMENT
12. 348-896 1 COVER PLATE FOR UNITS WITHOUT 90D ANTENNA
13. 217-552 1 PRESSURE GAUGE (6000 PSI)
14. 191-048 1 GAUGE KIT
15. 214-413 1 RIG RF CABLE (2130mm)
16. 217-156 2 DIFFUSION LENS (GREEN)
17. 217-923 1 ROCKER SWITCH (DPDT) ON-OFF-ON
217-925 1 ROCKER SWITCH (ACTUATOR)
18. 106-205 4 WASHER (.191")
19. 217-079 1 PRESSURE GAUGE (10,000 PSI)
20. 110-560 4 POP RIVET (3/16" X 1/2", ALUM)
21. 217-241 1 ESID MODULE NEW (T)
197-079 - REBUILT ESID MODULE 217-241 ELECTRIC STRIKE SYSTEM
22. 106-640 8 SCREW (M6-1.00 X 20MM, BUT SOC)
23. 106-670 8 NUTSERT (M6-1.00)
24. 214-912 1 ROCKER SWITCH (DPST) ON-OFF
25. 214-489 2 ROCKER SWITCH (DPST) (ON) OFF (ON)
26. 221-177 1 ANTENNA UHF US-UK EXR450TN CEN USA
219-948 - ANTENNA 420-450MHZ RT ANG TNC INTERNATIONAL
27. 106-049 6 BOLT (#10-24 X 3/4", PLPS)
28. 275-089 1 STEERING WHEEL PLAQUE
29. 216-009 1 COVER (13/16", NYLON)
30. 106-048 2 LOCKNUT (#10-24)
31. 274-949 - FLUID PRESSURE GAUGE 1193 PSI SEE FOOTNOTE 1
32. 116-789 - RUBBER EDGE TRIM 1/8" (12 GA) 1 @ 93", USE 401 LOCTITE
33. 116-789 - RUBBER EDGE TRIM 1/8" (12 GA) 1 @ 83", USE 401 LOCTITE
34. 315-878 1 ADAPTOR PLATE
35. 319-412 1 FLOW METER WEATHER COVER
NOT SHOWN:
FOOTNOTES:
1. REFER TO SERVICE BULLETIN 052-317
2. REFER TO SERVICE BULLETIN 051-321
NOTE:
07 ID0052002
102
103
104
NOTES:
ID0134963
105
HYDRAULICS
ID0135071
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
SPINDLE BRAKE
13
14 7
15
8
6
4
11 9
5 12
2 10
06 ID0063518
131
SPINDLE BRAKE
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
1. 350-752 - RIGHT CARRIAGE SIDE REUSE EXISTING SIDEPLATE & FITTINGS
2. 515-732 - HOSE (16OFX90M-40"-6000) REUSE EXISTING HOSE
3. 115-715 - ABRASION SLEEVE (2.07" X 42") REUSE EXISTING ABRASION SLEEVE
4. 149-777 1 HOSE (16OFX90S-26"-6000)
5. 117-296 1 ABRASION SLEEVE (2.07" X 30")
6. 117-678 1 ABRASION SLEEVE (1.75" X 29")
7. 158-012 - HYDRAULIC MOTOR OBSOLETE REUSE EXISTING MOTOR & FITTINGS
153-245 - HYDRAULIC MOTOR
8. 160-1099 1 MODULAR BRAKE SEE FOOTNOTE 1 & 2
500-1283 - OIL SEAL
191-166 - O-RING KIT (160-510)
191-167 - GASKET KIT (160-510)
191-168 - BEARING KIT (160-510)
191-169 - STACK SERVICE KIT (160-510)
163-212 - BLEEDER SCREW, DISC BRAKE
9. 166-152 - ROTATION GEARBOX PLANETARY
10. 149-823 1 HOSE (12OFX90L-26"-3000)
11. 107-495 4 BLT (1/2-NC X 4.50", SOC) GD 8 USE 242 LOCTITE
12. 166-148 - ROTATION DRIVE GEARBOX REUSE EXISTING GEARBOX
13. 105-997 - BOLT (5/8-NC X 1-3/4", SOC) REUSE EXISTING BOLTS, USE 242 LOCTITE
14. 106-398 - WASHER (M16, HARDENED) REUSE EXISTING WASHERS
15. 154-411 1 CONNECTOR (04S-06O) SEE FOOTNOTE 2
NOT SHOWN:
FOOTNOTES:
1. BRAKE IS SHIPPED DRY. BEFORE INSTALLING FILL WITH 5 OZ. OF THF LOCATION OF THE FILLER DRAIN PORT
IS APPROXIMATELY MIDWAY BETWEEN FRONT & REAR OF THE BODY.
PUT THE 5 OZ. OF THF IN ONE OF THESE PORTS.
2. LOCATION OF THE PRESSURE/BLEEDER PORTS IS NEARER THE MOTOR MOUNT END OF THE BODY.
ONE OF THESE PORTS WILL HAVE A BLEEDER VALVE IN IT. INSTALL THE CONNECTOR FITTING IN THE OTHER PORT
AND POINT TOWARD HOSE TRACK SIDE OF CARRIAGE.
NOTE:
06 ID0063518
132
SPINDLE BRAKE HYDRAULICS
8
TO GEARBOX
7
3
D
EE
SP ST
2-H RU
T
D
EE
- SPCK
2 RA VE
T RI
D
5 TO EXISTING HOSE
06 ID0063517
133
SPINDLE BRAKE HYDRAULICS
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
1. 158-012 - HYDRAULIC MOTOR OBSOLETE
153-245 - HYDRAULIC MOTOR
2. 160-1099 - MODULAR BRAKE
500-1283 - OIL SEAL
191-166 - O-RING KIT
191-167 - GASKET KIT
191-168 - BEARING KIT
191-169 - STACK SERVICE KIT
163-212 - BLEEDER SCREW, DISC BRAKE
3. 350-767 - HOSE TRACK (5" X 150")
4. 117-209 - ABRASION SLEEVE (1.00" X 90")
5. 149-824 1 HOSE (06OFX90S-240"-3000)
6. 154-344 1 UN RUN TEE (06OFX-06O-06O)
7. 117-676 1 ABRASION SLEEVE (1.00" X 30")
8. 154-411 - CONNECTOR (04S-06O)
NOT SHOWN:
FOOTNOTES:
NOTE:
06 ID0063517
134
135
136
TRACK SHIFT
FROM TWO-SPEED
TRACK VALVE ON
FIREWALL
5
LEFT 3
5
PILOT
RIGHT
03 ID0109733
137
TRACK SHIFT
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
1. 154-797 1 HOSE (06OFX-48"-3000)
2. 514-049 2 CONNECTOR (04S-06O90)
3. 154-344 1 UNION RUN TEE (06OFX-06O-06O)
4. 154-806 1 HOSE (06OFX-54"-3000)
5. 159-453 - COUNTERBALANCE MANIFOLD OBSOLETE, SERVICE CARTRIDGE
NOT SHOWN:
FOOTNOTES:
NOTE:
REFER TO O-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS.
03 ID0109733
138
139
140
141
142
143
144
145
146
147
148
149
150
TRACK DRIVE HYDRAULICS
20
9
FROM CHARGE
LEF
T FILTER HEAD
PORT OUTSIDE 14
15
2 2 13
4 E
R
SSU
3 AR
G EP
RE
CH
16
3 7
10
HT
RIG
5
4 2
5 11
15
12 2
06 ID0108813
151
TRACK DRIVE HYDRAULICS
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
1. 158-951 1 HYD MOTOR LEFT TRACK
2. 154-300 4 CONNECTOR (10O-12S90)
3. 515-520 2 HOSE (10OFX90-15.5"-3000)
4. 154-301 2 CONNECTOR (10S-10O)
5. 154-298 2 CONNECTOR (10S-10O90)
6. 515-597 2 HOSE (10OFX90-17"-3000)
7. 158-949 1 HYD MOTOR RIGHT TRACK
8. 154-345 1 RUN TEE (06S-06O-06O)
9. 515-151 1 HOSE (06OFX90-96"-3000)
10. 106-079 4 SCREW (M10-1.50 X 30mm)
11. 106-396 4 WASHER (M10, HARDENED)
12. 105-894 4 LOCKNUT (M10-1.50,PRV TRQ,10.9)
13. 516-119 1 HYD CONTROL VALVE
14. 117-713 1 ABRASION SLEEVE (1.00" X 76")
15. 159-453 2 COUNTERBALANCE MANIFOLD OBSOLETE
158-020 HYDRAULIC VALVE
16. 154-224 1 CONNECTOR (06S-06O45) BACK PORT (NOT SHOWN)
17. 154-252 2 CONNECTOR (04S-04O90)
18. 154-265 1 UN RUN TEE (04OFX-04O-04O)
19. 154-278 2 CONNECTOR (04S-04O)
20. 159-157 1 QDC ADAPTER (02-06OF)
NOT SHOWN:
FOOTNOTES:
NOTE:
REFER TO O-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS.
06 ID0108813
152
TRACK CASE DRAIN HYDRAULICS
TO LOWER COOLER TUBE
6
T
LEF
1
3
5 RIG
HT
2
3
03 ID0069569
153
TRACK CASE DRAIN HYDRAULICS
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
1. 158-949 - HYDRAULIC MOTOR
2. 159-453 - COUNTERBALANCE MANIFOLD OBSOLETE
3. 154-252 2 CONNECTOR (04S-04O90)
4. 154-265 1 UN RUN TEE (04OFX-04O-04O)
5. 154-728 2 HOSE (04OFX90-36"-3000)
6. 158-951 - HYDRAULIC MOTOR
NOT SHOWN:
FOOTNOTES:
NOTE:
REFER TO O-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS.
03 ID0069569
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
HYDRAULIC CYLINDER
2.0" ID BARREL X 1.00" OD ROD X 3.0" STROKE
1
3
C 806-686
195
HYDRAULIC CYLINDER
2.0" ID BARREL X 1.00" OD ROD X 3.0" STROKE
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
151-173 HYD CYL (2" X 1" X 3") INCLUDES REF NO.'S 1 THRU 7
1. 190-165 1 SEAL REPAIR KIT (2" X 1")
2. 150-778 1 LOCK RING (2")
3. 150-282 1 CYLINDER BARREL (2")
4. 106-096 1 FLG BOLT (1/2-NC X 1-3/4", GD8) SEE FOOTNOTE 1
5. 150-775 1 CYLINDER PISTON (2" X 1")
6. 150-772 1 CYLINDER HEAD (2" X 1")
7. 150-680 1 CYLINDER ROD (1")
NOT SHOWN:
259-100 U-SEAL INSTALLER (1" - 1.499")
259-235 WIPER INSTALLER (1")
259-239 WIPER/SEAL INSTALLER (2")
259-241 PISTON INSTALLER (2")
259-188 CYL HEAD SPANNER - TWO PIN
FOOTNOTES
1. APPLY LOCTITIE 271 OR 277. TORQUE TO 90-100 FT-LBS (120-135 N.M.)
NOTE:
C 806-686
196
HYDRAULIC CYLINDER
(4.0" X 2.00" X 10.0")
1
3
4
5
D 806-688
197
HYDRAULIC CYLINDER
(4.0" X 2.00" X 10.0")
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
151-187 CYLINDER ASSEMBLY INCLUDES REF NO.'S 1 THRU 7
1. 190-189 1 SEAL REPAIR KIT (4.0" X 2.0") INCLUDES REF. NO.'S 4 & 5
2. 149-303 1 LOCK RING (4")
3. 152-071 1 CYLINDER BARREL
4. 106-145 1 BOLT (1-NC X 2-1/4", GD8) SEE FOOTNOTE 1
5. 106-144 1 WASHER (1")
6. 149-307 1 CYLINDER PISTON (4" X 2")
7. 149-006 1 CYLINDER HEAD (4" X 2")
8. 153-016 1 CYLINDER ROD
NOT SHOWN:
259-040 U-SEAL INSTALLER (1.500"-UP)
259-239 WIPER/SEAL INSTALLER (2")
259-246 PISTON SEAL INSTALLER (4")
259-247 PISTON INSTALLER (4")
259-188 CYL HEAD SPANNER - TWO PIN
FOOTNOTES
1 APPLY LOCTITE 271 OR 277. TORQUE TO 630-700 FT-LBS (855-950 N.M.)
NOTE:
D 806-688
198
199
200
HYDRAULIC CYLINDERS (2.0" X 1.0")
11
13 12
4
8
9
3
10
03 ID0015823
201
HYDRAULIC CYLINDERS (2.0" X 1.0")
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
151-094 - CYL (2.0 X 1.0 X 2.0) SEE FOOTNOTES 1 & 2
1 152-029 1 CYLINDER BARREL (2.0 X 2.0)
2 153-007 1 CYLINDER ROD (1.00 X 2.0)
149-667 - CYL (2.0 X 1.0 X 2.5) SEE FOOTNOTES 1 & 2
1 149-761 1 CYLINDER BARREL (2.0 X 2.5)
2 149-728 1 CYLINDER ROD (1.00 X 2.5)
151-027 - CYL (2.0 X 1.0 X 3.0) SEE FOOTNOTES 1 & 2
1 150-282 1 CYLINDER BARREL (2.0 X 3.0)
2 150-414 1 CYLINDER ROD (1.00 X 3.0)
151-038 - CYL (2.0 X 1.0 X 4.0) SEE FOOTNOTES 1 & 2
1 150-290 1 CYLINDER BARREL (2.0 X 4.0)
2 150-421 1 CYLINDER ROD (1.00 X 4.0)
151-039 - CYL (2.0 X 1.0 X 5.0) SEE FOOTNOTES 1 & 2
1 150-291 1 CYLINDER BARREL (2.0 X 5.0)
2 150-422 1 CYLINDER ROD (1.00 X 5.0)
151-044 - CYL (2.0 X 1.0 X 6.0) SEE FOOTNOTES 1 & 2
1 150-294 1 CYLINDER BARREL (2.0 X 6.0)
2 150-424 1 CYLINDER ROD (1.00 X 6.0)
151-031 - CYL (2.0 X 1.0 X 8.0) SEE FOOTNOTES 1 & 2
1 150-285 1 CYLINDER BARREL (2.0 X 8.0)
2 150-417 1 CYLINDER ROD (1.00 X 8.0)
151-076 - CYL (2.0 X 1.0 X 10.0) SEE FOOTNOTES 1 & 2
1 152-017 1 CYLINDER BARREL (2.0 X 10.0)
2 150-444 1 CYLINDER ROD (1.00 X 10.0)
149-668 - CYL (2.0 X 1.0 X 12.0) SEE FOOTNOTES 1 & 2
1 150-286 1 CYLINDER BARREL (2.0 X 12.0)
2 149-729 1 CYLINDER ROD (1.00 X 12.0)
.
3 150-772 1 CYLINDER HEAD (2.0 X 1.00)
4 150-778 1 LOCK RING (2.0)
5 150-775 1 CYLINDER PISTON (2.0 X 1.00)
6 106-096 1 FLG BOLT (1/2-NC X 1-3/4",GD8) SEE FOOTNOTE 3
7 157-022 1 O-RING (224 D90)
8 155-732 1 BACKUP RING (224 D90)
9 157-540 1 U-SEAL (1.000")
10 157-537 1 WIPER SEAL (1.000")
11 125-774 1 WEAR RING
12 157-534 1 BACKUP RING (131 D90)
13 157-018 1 O-RING (131 D90)
NOT SHOWN:
259-100 U-SEAL INSTALLER (1" - 1.499")
259-235 1.00 ROD WIPER TOOL
259-239 WIPER/SEAL INSTALLER (2")
259-241 PISTON INSTALLER (2")
259-188 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:
03 ID0015823
202
HYDRAULIC CYLINDERS (3.0" X 1.75")
6
11
7
8
4
9
3
10
A 809-366
203
HYDRAULIC CYLINDERS (3.0" X 1.75")
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
149-683 - CYL (3.0 X 1.75 X 3.0) SEE FOOTNOTES 1 & 2
1 150-299 1 CYLINDER BARREL (3.0 X 3.0)
2 150-446 1 CYLINDER ROD (1.75 X 3.0)
149-684 - CYL (3.0 X 1.75 X 4.0) SEE FOOTNOTES 1 & 2
1 152-004 1 CYLINDER BARREL (3.0 X 4.0)
2 153-015 1 CYLINDER ROD (1.75 X 4.0)
149-685 - CYL (3.0 X 1.75 X 5.0) SEE FOOTNOTES 1 & 2
1 152-068 1 CYLINDER BARREL (3.0 X 5.0)
2 150-432 1 CYLINDER ROD (1.75 X 5.0)
151-058 - CYL (3.0 X 1.75 X 6.0) SEE FOOTNOTES 1 & 2
1 152-008 1 CYLINDER BARREL (3.0 X 6.0)
2 150-428 1 CYLINDER ROD (1.75 X 6.0)
151-070 - CYL (3.0 X 1.75 X 8.0) SEE FOOTNOTES 1 & 2
1 152-014 1 CYLINDER BARREL (3.0 X 8.0)
2 150-436 1 CYLINDER ROD (1.75 X 8.0)
149-686 - CYL (3.0 X 1.75 X 10.0) SEE FOOTNOTES 1 & 2
1 150-284 1 CYLINDER BARREL (3.0 X 10.0)
2 149-732 1 CYLINDER ROD (1.75 X 10.0)
151-042 - CYL (3.0 X 1.75 X 12.0) SEE FOOTNOTES 1 & 2
1 150-293 1 CYLINDER BARREL (3.0 X 12.0)
2 150-425 1 CYLINDER ROD (1.75 X 12.0)
151-083 - CYL (3.0 X 1.75 X 16.0) SEE FOOTNOTES 1 & 2
1 150-288 1 CYLINDER BARREL (3.0 X 16.0)
2 153-004 1 CYLINDER ROD (1.75 X 16.0)
151-122 - CYL (3.0 X 1.75 X 20.0) SEE FOOTNOTES 1 & 2
1 150-667 1 CYLINDER BARREL (3.0 X 20.0)
2 153-020 1 CYLINDER ROD (1.75 X 20.0)
149-687 - CYL (3.0 X 1.75 X 24.0) SEE FOOTNOTES 1 & 2
1 149-763 1 CYLINDER BARREL (3.0 X 24.0)
2 149-733 1 CYLINDER ROD (1.75 X 24.0)
149-688 - CYL (3.0 X 1.75 X 30.0) SEE FOOTNOTES 1 & 2
1 149-764 1 CYLINDER BARREL (3.0 X 30.0)
2 149-734 1 CYLINDER ROD (1.75 X 30.0)
.
3 150-763 1 CYLINDER HEAD (3.0 X 1.75)
4 150-911 1 LOCK RING (3.0)
5 150-765 1 CYLINDER PISTON (3.0 X 1.75) INCL. MOLDED-ON WEAR RING
6 106-122 1 BOLT (7/8-NC X 2-1/4", GD8) SEE FOOTNOTE 3
7 155-734 1 O-RING (334 D90)
8 155-733 1 BACKUP RING (334 D90)
9 157-550 1 U-SEAL (1.750")
10 157-549 1 WIPER SEAL (1.750")
11 105-363 1 WASHER (7/8")
FOOTNOTES
1. REF. #1 & #2 ARE SPECIFIC TO EACH CYLINDER, REF. #3 THRU #11 ARE COMMON FOR ALL THE ABOVE LISTED CYLINDERS.
2. SEAL REPAIR KIT P/N: 190-172
3. APPLY LOCTITE 277 OR EQUIVALENT, TORQUE TO 410-460 FT-LBS
NOT SHOWN:
259-040 U-SEAL INSTALLER (1.5" - UP)
259-238 WIPER INSTALLER (1.75")
259-244 PISTON SEAL INSTALLER (3.5")
259-245 PISTON INSTALLER (3.5")
259-188 CYL HEAD SPANNER - TWO PIN
A 809-366
204
HYDRAULIC CYLINDERS (4.0" X 2.0")
6
14 11
12
13
5
4
9
8
10
A 809-369
205
HYDRAULIC CYLINDERS (4.0" X 2.0")
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
149-698 - CYL (4.0 X 2.0 X 4.0) SEE FOOTNOTES 1 & 2
1 149-768 1 CYLINDER BARREL (4.0 X 4.0)
2 153-021 1 CYLINDER ROD (2.00 X 4.0)
151-066 - CYL (4.0 X 2.0 X 5.0) SEE FOOTNOTES 1 & 2
1 152-012 1 CYLINDER BARREL (4.0 X 5.0)
2 150-440 1 CYLINDER ROD (2.00 X 5.0)
149-699 - CYL (4.0 X 2.0 X 6.0) SEE FOOTNOTES 1 & 2
1 152-062 1 CYLINDER BARREL (4.0 X 6.0)
2 149-735 1 CYLINDER ROD (2.00 X 6.0)
149-700 - CYL (4.0 X 2.0 X 8.0) SEE FOOTNOTES 1 & 2
1 152-030 1 CYLINDER BARREL (4.0 X 8.0)
2 149-736 1 CYLINDER ROD (2.00 X 8.0)
149-701 - CYL (4.0 X 2.0 X 10.0) SEE FOOTNOTES 1 & 2
1 149-769 1 CYLINDER BARREL (4.0 X 10.0)
2 153-016 1 CYLINDER ROD (2.00 X 10.0)
151-088 - CYL (4.0 X 2.0 X 12.0) SEE FOOTNOTES 1 & 2
1 150-298 1 CYLINDER BARREL (4.0 X 12.0)
2 150-429 1 CYLINDER ROD (2.00 X 12.0)
149-702 - CYL (4.0 X 2.0 X 16.0) SEE FOOTNOTES 1 & 2
1 152-007 1 CYLINDER BARREL (4.0 X 16.0)
2 149-737 1 CYLINDER ROD (2.00 X 16.0)
149-703 - CYL (4.0 X 2.0 X 20.0) SEE FOOTNOTES 1 & 2
1 149-770 1 CYLINDER BARREL (4.0 X 20.0)
2 149-738 1 CYLINDER ROD (2.00 X 20.0)
149-704 - CYL (4.0 X 2.0 X 24.0) SEE FOOTNOTES 1 & 2
1 152-063 1 CYLINDER BARREL (4.0 X 24.0)
2 149-739 1 CYLINDER ROD (2.00 X 24.0)
.
3 149-006 1 CYLINDER HEAD (4.0 X 2.00)
4 149-303 1 LOCK RING (4.0)
5 149-307 1 CYLINDER PISTON (4.0 X 2.00)
6 106-145 1 BOLT (1-NC X 2-1/4", GD8) SEE FOOTNOTE 3
7 157-035 1 O-RING (342 D90)
8 157-036 1 BACKUP RING (342 D90)
9 157-559 1 U-SEAL (2.000")
10 157-558 1 WIPER SEAL (2.000")
11 125-793 1 WEAR RING
12 157-570 1 BACKUP RING (238 D90)
13 157-044 1 O-RING (238 D90)
14 106-144 1 WASHER (1")
FOOTNOTES
1. REF. #1 & #2 ARE SPECIFIC TO EACH CYLINDER, REF. #3 THRU #14 ARE COMMON FOR ALL THE ABOVE LISTED CYLINDERS.
2. SEAL REPAIR KIT P/N: 190-189
3. APPLY LOCTITE 277 OR EQUIVALENT, TORQUE TO 630-700 FT-LBS
NOT SHOWN:
259-040 U-SEAL INSTALLER (1.5" - UP)
259-239 WIPER/SEAL INSTALLER (2")
259-246 PISTON SEAL INSTALLER (4")
259-247 PISTON INSTALLER (4")
259-188 CYL HEAD SPANNER - TWO PIN
A 809-369
206
NOTES:
ID0134963
207
ELECTRICAL
ID0135070
208
209
210
211
212
213
214
ELECTRICAL DIAGRAM
ENGINE HARNESS
GAUGE HARNESS
ORG/BLU
BLU BLK (12)
(30) (1) TAN/RED GRA/YEL
(24) (36)
ORG/BRN ORG
(18) 6 5 4 3 2 1
(11)
LT.BLU/RED
7 8 9 10 11 12
GRN
(33) (31)
ORG/BLK GRA/BLK
(40) BRN GRA/YEL (37)
(29) (36)
BLK
(1)
RED/ORG PUR
(67) (20)
ROTATION PUMP BLK (1)
BLK (1)
RED/YEL
(68)
TURBO TORQUE GRA/RED
ORG/BLU
SOLENOID (115)
(12)
BLK ORG WHT/BLU
(1)
(11) (42) BLK
6 14 BRN/ORG
(1) RED/YEL
(68)
ORG/BLK
WHT/ORG (21)
(43) (40)
COLD BRN/ORG TAN/RED
(24)
K
X
J
W
V
GRA/RED
(115)
START (21)
GRN/BLK
L B H U
M C A G BRN/YEL
(44) T
(105)
N D F
ORG/GRN E S GRA/BLK
(17) O R (37)
P Q
BLK LT.BLU/RED DRK. BLU/RED
(1) (33) (100)
WHT/PUR
(51A) GRA/YEL
4 ORG/BRN
(18)
(36)
RED/ORG WHT/GRN
(35) GRA/BLK
(67)
(91)
HYD. FILTER TO RELAY HARNESS
GRA/YEL
(36)
15
2SPD. MOBILE BRN/YEL
(105)
BLK
(1)
HIGH SPEED
CARRIAGE GRA/BLK
THRUST (91)
BLK
(1)
15
-A-
01 ID0155413
215
ELECTRICAL DIAGRAM
ENGINE HARNESS
-A-
WATER TEMP WATER TEMP
SENDER SWITCH.
TO FUEL
SOLENOID
3
1
GRN ORG/BLK WHT/GRN
(31) (40) (35)
2
ENGINE BRN
(29)
TO FUEL
BLU OIL PRES. SENDER
(30)
SWITCH
RED
(2)
OIL PRESURE WHT/BLU
(42) PUR
SENDER (20)
10
S
5
BLK (1) GRN
WHT
B M
GRN/BLK (44)
BLK
WHT/ORG (43)
STARTER
BLK
WHT
GRN
RED
BLK
7 ALTERNATOR
LINEAR ACTUATOR
11
BLK
(1)
8
WHT/PUR
(51A)
EL STR SYS STROBE
RED
(2)
BLK ALTERNATOR
DRK BLU/RED
(1)
13 DIODE
(100)
ORG/BLU
(26)
9 12
BLK
(1)
ORG/GRN
(17)
BACKUP ALARM
01 ID0155413
216
ELECTRICAL DIAGRAM
ENGINE HARNESS
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
1. 217-550 1 WATER TEMPERATURE SENDER
2. 215-113 1 OIL PRESSURE SENDER
215-183 1 SENDER, OIL PRESSURE HD
3. 217-575 1 HIGH TEMPERATURE SWITCH
4. N/A 1 RESTRICTION SWITCH
5. 217-736 1 OIL PRESSURE SWITCH
6. 214-209 1 2-WAY MALE CAP
7. 215-231 1 LINEAR ACTUATOR INCL CABLE & ROLL PIN & PIGTAIL
214-299 1 ACTUATOR PIGTAIL
196-331 1 CABLE (LINEAR ACTUATOR)
501-358 - ROLL PIN (3/32" X 3/4") INCL BULB
8. 217-041 1 STROBE LIGHT
217-720 1 BULB (12V DC)
9. 306-602 1 BACKUP ALARM
10. 211-022 1 STARTER
11. 217-451 1 ALTERNATOR
12. 214-256 1 DIODE CONNECTOR
13. 214-480 1 ENGINE HARNESS
14. 217-947 1 COIL
15. 217-770 1 SOLENOID COIL
NOT SHOWN:
FOOTNOTES:
NOTE:
01 ID0155413
217
218
ELECTRICAL DIAGRAM TO OPERATOR
RELAY PANEL HARNESS STATION HARNESS
RF5
RF6
RF7
RF1
RF8
RF4
RF2
RF3
WHT/BLK WHT/ORG
{10} {43} GRN/BLK
{44} BLK
15AMP
15AMP
15AMP
15AMP
15AMP
15AMP
15AMP
15AMP
ORG {1}
{8} X H
W J
WHT/PUR
BRN/ORG {51}
{21} V G K
B
GRA/ORG U F A C
{61} GRA/RED L
2 2 M PUR {115} T E D
S N {20}
ORG/BLUORG/GRN R P
GRA/GRN
ORG {12} {17} ORG/BRN ORG/BLU {66}
{11} {18} {9}BRN/YEL RED/BLU
{105} GRA/BLK RED/ORG {3}
{91} RED/YEL {67}
{68}
ORG ORG/BLU
{8} {9}
DIODE BLOCK 4
LT.BLU/RED TO
{33} LT.BLU/RED WORK
GRA/BLK
{37}
{33}
WHT/GRN
LIGHT
12 11 10 {35}
9 8 7
6 5 4
BLK/ORG
{40}
3
3 2 1
BLK/ORG
{40} GRA/BLK
GRA/YEL {37}
YEL{25}
{36}
BLK{1}
B5
B4
5 B3 BLK
{1}
B2
RED
WHT/ORG{41}
{2}
B1
BLK{1}
A2 1
6
WHT/BLK {10}
ORG/GRN{17}
A1
B5
BLK{1}
1
BACKUP ORG{11}
2 4
3
5
DRKBLU/RED GRA/GRN
RELAY {100} {66}
B4
RED/BLU
STROBE BLK{1}
1
{3}
2 4
3
5
WHT/PUR
RELAY WHT/PUR
{51A} {51}
B3
7
EOP WHT/BLU {42}
1
ORG/GRN
SHUTDOWN {17} ORG/BLK
2 4
3
5
{40}
RELAY WHT/ORG
{41}
B A
BLK PUR
B2 {20}
BLK{1} {1}
1
LIGHT TEST BLK/ORG
2 4
3
5
{40} RED/BLU
WHT/BLK
RELAY BLK{1}
{10}
{3} RED/BLK BLU
{4}
{6}
WHT/BLU ORGORG/BLU
BLK {12}
{42} {11}
B1 RED/YEL {1}
1
4
6
BRN/ORG
5
2
3
BLK{1}
SEAT START {68}
1
GRN {21}
3
5
ORG/BLK
2 4
{23} GRA/ORG WHT/ORG
RELAY BLK{1} {61} RED RED
{2}
RED
{2}
{40}
W X {43}
{2} GRA/RED V K TAN/RED
{115} J {24}
RF10
RF11
RF13
RF14
RF12
L
A2 U H B
RF9
BLU BLK{1} BRN/YEL GRN/BLK
86
WORKLIGHT {6} {105} T G A C M {44}
87A
87
30
YEL{25}
RELAY TAN/RED F D N
85
GRA/BLK S E
40AMP
40AMP
20AMP
20AMP
20AMP
20AMP
{24} {37} ORG/GRN O
R {17}
Q P
A1 DRKBLU/RED LTBLU/RED
RED/BLK GRN {100} {33}
START
86
{4} {23} GRA/YEL WHT/PUR
87A
30
87
RELAY WHT/BLK PUR
9 8 9 {36} GRA/BLK RED/ORG {51A}
85
{18} {20} {91} WHT/GRN {67}
ORG/BRN {35}
START BYPASS DELAY {18}
TO ENGINE HARNESS
01 ID0041880
219
ELECTRICAL DIAGRAM
RELAY PANEL HARNESS
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
1. 214-485 1 RELAY PANEL HARNESS
2. 217-811 8 FUSE (ATC, 15 AMP)
3. 214-398 1 WORK LIGHT HARNESS
4. 216-521 1 DIODE BLOCK
5. 217-710 5 MICRO RELAY (SPDT)
6. 217-826 2 MINI RELAY (SPDT)
7. 217-937 1 START BYPASS DELAY TIMER
8. 217-791 2 FUSE (MAXI, 40 AMP)
9. 217-805 4 FUSE (MAXI, 20AMP)
NOT SHOWN:
FOOTNOTES:
NOTE:
01 ID0041880
220
ELECTRICAL DIAGRAM
WORK LIGHT HARNESS
1
1
WORK
LIGHTS
YEL
(25)
BLK
(1)
TO RELAY
PANEL
01 ID0041882
221
ELECTRICAL DIAGRAM
WORK LIGHT HARNESS
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
1. 217-057 2 WORKING LIGHT - CLEAR
2. 214-398 1 WORK LIGHT HARNESS
NOT SHOWN:
FOOTNOTES:
NOTE:
01 ID0041882
222
ELECTRICAL DIAGRAM
OPERATOR STATION HARNESS
JT4020
1 -A-
GRA/ORG
(16)
WHT/ORG
GRN/BLK (43)
(44)
THROTTLE
5
B
D
6
4
C
1
2
A
3
WHT/ORG
(13) GRN/BLK
(44)
BLK
(1)
2 SPEED C D
5
B
4
3 6
1
2
A
GROUND DRIVE ORG BRN/YEL
(105)
(13)
TAN/BLU (28)
HORN ORG (13)
2
3
D
5
4
6
B
C
1
2
A
SHUTTLE BLU/YEL
(94)
GRA/YEL
(95)
BRN/ORG
4 (93)
5
B
C D
4
PIPE GRIP
1
2
A
YEL/RED YEL/BLU
(98) (99)
ORG/WHT
(14)
PIPE LIFT
C D
5
B
4
3 6
1
2
A
PUR/YEL
(96) WHT/YEL
(97)
BRN/ORG
4 (93)
C D
5
B
4
6
1
2
A
FRONT WRENCH BLU/RED
(109)
ORG
(13)
BLU/BLK
(108)
D
5
B
4
6
C
1
2
A
REAR WRENCH
3
TAN/BLK TAN/BLU
(110) (111)
4 ORG
(13)
D
5
6
B
4
C
1
2
A
GRA/BLK GRA/BLU
CAB SWING (107)
ORG
(106)
(13) BLK/YEL (50) BLU A
YEL GRN (49)
BLU (47)
LT GRN
BLK
B
C FLUID POT
GRA/BLU
BRN/ORG (81)
(93)
PIPE LOADER 7
5
D
1 4
A B
6
C
SWITCH
2
3
GRN/BLU YEL
(80) ORG/WHT BLK (1) BLU A
5 (14) GRN/BLK (103)
BLU/BLK (101)
LT GRN
BLK
B
C
ROTATION POT
BLK ORG/RED
(1) (53)
BLK
(1)
B
TO EL STR SYS
C
J
H
D
BRN
G
E
F
(52)
WHT/PUR
(51)
BLK BLK
(1) (1)
C D
B
4
3 6
2 5
ORG (13)
GRN/RED BLU/BRN MOBILE BORE SWITCH
A
1
PUR/RED (114) (63) (65)
YEL/BRN TAN/RED
(64) GRA/ORG (62)
TURBO TORQUE
3 (61)
04 ID0041886
223
ELECTRICAL DIAGRAM
OPERATOR STATION HARNESS
JT4020 -B-
-A-
BLK (1) RED/WHT (15)
BLK/WHT (104) GRA (45)
ROTATION TAN/RED (62)
GRN/BLK (102)
GRA/RED (46)
BLU (47)
DRILL FLUID
SPEED BLU/BLK (101) GRN (48)
BLK (1)
CONTROLLER
CONTROLLER CAVITY PLUG
8
9
BLK
(1)
GRN/BLK GRN/BLK
ROTATION (102)
1
(103)
3
5
4
SPEED RELAY BLK WHT/GRN
10
2
(1) (89)
BLK
(1)
GRN
FLUID SHUTOFF GRN
1
3
5
2 4
(49) (48)
RELAY WHT/GRN
(89)
ORG BLK
FRONT WRENCH WHT/GRN(13)
1
(1) WHT
3
5
4
RELAY
2
(89) (90)
EL STR SYS
RED/BLU
(3A)
GRA/BLK
(116) 11
1
3
5
2 4
ORG/RED RED/BLU
TIMER RELAY (53) (3A)
BLK
(1)
THRUST STOP WHT/BLK
(75)
DIODE
1
ORG/WHT
BLOCK
3
5
4
RELAY (14)
2
TAN/BLK
(92)
RED WHT/RED
(79) (86) RED
ORG/WHT PUR/GRN (79)
HIGH SPEED (14) (77)
10
1
A
C D
5
3
2 4
YEL
RELAY GRA/BLK
B
(91) (76)
YEL
(76) WHT/BLU RED
(78) (79)
ORG/WHT BLK
SLOW DOWN
1
(14) (1)
3
5
BLU/WHT
2 4
RELAY WHT/BLU
(78)
(82)
ORG/BLU
(9) ORG/GRN
(19) 15A
12
RED/BLU
(3) RED/BLU
(3)
15A
15A
13
FUSE BLOCK #2 5A
J1
ORG
(13)
ORG/WHT 15A
12
(14)
15A
ORG
(8) RED/WHT
15A
(15)
5A
FUSE BLOCK #1 GRA/ORG
(16) J1
13
14 15
ORG/RED (53)
GRA/RED (115) WHT/PUR (51)
BLK (1) GRA/BLK (116)
PUR/RED (114) BLK (1)
HYPERTORQUE EL STR SYS
TIMER TIMER
04 ID0041886
224
ELECTRICAL DIAGRAM
OPERATOR STATION HARNESS
JT4020 16
GRN/ORG
1 2 3 4 5 6
12 11 10 9 8 7
(58)
C WHT/BLK
C3 - THRUST STOP (75) GRN/BLU
C2 - MO BILEE NABLE (59)
C1- BORING ENABLE
C9 - THRUST / DRIVE
BLU/BRN
(65)
BLK/ORG
(60)
22
BRN/RED BLU/ORG
C10 - ROTATE / STE ER (63) (57)
A7 - POWER
274988
STATUS ORG/WHT
A8 - CW ROTATION
(14) RED/YEL
A4 - LT TRACK REV ERSE
A3 - LT TRACK FORWARD
(67)
YEL/GRN
12 11 10 9 8 7
TO REMOTE
1 2 3 4 5 6
A2- RT TRACK REVERSE
BLK
A1- RT TRACK F ORWARD
(74) (1)
A11- FORWARD THRUST
A12 - REV ERSE THRUST
A
RED/ORG DISPLAY
A10 - C CWROTATION TAN/GRN (68)
(73) WHT/GRN
(69)
PUR/GRN
JOYSTICK
(72) GRA/GRN BLU/GRN
(70)
23
(71)
FUNCTION
CONTROLLER
TAN/WHT
(84) GRN/RED
GRA/WHT (85)
(83) WHT/RED
B7 - EXTENDED SWT
B (86) TO 1
12 11 10 9 8 7
ORG (13)
1 2 3 4 5 6
BLU/WHT
B4 - SLO WZONE SWT
B3- WRENCH SWT
B2 - BACKREAM SWT
(82) PUR/ORG
(87)
TAN/WHT (27)
BLK (1) TO 3 R 0
B1 - BORE SWT WHT/GRN T/R RST
B8- RETRACTED S WT
(89) BRN/ORG
B6 - FULLBACK SWT
B10 - PIPEBAD SWT (88)
GRA/BLU
B5 - STOPZONES WT
B9 - PIPEOK S WT
274989
(81) GRN/BLU FLUID METER
A7 - POWER (80)
STATUS
A8 - PIPE GRIP OUTPUT ORG/WHT
A4 - PIPEDOWN OUTPUT (14) YEL/RED
A3 - PIPEUP OUTPUT
(98) ORG
A2- EXTEND OUTPUT
(13) TO MAIN
12 11 10 9 8 7
1 2 3 4 5 6
A1- RETRACT OUTPUT WHT/YEL BLK
A11- STOP OUTPUT
A12 - GOFASTER OUTPUT
(97) (1) BLK
(1) FRAME HARNESS
A10- PIPE REL OUTPUT A PUR/YEL YEL/BLU
(96) (99)
WHT/RED
GRA/YEL TAN/BLK GRN/RED WHT/GRN (86)
(95) (92) GRA (85) (69) PUR/GRN
SEQUENTIAL BLU/YEL GRA/BLK (45) GRA/RED BLU/GRN (72)
PIPE LOADER 17
(94) (91) (46) (70) BLU/YEL
ORG PUR/ORG TAN/GRN (94)
(87)
CONTROLLER (13) TAN/WHT
(84)
(73) YEL/GRN
(74)
GRA/WHT
BRN/ORG (83) BLU/WHT
(21) (82)
YEL/RED
A
1
B
4
(98) 1 2 3 4 5 6 7 8 9 10 GRA/YEL
(95)
COLD START 3
2
6
5 WHT/YEL
(97)
11 12 13 14 15 16 17 18 19 20
C D 21 22 23 24 25 26 27 28 29 30 PUR/YEL
PUR BLU/RED (96)
(109) 31 32 33 34 35 36 37 38 39 40
(20) PUR/GRN TAN/BLK GRA/BLK
19 18 ORG ORG
YEL/BRN
(64)
(77) BLK/YEL
(50) GRN YEL/BLU
(110) (107)
GRA/GRN (49) (99) GRA/GRN BLK BLU/BLK
(8) (8) BLK TAN/BLU (71) (1) (108)
(66) 6 5 4 3 2 1 (1) WHT
RED/BLU (111) TAN/RED (90) BLK/WHT GRA/BLU
ACC
BAT
IGNITION (3) BLK BLU/ORG
7 8 9 10 11 12
(62) BRN/ORG (104) (106)
ST
(57) (88)
IGN
(1) YEL/BRN TAN/WHT
GRN/ORG BLK/ORG (27)
WHT/BLK
(10)
ORG/BLU
(58) GRN/BLU (60) BLU/BRN (64) BLK
(9) (65)
ORG/BLU (59) (1)
(9) 4 5 6
20 TO JOYSTICK 3 2 1
GRN/RED TAN/BLU
(63) TAN/RED (28)
BRN
(52) (62)
BLK
EL STR SYS (1) TO HORN/SWITCH
ALARM HARNESS
ORG/GRN
(19)
SEAT SWITCH
GRA/ORG
(61)
24
WHT/ORG
(43)
21 -B-
BLK
GRN/BLK (1)
WHT/BLK
(10)
(44) ORG
WHT/PUR (8)
(51) H X
BRN/ORG
J W (21)
PUR V
TO RELAY (20)
GRA/ORG L
K
C
B
A
G
F U
GRA/RED
(115)
PANEL HARNESS (61) M D E
S
T
GRA/GRN N
P R
(66) ORG/BLU
RED/BLU (9)
(3) BRN/YEL
RED/ORG (105)
(68) GRA/BLK
RED/YEL (91)
(67)
04 ID0041886
225
ELECTRICAL DIAGRAM
OPERATOR STATION HARNESS
JT4020
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
1. 214-489 1 ROCKER SWITCH (DPDT,(ON)-OFF-(ON)
2. 217-907 1 ROCKER SWITCH (DPDT) ON-ON
3. 306-607 2 HORN BUTTON
4. 217-911 6 ROCKER SWITCH (SPDT,(ON)-OFF-(ON)
5. 217-912 1 ROCKER SWITCH (DPDT) ON-ON-ON
6. 217-923 1 ROCKER SWITCH (DPDT) ON-OFF-ON
7. 217-940 2 FLUID FLOW POTENTIOMETER
8. 215-914 1 DRILL FLUID CONTROLLER ROTATION SPEED CONTROLLER
9. 214-486 1 DRILL FLUID CONTROLLER
10. 217-710 7 MICRO RELAY (SPDT)
11. 214-449 1 DIODE CONNECTOR
12. 217-811 6 FUSE (ATC, 15 AMP)
13. 217-809 2 FUSE (ATC, 5 AMP)
14. 217-208 1 TEN-SECOND DELAY TIMER RELAY
15. 214-430 1 DELAY TIMER
214-502 DELAY TIMR
16. 214-487 1 JOYSTICK CONTROLLER
17. 214-488 1 PIPE LOADER CONTROLLER OPTION
18. 217-917 - ROCKER SWITCH (DPDT, (OFF-(ON)
19. 214-852 1 IGNITION SWITCH
214-961 KEY, PAIR
214-962 SWITCH MOUNTING NUT
20. 214-416 1 HORN (ELECTRIC)
21. 217-750 1 SEAT SWITCH
22. 214-415 1 90D MODULE TO RIG CABLE
23. 217-221 1 FLOW METER DISPLAY
24. 214-483 1 OPERATOR STATION HARNESS
NOT SHOWN:
FOOTNOTES:
NOTE:
04 ID0041886
226
ELECTRICAL DIAGRAM
JOYSTICK HARNESS
PUR/GRN
BLK/YEL
YEL/BRN
GRN
BLK 1 2 3 4 5 6 GRA/GRN
12 11 10 9 8 7
BLU/ORG
GRN/BLU
BLK/ORG GRN/ORG
GRN/BLU YEL/BRN
(59) (64)
BLU/ORG BLK/ORG
(57) (60) BLU/ORG
(57) BLK/ORG
(60)
68.1 OHMS
WHT/ORG
2% TOL GRA/GRN
WHT/PUR
WHT/GRN
1/4 WATT (66)
GRN/ORG
(4) PUR
GRN (58)
340 OHMS ORG
RN
1% TOL
GRN
L/G
W
BR
YE
H
T
N
1/4 WATT
GRN 1
(49)
BLK PUR/GRN
(1) (77)
BLK/YEL
(50)
06 ID0041888
227
ELECTRICAL DIAGRAM
JOYSTICK HARNESS
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
1. 191-078 1 JOYSTICK AND HARNESS KI INCLUDES JOYSTICK & HARNESS
307-288 - BOOT (RUBBER)
214-473 - JOYSTICK 'HANDLE' {GRAY}
499-108 - PUSH BUTTON
499-109 - 3 POSITION SWITCH
599-285 - JT4020 JOYSTICK CONVERSION KIT INCLUDES JOYSTICK & HARNESS
214-703 - DUAL AXIS JOYSTICK
2. 214-482 1 JOYSTICK HARNESS HARNESS ONLY
217-279 1 JOYSTICK HARNESS HARNESS ONLY
NOT SHOWN:
FOOTNOTES:
NOTE:
06 ID0041888
228
ELECTRICAL DIAGRAM
HORN/SWITCH HARNESS TO OPERATOR
HARNESS
3
2
TAN/RED (62)
BLK (1)
TAN/BLU (28) GRN/RED (63)
BLK (1)
BLK YEL/BRN
(1) (64)
BLU/BRN
(65)
BORING
1 POSITION SWITCH
MOBILE
POSTION SWITCH
01 ID0041891
229
ELECTRICAL DIAGRAM
HORN/SWITCH HARNESS
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
1. 217-227 2 PROXIMITY SWITCH
2. 214-416 1 HORN (ELECTRIC)
3. 214-405 1 HORN/SWITCH HARNESS
NOT SHOWN:
FOOTNOTES:
NOTE:
01 ID0041891
230
231
232
ELECTRICAL DIAGRAM
MAIN FRAME HARNESS
LEFT TRACK LEFT TRACK
REVERSE FORWARD
BLK
1 YEL/GRN
(74)
(1)
1
BLK TAN/GRN
(1) (73)
PULL BACK
3
BLK (1)
WHT/GRN (70) 1
GRA/RED (46)
BLK (1)
2
DRILL FLUID
SOLENOID #2
GRA (45)
BLK (1)
1
2
FORWARD
DRILL FLUID THRUST
SOLENOID #1
BLK (1)
PUR//GRN (72) BLU/GRN (69)
BLK (1)
1 4
RIGHT TRACK BLK (1)
REVERSE
GRA/GRN (71) TAN/WHT
(27)
FLUID FLOW
BLK (1)
SENSOR
ORG (13)
1 WHT BLK
BLU/YEL ORG
BLU/WHT (94) (13) (90) (1) TAN/BLU
RIGHT TRACK (82)
GRA/YEL
(111)
BRN/ORG
FORWARD TO DRILL GRA/WHT
(95) K
X
J
W
V
(88) TAN/BLK
(110)
FRAME HARNESS (83)
PUR/YEL
L
M C
B
A
H
G
U
T
BLU/RED
(109)
(96)
N D F PUR/ORG
WHT/YEL E S
(87)
(97) O R
P Q BLU/BLK
TAN/WHT (108)
TO ROTATION (84)
YEL/RED
WHT/RED
GRA/BLK (86)
BLK (1)
HARNESS (98) GRN/RED
(85)
(107)
YEL/BLU GRA/BLU
(99) (106)
GRA/GRN
(71)
BRN/ORG BLU/GRN
WHT/GRN
(88) (69)
(70)
PUR/GRN WHT/RED
PUR/ORG (86)
(72)
(87) GRN/RED
TAN/GRN
(73) GRA/RED (85)
WHT (46) GRA
YEL/GRN BLU/YEL
(90) (45)
(74) (94)
BLU/WHT ORG
(82) (13) TAN/WHT
GRA/YEL 10 9 8 7 6 5 4 3 2 1 (84)
(95)
20 19 18 17 16 15 14 13 12 11 GRA/WHT
PUR/YEL (83)
30 29 28 27 26 25 24 23 22 21
(96)
BLU/BLK 40 39 38 37 36 35 34 33 32 31 WHT/YEL
(108) BLK (97)
(1) BLU/RED
YEL/RED (109)
GRA/BLK
(98)
(107) BLK/WHT
GRA/BLU TAN/RED
(104) (106) TAN/BLK
(62) YEL/BLU (110)
TAN/WHT
TO OPERATOR (27) (99) TAN/BLU
(111)
STATION HARNESS
01 ID0041892
233
ELECTRICAL DIAGRAM
MAIN FRAME HARNESS
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
1. 214-434 6 SOLENOID COIL
2. 217-897 2 SOLENOID COIL
3. 214-481 1 MAIN FRAME HARNESS
4. 216-047 1 SPEED PICKUP
NOT SHOWN:
FOOTNOTES:
NOTE:
01 ID0041892
234
ELECTRICAL DIAGRAM
DRILL FRAME HARNESS
BLK (1)
TAN/WHT (84)
ORG (13)
FULL BACK
SWITCH
BLK (1)
GRA/WHT (83)
ORG (13)
STOP ZONE
SWITCH
BLK (1)
BLU/WHT (82)
ORG (13)
SLOW DOWN
SWITCH
2
4 PIPE OK
SWITCH
BLK (1)
BRN/ORG (88)
ORG (13)
BLK
(1)
BLK (1)
PUR/ORG (87)
TO MAIN FRAME ORG (13)
HARNESS
WHT ORG
BLK
(90) (13) BLU/YEL
CAVITY (94)
(1)
PLUG BLU/WHT
PIPE BAD
TAN/BLU (82) SWITCH
(111) GRA/YEL
BRN/ORG (95)
(88) W X
K GRA/WHT
2
TAN/BLK V J (83)
H L
U B PUR/YEL BLK (1)
(110)
G A C M (96) GRN/RED (85)
BLU/RED T ORG (13)
(109) F D N WHT/YEL
S E (97)
PUR/ORG R
O SHUTTLE
(87) Q P
TAN/WHT -A- RETRACTED
BLU/BLK (84)
(108) YEL/RED
(98)
WHT/RED
GRA/BLK
YEL/BLU 1
(107)
(86) GRN/RED (99)
GRA/BLU (85)
(106)
03 ID0041893
235
ELECTRICAL DIAGRAM
DRILL FRAME HARNESS
-A- TOWARD DRILL FRAME REAR
SEAT
ROTATE
GRA/BLU (106) BLK (1)
BLK (1) GRA/BLK (107)
3 REAR 3
BREAKOUT
WRENCH
TAN/BLU (111) BLK (1)
BLK (1) TAN/BLK (110)
PIPE
GRIPPER
YEL/RED (98) BLK (1)
BLK (1) YEL/BLU (99)
3 3
FRONT
BREAKOUT
WRENCH
BLU/RED (109) BLK (1)
BLK (1) BLU/BLK (108)
PIPE
LIFT
PUR/YEL (96) BLK (1)
BLK (1) WHT/YEL (97)
3 3
PIPE
SHUTTLE
GRA/YEL (95) BLK (1)
BLK (1) BLU/YEL (94)
BLK (1) 1
WHT (90)
ORG (13)
FLUID SHUTOFF
SWITCH BLK (1)
WHT/RED (86)
ORG (13)
SHUTTLE
TOWARD DRILL FRAME FRONT EXTENDED
03 ID0041893
236
ELECTRICAL DIAGRAM
DRILL FRAME HARNESS
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
1. 217-227 6 PROXIMITY SWITCH
2. 214-504 2 PHOTO ELECTRIC SENSOR L-RANGE
3. 214-435 12 SOLENOID COIL (12V)
4. 214-484 1 DRILL FRAME HARNESS
NOT SHOWN:
FOOTNOTES:
NOTE:
03 ID0041893
237
238
239
240
ELECTRICAL STRIKE SYSTEM 8
BEGINS W/ S/N 2T4302
6
2
1
D 807-721
241
ELECTRICAL STRIKE SYSTEM
BEGINS W/ S/N 2T4302
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
1. 350-746 - OPERATOR FRAME
2. 259-210 8 TRAFFIC CONE - ORANGE OBSOLETE
3. 259-234 8 CONE CLIP OBSOLETE USED W/ REF NO.'S 2 & 4
4. 260-223 1 BARRIER TAPE (3" X 1000') OBSOLETE
5. 215-799 1 VOLTAGE STAKE
6. 217-241 1 ESID MODULE NEW (T)
197-079 - ESID MODULE -REBUILT REBUILT 217-241
7. 216-063 1 CURRENT TRANSFORMER OBSOLETE
211-084 1 CURRENT TRANSFORMER
8. 214-542 1 CURRENT COIL CABLE
9. 211-042 1 VOLTAGE LIMITER CABLE
FOOTNOTES
NOTE:
D 807-721
242
243
244
ELECTRICAL DIAGRAM
ROTATION HARNESS
VARIABLE
ROTATION
1
TAN/RED
(62)
BLK/WHT
(104)
BLK/WHT
(104)
TAN/RED
(62)
TO MAINFRAME
HARNESS
01 ID0041896
245
ELECTRICAL DIAGRAM
ROTATION HARNESS
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
1. 217-745 1 CONTROL SOLENOID
2. 214-479 1 ROTATION HARNESS
NOT SHOWN:
FOOTNOTES:
NOTE:
01 ID0041896
246
247
248
249
250
NOTES:
ID0134963
251
ANCHOR
SYSTEMS
ID0135075
252
253
254
255
256
257
258
259
260
ANCHOR DRIVE HYDRAULICS-LEFT
10
17
16
14 9
8
9 15
12
10
13
7
17
6
11
5 18
5
1
19
03 ID0138143
261
ANCHOR DRIVE HYDRAULICS-LEFT
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
1. 154-261 1 CONNECTOR (04O-08S)
2. 154-276 1 CONNECTOR (04O-08S90)
3. 515-593 1 HOSE (040FX90-38"-3000)
4. 154-728 1 HOSE (04OFX90-36"-3000)
5. 117-718 2 ABRASION SLEEVE (1" X 36")
6. 154-255 2 UNION (04O-04OFX90)
7. 154-424 1 BK RUN TEE (04O-04O-04OBK)
8. 154-265 1 UNION RUN TEE (04OFX-04O-04O)
9. 154-403 2 CONNECTOR (04S-04O, XL)
10. 154-252 2 CONNECTOR (04S-04O90)
11. 515-054 1 HOSE (04OFX-74"-3000)
12. 515-683 1 HOSE (04OFX90-28"-3000)
13. 117-684 1 ABRASION SLEEVE (1" X 26")
14. 117-657 1 ABRASION SLEEVE (1.59" X 54")
15. 515-682 1 HOSE (04OFX90M-48"-3000)
16. 117-676 1 ABRASION SLEEVE (1" X 30")
17. 151-167 2 CYL (2.0" X 1.25" X 24.000")
18. 343-238 1 BULKHEAD PLATE
19. 516-120 - HYD CONTROL VALVE
NOT SHOWN:
FOOTNOTES:
NOTE:
REFER TO O-RINGS CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENTS OF O-RINGS.
03 ID0138143
262
263
264
265
266
267
268
HYDRAULIC CYLINDER
2.0" X 1.25" X 24.0"
D 806-687
269
HYDRAULIC CYLINDER
2.0" X 1.25" X 24.0"
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
150-747 CYL (2" X 1.25" X 24") INCLUDE REF NO.'S 1 THRU 7
1. 190-169 1 SEAL REPAIR KIT (2.0" X 1.25") INCLUDES REF NO.'S 4 & 5
2. 150-778 1 LOCK RING (2")
3. 151-170 1 CYLINDER BARREL
4. 106-097 1 FLG BOLT (5/8-NC X 1-3/4", GD8) SEE FOOTNOTE 1
5. 150-771 1 CYLINDER PISTON (2.0" X 1.25") INCLUDES MOLDED-ON WEAR RING
6. 150-770 1 CYLINDER HEAD (2.0" X 1.25")
7. 150-679 1 CYLINDER ROD (1.25")
NOT SHOWN:
259-100 U-SEAL INSTALLER (1"-1.499")
259-236 WIPER INSTALLER (1.250")
259-239 WIPER/SEAL INSTALLER (2")
259-241 PISTON INSTALLER (2")
259-188 CYL HEAD SPANNER - TWO PIN
FOOTNOTES
1. APPLY LOCTITE 271 OR 277. TORQUE TO 180-200 FT-LBS (245-270 N.M.)
NOTE:
D 806-687
270
271
272
273
274
275
276
NOTES:
ID0134963
277
FLUID
SYSTEMS
ID0135021
278
279
280
ON BOARD MUD SUPPLY HYDRAULICS 41
40 42
20
TO WATER SWIVEL
43
18
17
19
16
1
53 52
17 49 50
2 51 18
48
51 3
44
54 13
22 12
21 11
10
9
55
8 15
6
7 39
23
24
5 30
7
37 46
29
27 32 32 24
28 45
27
38
35
25 31
FROM ANTIFREEZE
TANK 26 25
25 34
25 33 4
26
R 47 805-813
281
ON BOARD MUD SUPPLY HYDRAULICS
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
1. 514-413 1 BK RUN TEE (24O-24O-24OBK)
2. 156-892 1 HYD LINE (24O-24OFX-96.6") SEE FOOTNOTE 4
3. 149-162 1 HOSE (20OFX-30"-3000)
4. 105-400 3 BOLT (5/8-NC X 1-1/4")
5. 120-078 1 SHUT-OFF VALVE (20SF-20SF)
6. 149-081 - CONNECTOR (20N-20O90) SEE FOOTNOTE 1
7. 149-082 2 CONNECTOR (20J-20OFX)
8. 115-231 1 COLLAR (20NF)
9. 158-434 - FLUID PUMP 70 GPM FLUID PUMP OPTION
10. 115-236 1 REDUCER (20N-16NF)
11. 115-276 1 REDUCER (16N-08NF)
12. 514-240 1 CONNECTOR (08N-08S)
13. 159-088 1 QDC BODY (08-08SF)
190-186 1 SEAL REPAIR KIT
15. 159-485 1 FHC BODY (32-32N)
16. 149-083 1 CAP (24OF)
17. 149-086 2 NUT (24O)
18. 149-085 2 REDUCER STEM (20O-24OF)
19. 514-422 1 CONNECTOR (20O-20OFX90)
20. 149-089 1 HOSE (20OFX90-196"-3000)
21. 115-161 1 NIPPLE (08N-3-1/2")
22. 514-106 1 CAP (08NF)
23. 149-079 1 NIPPLE (20N X 4")
24. 114-024 2 REDUCER (40N-32NF) SEE FOOTNOTE 3 (ON NEXT PAGE)
25. 106-398 6 WASHER (M16, HARDENED)
26. 105-456 2 BOLT (5/8-NC X 1-3/4",GD8)
27. 515-678 2 REDUCER (32N-20NF)
28. 370-251 1 CHECK VALVE (MUD)
29. 514-151 1 CONNECTOR (20N-20O)
30. 155-702 2 O-RING (920 D90)
31. 350-891 1 PUMP PLATE
32. 106-470 2 FLG SCREW (M16-2.00 X 40mm)
33. 106-685 1 LOCKNUT (M12-1.75,PRV TRQ,10.9)
34. 106-545 2 LOCKNUT (M16-2.0,PRV TRQ,10.9)
35. 106-632 1 FLG LK SCREW (M12-1.75 X 35mm)
37. 514-450 1 CAP (20 NF) SEE FOOTNOTE 1
38. 514-449 1 TEE (20N-20O-20N)
39. 149-120 1 DUST PLUG (32 FHC)
40. 514-137 1 CONNECTOR (16N-20O)
41. 115-894 1 ABRASION SLEEVE (2.38" X 60")
42. 149-088 1 HOSE (20OFX90L-60"-3000)
43. 514-096 1 BK CONNECTOR (20O)
44. 307-808 1 PUMP BRACKET MOUNT USING EXISTING HARDWARE
45. 211-041 1 CONNECTOR CLIP
46. 106-381 1 FLG LK SCREW (M8-1.25 X 25MM)
47. 106-386 1 FLG LOCKNUT (M8-1.25)
48. 216-047 1 SPEED PICKUP
49. 216-026 AR FLEX GUARD (.250") USE 1 @ 20"
50. 215-224 1 3-WAY WP MALE CONNECTOR SEE FOOTNOTE 2
FOOTNOTES
1. EARLY MODELS HAD 149-081 (20N-20O90) IN PLACE OF 514-449 (TEE) & 514-450 (CAP).
2. 3 EA 214-104 AND 3EA 157-645 ARE NEEDED TO INSTALL 215-224
NOTE:
REFER TO O-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS.
R 805-813
282
ON BOARD MUD SUPPLY HYDRAULICS
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
51. 111-008 1 BLT-ON CLP (1.5",SOLD PER SET)
52. 322-362 1 BACKUP SPACER
53. 105-224 2 BOLT (1/4-NC X 2-1/2")
54. 157-130 1 O-RING (029 D90)
55. 114-004 1 STREET ELBOW (32N-32NF90)
FOOTNOTES
3. IF AN ANTIFREEZE TANK KIT IS NOT INSTALLED, A (114-008 PLUG 32N, SQ, GALV) WILL BE REQUIRED TO PLUG
THE SECOND INLET.
4. NEED 154-326 CAP AND 157-038 O-RING TO CAP FITTING USED ON LATER MODELS FOR MUD PRESSURE SENSING.
R 805-813
283
284
285
286
FLUID PUMP (FLUID END)
70 GPM
4
2
10
11
6
7
5
8
9
2
11 ID0064771
287
FLUID PUMP (FLUID END)
70 GPM
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
158-434 FLUID PUMP INCL REF NO'S 1 - 11
197-062 REBUILT 158-434 MUD PUMP INCL REF NO'S 1 - 11
158-017 MUD PUMP
190-783 L1122 A/R VALVE SERVICE KIT INCL REF NO'S 2, 4 & 11
1. 499-035 1 FLUID CYLINDER
2. 499-036 6 VALVE
3. 499-037 3 VALVE COVER
4. 157-190 3 O-RING (139 D90)
5. 191-1008 1 PACKING REPAIR KIT SEE FOOTNOTE 1
6. 499-039 3 PLUNGER NUT
7. 155-778 3 O-RING (014 D70, VITON)
8. 499-040 3 CYLINDER (2-3/4")
9. 499-041 3 CUP HOLDER
10. 499-042 6 CYLINDER GASKET
11. 157-191 3 O-RING (233 D90)
NOT SHOWN:
FOOTNOTES:
KIT INCLUDES ALL PARTS, O-RINGS, GASKETS AND PLUNGER NUTS TO REBUILD ALL CYLINDERS
NOTE:
11 ID0064771
288
289
290
291
292
293
294
NOTES:
ID0134963
295
PIPE LOADER
SYSTEMS
ID0135289
296
297
298
299
300
AUTO-LUBER ASSEMBLY
11 ID0069307
301
AUTO-LUBER ASSEMBLY
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
1 350-400 1 COVER WELDMENT
2 350-399 1 BASE
3 105-297 2 BOLT (1/4-NC X 3-1/4")
4 106-378 4 FLG LK SCREW (M6-1.00 X 12MM)
5 195-339 2 WING NUT (1/4-NC)
6 350-1932 1 TOOL JOINT LUBE FOLLOWER
7 350-398 1 GREASE PUMP PARTS
8 259-858 1 TOOL JNT LUBE, STD SPRY 2 GAL
256-031 - TOOL JNT LUBE, SUMR SPRY 2 GAL
NOT SHOWN:
FOOTNOTES:
NOTE:
11 ID0069307
302
GREASE PUMP
1
18
15
5
9
6 19
10
20
8
7
14
21
11
12
16
15 4
7
13
17 17
12
22
08 ID0109693
303
GREASE PUMP
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
350-398 GREASE PUMP PARTS INCL REF NO'S 1-20
1. 107-492 1 SCREW (M8-1.25 X 35MM,ALL THD)
2. 106-078 1 NUT (M8-1.25)
3. 350-686 1 CYLINDER CAP
4. 350-692 1 INLET TUBE
5. 157-049 2 O-RING (113 D70)
6. 350-421 1 ADJUSTING SPOOL
7. 350-671 1 ROD GUIDE SEE FOOTNOTE 2
8. 350-682 1 BARREL
9. 117-228 1 COMPRESSION SPRING
10. 125-424 2 BRONZE BUSHING (.750")
11. 350-691 1 VALVE SEAT SEE FOOTNOTE 1
12. 117-227 2 SEAL (POLY PAK)
13. 350-687 1 PUMP BODY
14. 125-125 1 DETENT BALL (.750")
15. 155-702 2 O-RING (920 D90)
16. 117-226 - EXTERNAL SNAP RING (.750") SEE FOOTNOTE 2
115-545 - EXTERNAL SNAP RING (.75")
17. 350-689 - PLUNGER SEE FOOTNOTE 2
308-603 - PLUNGER SEE FOOTNOTE 3
166-280 1 PLUNGER
18. 155-748 1 O-RING (916 D90)
19. 350-693 1 PUMP BARREL
20. 301-0196 1 RETAINER CLIP SEE FOOTNOTE 4
21. 105-525 1 ROLL PIN (3/16" X 1/4") SEE FOOTNOTE 3
22. 178-467 1 ROD CAP SEE FOOTNOTE 3
NOT SHOWN:
FOOTNOTES:
1. INSTALL WITH SMALLER BEVEL TOWARD INSIDE OF PUMP
2. 308-603 PLUNGER IS A DIRECT REPLACEMENT OF 350-689 PLUNGER, 117-226 RETAINER RING, AND AN
ADDITIONAL 350-671 ROD GUIDE.
3. USE 166-280, 178-467 & 105-525 TO SUPERSEDE 308-603
4. RETAINER CLIP 301-0196 SUPERSEDES CLIP 105-653
NOTE:
08 ID0109693
304
APPLICATOR
2 1
3 5
03 ID0138652
305
APPLICATOR
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
1. 305-911 2 BRACKET, APPLICATOR
2. 106-385 2 FLG LOCKNUT (M6-1.00)
3. 306-423 1 WIPER PARTS ASS'Y
116-937 1 APPLICATOR
107-394 4 WASHER (.375", ALUMINUM)
107-395 2 RIVET (.156 X .500) SEMI-TUBUL
4. 305-912 1 BASE, APPLICATOR
5. 106-093 2 SCREW (M6-1.00 X 45MM)
NOT SHOWN:
FOOTNOTES:
NOTE:
03 ID0138652
306
307
308
309
310
311
312
313
314
315
316
PIPE LOADER GRIPPER
2
4
6
3
1
12
7
12
4
3
9
10
8
15
16
11
13
14
01 ID0148864
317
PIPE LOADER GRIPPER
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
1. 354-321 1 FRONT SHUTTLE
308-613 1 REAR SHUTTLE
2. 105-044 1 JAM NUT (1/2-NC)
3. 125-469 2 COMPOSITION BUSHING (.500")
4. 105-507 3 ROLL PIN (3/8" X 2")
5. 354-363 2 GRIPPER PLATE
6. 354-322 1 ROD GRIPPER
7. 370-154 1 ROLLER
8. 106-378 1 FLG LK SCREW (M6-1.00 X 12mm)
9. 354-376 1 PIN
10. 105-549 1 BOLT (1/2-NC X 3-3/4", GD8)
11. 191-161 1 GRIPPER CYLINDER
12. 125-137 2 BALL BEARING (.375")
13. 106-089 2 NUT (M12-1.75, 10.9)
14. 105-741 2 SET SCREW (M12-1.75 X 70mm, CUP)
15. 354-354 1 SPACER
16. 105-076 1 BOLT (1/2-NC X 3")
NOT SHOWN:
FOOTNOTES:
NOTE:
01 ID0148864
318
319
320
321
322
NOTES:
ID0134963
323
ACCESSORIES
324
FLUID MIXING ACCESSORIES
3
2
4
8
6
9 10
11
10 ID0109085
325
FLUID MIXING ACCESSORIES
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
1. 259-195 1 VISCOSITY FUNNEL
2. 259-196 1 VISCOSITY CUP
3. 259-804 AR BENTONITE, QUIK-GEL (50 LB)
4. 259-805 AR LIQUID POLYMER, EZ-MUD (5 GAL)
5. 259-807 AR BENTONITE, BORE-GEL (50 LB)
6. 259-808 AR VISCOSIFIER, LIQUI-TROL (5 GAL)
7. 259-809 AR POWDER POLYMER, QUIK-TROL (20 LB)
8. 259-810 AR WET AGENT, CON-DET (5 GAL)
9. 259-821 AR 'PAC-R' FILTRATION CONTROL
10. 259-822 AR 'BARAZAN D+' VISCOSIFIER
11. 259-832 AR 'NO SAG' (20# BOX/10-2#BAGS)
NOT SHOWN:
191-158 1 DRILLING FLUID TEST KIT
259-487 1 SHEAROMETER
FOOTNOTES:
NOTE:
10 ID0109085
326
WIRELINE KIT
1
2
10
8
5 12
11
7
3
TO MUD SUPPLY HOSE
04 ID0092960
327
WIRELINE KIT
REF PART
NO. NUMBER QTY DESCRIPTION REMARKS
190-910 - WIRELINE KIT
100-082 - WIRELINE KIT INCLUDES REFERENCES 1 THRU 12
1. 350-631 1 BRACKET
2. 106-685 2 LOCKNUT (M12-1.75, PRV TRQ, 10.9)
3. 358-855 1 PACK-OFF FITTING (.125-.187)
4. 115-156 1 REDUCER (08N-06NF)
5. 214-548 1 COLLECTOR RING
6. 350-630 1 COIL MOUNT
7. 514-095 1 CONNECTOR (20S-20O90)
8. 514-446 1 REDUCER (24S-20SF)
9. 350-476 1 WATER SWIVEL
190-1423 SEAL KIT
10. 106-333 2 SCREW (M12-1.75 X 40MM, 8.8)
11. 105-688 4 SCREW (M6-1.00 X 35MM)
12. 105-693 1 ALLIGATOR CLIP (.312 X 2.343)
NOT SHOWN:
FOOTNOTES:
NOTE:
REFER TO O-RING CHART (800-301) IN BACK OF THE BOOK FOR REPLACEMENT OF O-RINGS
04 ID0092960
328
329
330
331
332
NOTES:
ID0134963
333
MISCELLANEOUS
ID0135063
334
SAE Bolt and Nut Torque Value Chart
Grade 5: UNC or UNF Thread
Size Hex nut, or bolt tapped into hex Hex top deformed locknut Flange nut, locknut, or bolt tapped
nut, or d&t hole into flange nut or d&t* hole
ftlb Nm ftlb Nm ftlb Nm
1/4 12 16 8 11 20 27
5/16 25 34 15 20 45 60
3/8 40 54 25 34 75 100
7/16 65 90 40 55 125 170
1/2 100 135 60 80 190 260
9/16 150 200 90 125 270 370
5/8 200 270 120 165 370 500
3/4 350 475 210 285 650 880
7/8 560 760 340 460 1250 1425
1 840 1140 500 680 1580 2145
1-1/8 1030 1400 320 840 1950 3645
1-1/4 1460 1980 880 1195 2760 3475
Grade 8: UNC or UNF Thread
Size Hex nut, or bolt tapped into hex Hex top deformed locknut Flange nut, locknut, or bolt tapped
nut, or d&t hole into flange nut or d&t* hole
ftlb Nm ftlb Nm ftlb Nm
1/4 14 19 10 14 24 33
5/16 30 40 18 25 50 70
3/8 55 73 35 50 90 125
7/16 85 115 50 70 140 190
1/2 130 175 80 110 220 300
9/16 190 260 110 150 310 420
5/8 260 355 160 245 430 585
3/4 450 610 270 365 750 1015
7/8 730 990 440 600 1210 1640
1 1090 1480 650 880 1320 2465
1-1/8 1550 2100 930 1260 2580 3500
1-1/4 2180 2955 1310 1780 3640 4935
*drilled and tapped
335
Metric Bolt and Cap Screw Torque Values
Size Class 4.8 Class 8.8 and 9.8 Class 10.9 Class 12.9
Lubricated Dry Lubricated Dry Lubricated Dry Lubricated Dry
Nm ftlb Nm ftlb Nm ftlb Nm ftlb Nm ftlb Nm ftlb Nm ftlb Nm ftlb
M6 4.8 3.5 6 4.5 9 6.5 11 8.5 13 9.5 17 12 15 11.5 19 14.5
M8 12 8.5 15 11 22 16 28 20 32 24 40 30 37 28 47 35
M10 23 17 29 21 43 32 55 40 63 47 80 60 75 55 95 70
M12 40 29 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 47 80 60 120 88 150 110 175 130 225 165 205 150 260 190
M16 100 73 125 92 190 140 240 175 275 200 350 225 320 240 400 300
M18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410
M20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580
M22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800
M24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000
M27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1500
M30 675 490 850 625 1600 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000
M33 900 675 1150 850 1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500
Do not use these values if a different torque value or tightening procedure is given for specific application.
Torque values listed are for general use only. Check tightness of fasteners periodically.
Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical
property class fasteners.
Fasteners should be replaced with the same or higher property class. If higher property class fasteners are
used, these should only be tightened to strength of original.
Make sure fastener threads are clean and that the threads are properly started. This will prevent them from
cross threading or galling when tightened.
Tighten plastic insert or crimped type steel locknuts to approximately 50% of dry torque indicated on chart.
Apply torque to the nut - not the bolt head. Tighten toothed or serrated type locknuts to full torque value.
LUBRICATED means coated with lubricant. DRY means plain or zinc plated without any type of lubricant.
336
Hydraulic Cylinder Bolt Torque Chart
Bolt Size Bolt Cylinder Repair Kit Torque (ftlb) Torque (Nm)
(inch) Part No. Part No.
1/2 106-096 190-165 90-100 120-135
5/8 106-097 190-166 & 190-169 180-200 245-270
3/4 106-098 190-167 & 190-170 290-325 395-440
7/8 106-122 190-172 & 190-174 410-640 550-625
1 106-145 190-175 & 190-189 630-700 855-950
1-1/8 106-146 190-177 770-850 1045-1170
As a general rule:
1/2-inch bolts are used in cylinders with 1-inch rods
5/8-inch bolts are used in cylinders with 1 1/4-inch rods
3/4-inch bolts are used in cylinders with 1 1/2-inch rods
7/8-inch bolts are used in cylinders with 1 3/4-inch rods
1-inch bolts are used in cylinders with 2-inch rods (one with 1 3/4-inch)
1-1/8-inch bolts are used in cylinders with 2-1/4-inch rods
IMPORTANT: Do not reuse cylinder piston bolts when rebuilding a hydraulic cylinder. Each cylinder repair
kit contains a new bolt. Use it. Lubricate lightly and torque to value shown on chart.
337
SAE & ORS Hydraulic Fitting Replacement O-Ring
Chart
Fraction Dash SAE ORS
Size Size (Port Seal O-Ring) (Face Seal O-Ring)
Thread Size O-Ring P/N Thread Size O-Ring P/N
1/16 1 NA NA NA NA
1/8 2 5/16 - 24 NA NA NA
3/16 3 3/8 - 24 NA NA NA
1/4 4 7/16 - 20 155-760 9/16 - 18 157-037
5/16 5 1/2 - 20 NA NA NA
3/8 6 9/16 - 18 155-705 11/16 - 16 157-038
1/2 8 3/4 -16 155-706 13/16 - 16 157-039
5/8 10 7/8 - 14 155-707 1 - 14 157-040
3/4 12 1-1/16 - 12 155-709 1-3/16 - 12 157-017
7/8 14 1-3/16 - 12 155-747 NA NA
1 16 1-5/16 - 12 155-748 1-7/16 - 12 155-714
1-1/4 20 1-5/8 - 12 155-702 1-11/16 - 12 NA
1-1/2 24 1-7/8 - 12 157-001 2 -12 NA
2 32 2-1/2 - 12 NA NA NA
2-1/2 40 3 - 12 NA NA NA
3 48 3-1/2 - 12 NA NA NA
Thread size indicates the diameter of the threaded area in fractions of an inch and number of threads per
inch.
NA = not a current CMW part numbered o-ring, or dash size does not occur in current CMW applications
SAE = straight thread fitting that seals by sandwiching a hard o-ring between a shoulder on the male part
and an angular surface at the mouth of the female port.
ORS = o-ring face seal; a type of fitting that seals by compressing a hard, captive o-ring between two flat
parallel faces, one grooved for the o-ring and the other plain to act as the sealing surface
338
JT4020
Related Publications
Component Assy P/N
Model:
JT4020 .................. Parts Manual .................................................................... .............. 053-470
JT4020 .................. Operators Manual ............................................................ .............. 054-522
JT4020 .................. Repair Guide (Service Manual) ....................................... .............. 055-520
JT4020 .................. Supplementary Maint Guide - Trenchless ....................... .............. 055-485
JT4020 .................. Special Tools Guide ......................................................... .............. 052-901
Engine:
John Deere ............ Parts Manual - T6068TF150 .................................... 194-781 ...... 053-061
John Deere ............ Operators Manual - T6068TF150 .................................... .............. 054-049
John Deere ............ Service (Shop) Manual - T6068TF150 ............................ .............. 054-049
Filters
Engine:
Air Filter Parts Assy ......................................................................................................... 159-373
Element (primary) ............................................................................................ 194-827
Element (secondary) ........................................................................................ 194-828
Oil Filter Element (spin-on) - John Deere ......................................................................... 194-815
Fuel Filter Element (water trap, spin-on) - John Deere .................................................... 194-816
Fuel Strainer (04H) ........................................................................................................... 156-268
Hydraulic:
Oil Filter Element (1-3/8-UNF, spin-on) - Charge ............................................................. 159-074
Element (1-1/2-UNF, spin-on, Replacement) - Return .................................... 159-079
Element (1-1/2-UNF, spin-on, Break-In) - Return ............................................ 149-840
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.01 ID0201452
339
Parts Manual Change Request
(Please print clearly)
Date: _______________________ Dealer No. (required): _____________________________
Your Name: _____________________________ Position: _____________________________
Phone: _________________ Fax: _________________ E-mail: __________________
Publication Information:
Parts Manual No.: _____-_____ Model: __________
Illustration Part No.: Manual Page No.:
1. _____-_____ .......................................................... 1. __________
2. _____-_____ .......................................................... 2. __________
3. _____-_____ .......................................................... 3. __________
Nature of Change Request:
Text Graphics Missing Information
Describe change requested (if possible, include copy of publication page with changes marked.):
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
Please fax completed form to
Parts Manual Department (580) 572-3525
Thank you for taking the time to submit this request. We will contact you if further information is
needed to process your request.
ID0135001
340
341
ID0040564
342
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