Ditch Witch / CMW JT922 User Manual

Contents

1 JT922 ISSUE NO. 06PL-06/11 For Replacement Copy Order P/N 053-1134 This manual contains information concerning the following models: JT922 & JT922T4i Directional Drilling System Copyright 2007, 2009, 2011 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. ID0176431

Page 2

Contents

FOREWORD___________ 3 This manual contains illustrated parts lists to help you select quality ProTech ® Replacement parts for your Ditch Witch ® equipment. Using other replacement parts will lessen the productivity of your equipment. Part numbers enclosed in a box are no longer available from The Charles Machine Works, Inc. Your local Ditch Witch dealer may be able to locate the part for you. Footnotes provide more information to help you identify parts shown in the manual. Assembly instructions and Tech Bits articles referenced in footnotes are available through your local Ditch Witch dealer. Description and specifications in this book were current at publication.

However, The Charles Machine Works, Inc. reserves the right to improve equipment, so this manual might not reflect the most current improvements. Instructions on recommended equipment use and maintenance are in the Operator’s Manual that was shipped with your equipment. Keep the following in mind when ordering ProTech replacement parts: Specify parts you need by part number and description, not by illustration reference numbers. Have equipment model and serial number on hand to help ensure you get the right parts for your machine whether it’s old or new. Thank you for buying and using Ditch Witch equipment and ProTech replacement parts. 8/6/2010, Rev-B 800-001

Page 4

Contents

4 WARRANTY __________________________ DW WARRANTY Policy July, 2005 POLICY 1: DITCH WITCH ® EQUIPMENT AND REPLACEMENT PARTS LIMITED WARRANTY POLICY Subject to the limitation and exclusions herein, free replacement parts will be provided at any authorized Ditch Witch dealership for any Ditch Witch equipment or parts manufactured by The Charles Machine Works, Inc. (CMW) that fail due to a defect in material or workmanship within one (1) year of first commercial use (Exception: 2 years for all SK500 Attachments).

Free labor will be provided at any authorized Ditch Witch dealership for installation of parts under this warranty during the first year following “initial commercial” use of the serial numbered Ditch Witch equipment on which it is installed. The customer is responsible for transporting their equipment to an authorized Ditch Witch dealership for all warranty work. EXCLUSIONS FROM PRODUCT WARRANTY All incidental or consequential damages. All defects, damages, or injuries caused by misuse, abuse, improper installation, alteration, neglect, or uses other than those for which products were intended.

All defects, damages, or injuries caused by improper training, operation, or servicing of products in a manner inconsistent with manufacturer’s recommendations. All engines and engine accessories (these are covered by original manufacturer’s warranty). Tires, belts, and other parts which are subject to another manufacturer’s warranty. (Such warranty will be available to purchaser.) ALL IMPLIED WARRANTIES NOT EXPRESSLY STATED HEREIN, INCLUDING ANY WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY.

IF THE PRODUCTS ARE PURCHASED FOR COMMERCIAL PURPOSES, AS DEFINED BY THE UNIFORM COMMERCIAL CODE, THEN THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE FACE HEREOF AND THERE ARE NO IMPLIED WARRANTIES OF ANY KIND WHICH EXTEND TO A COMMERCIAL BUYER. ALL OTHER PROVISIONS OF THIS LIMITED WARRANTY APPLY INCLUDING THE DUTIES IMPOSED. Ditch Witch products have been tested to deliver acceptable performance in most conditions. This does not imply they will deliver acceptable performance in all conditions. Therefore, to assure suitability, products should be operated under anticipated working conditions prior to purchase.

Defects will be determined by an inspection within thirty (30) days of the date of failure of the product or part by CMW or its authorized dealer. CMW will provide the location of its inspection facilities or it’s nearest authorized dealer upon inquiry. CMW reserves the right to supply remanufactured replacement parts under this warranty as it deems appropriate. Extended warranties are available upon request from your local Ditch Witch dealer or CMW. Some states do not allow exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply.

Further, some states do not allow exclusion of or limitation of how long an implied warranty lasts, so the above limitation may not apply. This limited warranty gives product owner specific legal rights and the product owner may also have other rights which vary from state to state. For information regarding this limited warranty, contact CMW’s Product Support Department, P.O. Box 66, Perry, OK 73077-0066, or contact your local Ditch Witch dealer. Ver. 03 ID0134872

Page 5

Contents

CONTENTS______________________ 5 Decals Decal Location – JT922/JT922S ............................. 8 Engine Components Engine and Accessories ................................... 14 Engine and Accessories - Begins ....................... 16 Engine Installation ............................................ 16 Engine Mounts ................................................. 18 Exhaust System ............................................... 20 Exhaust System - Begins ................................... 22 Air Filter ............................................................ 24 Air Filter - Begins ................................................

26 Battery .............................................................. 28 Battery Cables .................................................. 30 Fuel Tank ......................................................... 32 Electrical Components ..................................... 34 Front Engine Cover .......................................... 36 Engine Enclosure Top ...................................... 38 Engine Enclosure Top - Begins .......................... 40 Engine Enclosure ............................................. 42 Engine Enclosure - Begins ................................. 44 Engine Access Panel .......................................

46 Engine Access Panel - Begins ........................... 48 Rear Cover ....................................................... 50 Rear Cover - Begins ........................................... 52 Setup Valve ...................................................... 54 Engine Skid Mounting ...................................... 56 Frame Components Cylinder Grease ............................................... 64 Drill Frame ........................................................ 65 Front Idler ......................................................... 62 Hose Carrier ..................................................... 80 Rotation Gearbox .............................................

78 Spindle Drive .................................................... 76 Stabilizer & Pivot .............................................. 68 Thrust Drive ...................................................... 74 Tracks .............................................................. 60 Wrench, Rotating ............................................. 72 Wrench, Stationary ........................................... 70 Operator’s Station Left Console ..................................................... 88 Operators Station ............................................. 84 Right Console ...................................................

86 Wrench Valve ................................................... 90 Hydraulics Anchor Hydraulics .......................................... 114 Anchor Valve Hydraulics ................................ 112 Anchor Valve Service Parts ............................ 110 Carriage Hydraulics ........................................ 136 Drilling Fluid Motor Hydraulics ........................ 116 Ground Drive Hydraulics ................................ 106 Hose Carrier Hydraulics ................................. 134 Hydraulic Cooler Bypass - Begins .................... 102 Hydraulic Cooler Bypass - Ends ...................... 100 Hydraulic Cylinder (2.0”x1.0”) ............................

150 Hydraulic Cylinder (3.5”x1.75”x2.0”) .................... 148 Hydraulic Cylinder (3.5”x2.0”) ............................ 152 Hydraulic Filter ................................................. 98 Hydraulic Pump ................................................ 94 Hydraulic Reservoir .......................................... 96 Joystick Service Parts .................................... 126 Manifold Service Parts ................................... 118 Pilot Manifold Service Parts ........................... 124 Pilot Pressure and Return .............................. 120 Pilot Pressure and Return - Begins .................. 122 Stabilizer/Tilt Hydraulics .................................

108 Thrust/Rotation & Setup Supply ..................... 104 Thrust/Rotation Gauges ................................. 138 Thrust/Rotation Pilot Hydraulics ..................... 128 Thrust/Rotation Pilot Hydraulics - Begins ......... 130 Thrust/Rotation Valve Hydraulics ................... 132 Wrench Valve Hydraulics ............................... 142 Wrench Valve Service Parts .......................... 140 Wrench, Rotating Hydraulics ......................... 146 Wrench, Stationary Hydraulics ....................... 144 Anchor Systems Anchor System ............................................... 156 Fluid Systems Drilling Fluid Plumbing ...................................

166 Drilling Fluid Pump Inlet – 13 Gal ..................... 164 Drilling Fluid Pump Inlet – 9 Gal ...................... 162 Mud Pump – 13 GPM ....................................... 170 Mud Pump – 9 GPM ......................................... 168 Water Tank .................................................... 160 Accessories Auto Luber Assembly ..................................... 174 Canopy ........................................................... 180 Grease Pump – Low Output .......................... 178 Grounding Cables .......................................... 190 Lubricator Mount, Nozzle & Applicator ........... 176 T18B Tie Down Kit .........................................

184 Umbrella Kit ................................................... 182 Wash Wand ................................................... 188 Wash Wand Plumbing ................................... 186 Miscellaneous Bolt/Nut Torque Chart .................................... 194 Filters ............................................................. 198 Optional Kits ................................................... 198 Parts Manual Change Request ...................... 199 Related Publications ...................................... 198 Replacement O-Ring Chart ............................ 197 Warranty Registration .................................... 202 ID00176432

Page 6