The Charles Machine Works, Inc. JT8020 T3 User Manual

Contents

1 JT8020 T3 ISSUE NO. 04PL-07/11 For Replacement Copy Order P/N 053-1053 JT8020 Tier 3 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:

Copyright 2006, 2007, 2008, 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. ID0159799

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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

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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

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CONTENTS______________________ 5 Decals Decal Location - Crane ..................................... 310 Decal Location - JT8020M1 T3 .............................. 8 Engine Components Air Filter Assembly ........................................... 20 Battery & Power Cables ................................... 34 Charge Air Cooler ............................................. 24 Engine Mount ................................................... 18 Engine Service ................................................. 16 Exhaust ............................................................ 22 Expansion Tank ...............................................

32 Fan Drive .......................................................... 26 Radiator Mounting ............................................ 28 Radiator Plumbing ............................................ 30 Frame Components Assisted Makeup - Begins .................................. 40 Assisted Makeup - Begins/Ends .......................... 38 Auxiliary Stabilizer - Begins .............................. 108 Battery Box ....................................................... 96 Cab Arm & ROPS........................................... 110 Cab Covers .................................................... 118 Cab Door/Windows ........................................

112 Cab Heat/Air ................................................... 138 Cab Lock ........................................................ 136 Carriage Sight Tube & Speed Pickup............... 58 Carriage Sight Tube ......................................... 56 Carriage ............................................................ 54 Chain Connector .............................................. 72 Covers .............................................................. 92 Cylinder Locks .................................................. 44 Drill Frame ........................................................ 42 Drive Gearbox - Rotation ....................................

62 Engine Covers - Begins ...................................... 78 Engine Covers - Ends ........................................ 82 Front Covers ..................................................... 86 Front Wrenches................................................ 48 Fuel Tank ......................................................... 94 Grille ................................................................. 76 Ground Drive Planetary Gearbox ................... 104 Heat/Air Component Mount ............................ 142 Heat/Air Diagram ............................................ 140 Hose Track Repair Section ..............................

52 Hose Track ....................................................... 50 Left Console Switches .................................... 130 Left Console ................................................... 128 Pipe Guide ........................................................ 46 Pivot ................................................................. 98 Planetary Gearbox - Rotation ............................. 64 Rear View Mirror - Left Side .............................. 120 Rear View Mirror - Right Side ............................ 122 Right Console ................................................. 134 Saver Sub .........................................................

74 Seat Mount - w/ Heat/Air .................................... 116 Seat Mount - w/o Heat/Air ................................. 114 Sound Insulation - Engine Covers ........................ 90 Spindle Brake ................................................... 60 Stabilizers ....................................................... 106 Thrust Chain Idler/Adjustment ......................... 70 Thrust Drive ..................................................... 66 Thrust Planetary Gearbox ................................ 68 Top Lining/Panel ............................................ 126 Track Group - Rubber - Begins ...........................

100 Track Group - Steel - Begins ............................. 102 Windshield Wipers/Washer ........................... 124 Hydraulics Adjustment Cylinder ....................................... 216 Auxiliary Valve ................................................ 190 Auxiliary Valve Hydraulics .............................. 188 Cab Swing Hydraulics .................................... 214 Case Drain - Ground Drive ................................. 210 Case Drain Hyd - Rotation & Thrust Motors .......... 172 Case Drain Hyd - Rotation & Thrust Pumps .......... 174 Charge Filter Hydraulics ................................. 154 Charge Manifold .............................................

184 Cooler Outlet Hydraulic - Begins ...................... 180 Cooler Outlet Hydraulic - Ends ........................ 178 Fluid Pump Control ........................................ 152 Hydraulic Control Valve - Auxiliary .................... 192 Hydraulic Cylinder - (2x1.25x14.25) .................... 220 Hydraulic Cylinder - (3x1.75) ............................ 222 Hydraulic Cylinder - (3.5x2) .............................. 224 Hydraulic Cylinder - (4x2.25) ............................ 226 Hydraulic Cylinder - (6x4x3) ............................. 218 Hydraulics Reservoir ...................................... 156 Hydrostatic Gauge Hydraulics ........................

160 Left Ground Drive Hydraulic - Begins ............... 206 Left Stabilizer Hydraulics ................................ 202 Motor Control - Begins ..................................... 166 Oil Cooler Hydraulics ..................................... 176 Park Brake Hydraulics ................................... 212 Pilot Valve Hydraulics .................................... 182 Pivot Front Lift Hydraulics .............................. 198 Pivot Rear Lift Hydraulics ............................... 200 Pump Hydraulics ............................................ 158 Pump Mounting .............................................. 146 Right Ground Drive Hydraulics .......................

208 Right Stabilizer Hydraulics ............................. 204 Rotating Clamp Hydraulics............................. 194 Rotation Motor Hydraulics .............................. 164 Rotation Pump Control ................................... 148 Rotation Pump Hydraulics.............................. 162 Spindle Brake Hydraulics ............................... 186 Stationary Clamp Hydraulics - Begins .............. 196 Thrust Motor Hydraulics ................................. 170 Thrust Pump Control ...................................... 150 Thrust Pump Hydraulics ................................. 168 Continued ID0173693

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