Ditch Witch JT4020 Mach 1 Service Manual & Parts Guide PDF (EN)

Contents

1 JT4020 Mach 1 All Terrain Tier 2 ISSUE NO. 06PL-07/11 For Replacement Copy Order P/N 053-137 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 Mach 1 All Terrain Tier 2 Directional Drilling System Copyright 2004, 2005, 2006, 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, The Underground, The Underground Authority Worldwide, and Zahn are registered trademarks of The Charles Machine Works, Inc. ID0135017

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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 - AT/JT42T2 ................................. 8 Engine Components Air Filter System ............................................... 30 Charge Air ....................................................... 36 Covers - Battery ................................................. 46 Covers - Engine ................................................. 40 Deareation ....................................................... 38 Engine .............................................................. 14 Engine Mount .................................................. 20 Engine Oil Drain ..............................................

28 Engine Skid ..................................................... 22 Engine Skid Edging .......................................... 24 Fan & Shroud Assembly ................................... 18 Fan Drive .......................................................... 16 Gauge Panel ................................................... 48 Radiator ........................................................... 32 Radiator Mount ............................................... 34 Sound Insulation .............................................. 44 Operator’s Station Console ........................................................... 58 Console Gauges ..............................................

62 Dual Axis Joystick ........................................... 66 Left Console Relay Panel ................................. 60 Operator Station .............................................. 52 Seat - Belts - Cover ............................................ 56 Track Frame & Main Frame 2-Post ROPS ................................................... 82 Cylinder Grease .............................................. 76 Drill Frame - Cover/Locks/Switches ....................... 84 Fuel Tank ........................................................ 80 Hose Retaining Clamp ..................................... 86 Idler .................................................................

72 Roller ................................................................ 74 Stabilizer - Rear ................................................ 78 Track Group - Rubber ......................................... 70 Anchor Systems Anchor ........................................................... 104 Anchor Drive - Left .......................................... 100 Anchor Drive - Right .......................................... 98 Anchor Valve/Cover Mount ............................. 92 Auger Anchor Base ......................................... 90 Flange Hex Driver .......................................... 102 Front Pipe Guide - JT4020AT ..............................

94 Front Pipe Guide - JT4020M1 ............................. 96 Drill Frame Carriage - AT42M1/AT42T2 ................................ 124 Carriage - JT42M1/JT42T2 ................................. 126 Carriage Chain ............................................... 128 Clamp Assembly ........................................... 152 Grease Cylinder ............................................. 156 Hose Track..................................................... 150 Hydraulic Cylinder (4.5” x 2.25” x 2.75”) ............... 158 Pivot .............................................................. 120 Rotation Drive Gearbox - JT4020AT - Begins ......

140 Rotation Drive Gearbox - JT4020AT - Ends ........ 136 Rotation Drive Gearbox - JT4020M1 ................. 144 Rotation Drive Gearbox - JT42M1/JT42T2 ......... 132 Spindle Drive Assembly ................................. 148 Thrust Drive ................................................... 122 Thrust Idler .................................................... 130 Wrench Pipe Guide ....................................... 154 Pipe Loader System Gripper Cylinder ............................................. 172 Guard Lock Pin .............................................. 184 Pipe Box - AT Pipe ...........................................

178 Pipe Box - JT Pipe ............................................ 180 Pipe Loader Gripper ...................................... 170 Pipe Loader Lifters ........................................ 164 Pipe Loader Shuttle - Front ............................. 166 Pipe Loader Shuttle - Rear ............................. 168 Pipe Loader Shuttle Drive ............................. 162 Shuttle Guard ................................................. 182 Shuttle Stop ................................................... 174 Shuttle Stop Indicator .................................... 176 Fluid System Antifreeze Tank ..............................................

204 Fluid Pump - Fluid - 70 GPM ............................. 196 Fluid Pump - Power ......................................... 198 Fluid Pump - Power - L1122, L1622 ..................... 202 Mud Pump Plumbing - 70 GPM ........................ 188 Mud Pump Plumbing - 120 GPM ...................... 190 Mud Pump - Fluid - 120 GPM ............................. 194 Mud System Plumbing .................................. 192 Pump Mount ................................................... 200 Wash Wand ................................................... 206 Hydraulics 2-Speed Track/Thrust .................................... 240 Anchor Motor Hydraulics - Left .......................

292 Anchor Motor Hydraulics - Right ..................... 290 Anchor Supply Hydraulics ............................. 286 Anchor Valve Pressure & Return Hydraulics 288 Auxiliary Supply/Return Hydraulics ............... 300 Auxiliary Valve ................................................ 298 Cylinder (2” x 1” x 8”) ......................................... 320 Lubricator Applicator ...................................................... 114 Auto-Luber ..................................................... 110 Grease Pump ................................................ 112 Grease Pump Mounting ................................ 108 Selector Valve ...............................................

116 Continued ID0135171

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