Ditch Witch JT4020 All Terrain Rack & Pinion User Manual

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1 JT4020 All Terrain Rack & Pinion ISSUE NO. 04PL06/11 For Replacement Copy Order P/N 053-1216 JT4020 All Terrain Rack & Pinion Directional Drilling System 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 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. ID0201755

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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/JT4020 Rack & Pinion ............... 8 Engine Components Lubricator Applicator ....................................................... 114 Auto-Luber Assembly .................................... 110 Grease Pump ................................................ 112 Grease Pump Mounting ................................. 108 Drill Frame Air Filter System ............................................... 30 Battery Covers ................................................. 46 Charge Air ........................................................ 36 Deareation........................................................

38 Engine .............................................................. 14 Engine Covers.................................................. 40 Engine Mounts ................................................. 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 Carriage AT .................................................. 128 Carriage JT ................................................... 130 Clamp Assembly ............................................ 144 Hose Track .................................................... 142 Hydraulic Cylinder (4.5" X 2.25" X2.75") .............. 148 Pivot ............................................................... 118 Rack Mounting ............................................... 120 Rotation Gearbox - AT4020 Only .......................

136 Rotation Gearbox - JT42M1/JT42T2 Only ........... 132 Spindle Drive ................................................. 140 Thrust Coupler & Shock ................................ 122 Thrust Drive Gearbox .................................... 126 Thrust Drive Rack .......................................... 124 Wrench Pipe Guide ....................................... 146 Pipe Loader System 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 Front Pipe Loader Shuttle .............................. 156 Gripper Cylinder ............................................. 162 Guard Lock Pin .............................................. 174 Pipe Box - AT42T2 Pipe .................................... 168 Pipe Box - JT42T2 Pipe ..................................... 170 Pipe Loader Gripper ...................................... 160 Pipe Loader Lifters ......................................... 154 Pipe Loader Shuttle Drive ..............................

152 Rear Pipe Loader Shuttle .............................. 158 Shuttle Guard ................................................. 172 Shuttle Stop ................................................... 164 Shuttle Stop Indicator .................................... 166 2-Post ROPS ................................................... 82 Drill Frame Covers/Locks/Switches ................. 84 Fuel Tank ......................................................... 80 Grease Cylinder ............................................... 76 Hose Retaining Clamp ..................................... 86 Idler ..................................................................

72 Rear Stabilizer .................................................. 78 Roller ................................................................ 74 Track Group ..................................................... 70 Anchor Systems Fluid System Antifreeze Tank.............................................. 194 Fluid Pump (Fluid End) 70 Gpm .......................... 186 Fluid Pump (Fluid End) 120 Gpm ........................ 184 Fluid Pump (Power End) .................................. 188 Fluid Pump (Power End) .................................. 190 Fluid Pump Plumbing - 70 Gpm ....................... 180 Fluid System Plumbing ..................................

182 Mud Pump Plumbing - 120 Gpm ...................... 178 Pump Mount- 70gpm/120gpm Fluid Pumps ............ 192 Wash Wand ................................................... 196 Anchor ............................................................ 104 Anchor Valve & Cover Mount ........................... 92 Auger Anchor Base .......................................... 90 Flange Hex Driver Assembly ......................... 102 Front Pipe Guide - All Terrain Only ....................... 94 Front Pipe Guide - JT4020 Mach 1 Only ................ 96 Left Auger Anchor Drive ................................. 100 Right Auger Anchor Drive ................................ 98 Continued ID0202363

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