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

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1 JT4020 Mach 1 ISSUE NO. 06PL-07/11 For Replacement Copy Order P/N 053-086 This product is covered by one or more of the following patents:

US 4,953,638; 5,148,880; 5,242,026; 5,341,887; 5,490,569; 5,684,466; 5,713,423, 5,740,703; 5,758,553; 5,794,719; 5,880,680; 5,941,322; 6,085,852C1; 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; 6,761,231; 6,776,246; 6,808,210; 6,827,158; 6,848,506; 6,871,712; 6,896,077; 7,000,710; 7011,166; 7,013,990; 7,018,164; 7,025,152; 7,038,454; 7,111,693; 7,150,331; RE37,450; RE37,923; RE37,975; RE38,418 AU 689,533; 706,544; 718,034, 755,862 CA 2,156,398; 2,217,899 FR 674,093 DE 694 17 019; 695 29 634; 697 28 716; EP 0927892; 1466068 GB 2,312,006; 2,418,553; EP674,093; EP817,901; EP846,841; EP927,892 JP 3,458,247 Other U.S.

and foreign patents pending This manual contains information concerning the following models: JT4020 Mach 1 Directional Drilling System Copyright 2004, 2005, 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. ID0135011

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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 - JT4020 Mach 1 .......................... 8 Engine Components Air Filter System ............................................... 24 Covers - Battery ............................................... 32 Covers - Engine ................................................ 28 Engine - John Deere Diesel ................................... 14 Engine Mounts ................................................. 18 Engine Oil Drain ............................................... 22 Engine Skid ...................................................... 20 Gauge Panel ....................................................

34 Radiator ............................................................ 26 Relay Panel ...................................................... 36 Sound Insulation ............................................... 30 Operator’s Station Console ............................................................ 46 Console - Right .................................................. 52 Console Relay Panel - Left ................................ 50 Console Gauges ............................................... 48 Dual Axis Joystick ............................................ 54 Operator Station ..............................................

40 Seat - Belts - Cover .......................................... 44 Track Frame & Main Frame Cylinder - Grease ................................................ 64 Drill Frame - Cover/Locks/Switches ........................ 72 Fuel Tank ......................................................... 68 Idler .................................................................. 60 Roller ................................................................ 62 Stabilizer - Rear ................................................. 66 Track Group - Rubber ......................................... 58 2-Post ROPS ....................................................

70 Anchor Systems Anchor .............................................................. 88 Auger Anchor Base .......................................... 76 Auger Anchor Drive - Left .................................. 84 Auger Anchor Drive - Right ................................ 82 Anchor Valve/Cover Mount .............................. 78 Flange Hex Driver ............................................ 86 Front Pipe Guide .............................................. 80 Lubricator Applicator ......................................................... 98 Auto-Luber Assembly ....................................... 94 Grease Pump ...................................................

96 Grease Pump Mounting ................................... 92 Selector Valve ................................................ 100 Drill Frame Carriage .......................................................... 108 Center Pipe Support ....................................... 118 Clamp Assembly ............................................ 120 Grease Cylinder ............................................. 124 Pivot ............................................................... 104 Rotation Drive Gearbox ................................. 114 Spindle Brake ................................................. 116 Thrust Drive ...................................................

106 Thrust Idler ..................................................... 112 Wrench Pipe Guide ........................................ 122 Pipe Loader System Guard Lock Pin .............................................. 146 Pipe Box ......................................................... 142 Pipe Loader Gripper ....................................... 136 Pipe Loader Lifters ......................................... 130 Pipe Loader Shuttle - Front .............................. 132 Pipe Loader Shuttle - Rear .............................. 134 Pipe Loader Shuttle Drive .............................. 128 Shuttle Guard .................................................

144 Shuttle Stop .................................................... 138 Shuttle Stop Indicator ..................................... 140 Fluid System Antifreeze Tank .............................................. 158 Fluid Pump - Power ......................................... 156 Mud Pump - Fluid ............................................ 154 Mud Pump Plumbing ...................................... 150 Mud System Plumbing ................................... 152 Wash Wand ................................................... 160 Hydraulics 2-Speed Track/Thrust Hydraulics .................. 192 Anchor Motor Hydraulics - Left ........................

230 Anchor Motor Hydraulics - Right ...................... 228 Anchor Supply Hydraulics .............................. 224 Anchor Valve Pressure Return Hydraulics ..... 226 Auxiliary Supply/Return Hydraulics ................ 238 Auxiliary Valve Hydraulics .............................. 236 Cylinder (2x1) ................................................... 258 Cylinder (2 x 1.25 x 24) ....................................... 260 Cylinder (3x1.75) .............................................. 262 Cylinder (4x2) ................................................... 264 Cylinder (4x2x10) ..............................................

266 Cylinder (4.5x2.25x2.75) ..................................... 268 Cylinder Anchor Thrust - Left .......................... 234 Cylinder Anchor Thrust - Right ........................ 232 Frame Tilt Hydraulics ..................................... 244 Greaser Hydraulics ........................................ 254 Gripper Hydraulics ......................................... 252 Hydraulic Diagram.......................................... 168 Hydraulic Reservoir ........................................ 176 Hydraulic Schematic ...................................... 164 Load Sense Hydraulics .................................. 204 Main Frame Bulkhead ....................................

180 Mud Check Supply Hydraulics ....................... 200 Mud Motor Hydraulics .................................... 210 Oil Cooler Hydraulics ..................................... 172 Pipe Lifter Hydraulics ..................................... 250 Pipe Loader Supply/Return ............................ 246 ID0135082

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