Ditch Witch AT4020M1 Parts Manual & Service Guide PDF Download (EN)

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1 AT4020M1 ISSUE NO. 06PL-07/11 For Replacement Copy Order P/N 053-092 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: AT/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. ID0135016

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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 - AT4020 Mach 1 ........................... 8 Engine Components Air Filter System ............................................... 30 Covers - Battery .................................................. 40 Covers - Engine .................................................. 34 Engine - John Deere Diesel .................................. 14 Engine Mounts ................................................ 20 Engine Oil Drain ............................................... 28 Engine Skid Edging ......................................... 24 Engine Skid .....................................................

22 Fan Clutch ....................................................... 18 Gauge Panel .................................................... 42 Radiator ............................................................ 32 Sound Insulation ............................................... 38 Operator’s Station Console ............................................................ 52 Console Gauges ............................................... 54 Dual Axis Joystick ........................................... 58 Operator Station ............................................... 46 Seat - Belts - Cover ............................................

50 Track Frame & Main Frame 2-Post ROPS .................................................... 74 Cylinder Grease ............................................... 68 Drill Frame - Covers/Locks/Switches ...................... 76 Fuel Tank ......................................................... 72 Hose Retaining Clamp ..................................... 78 Idler .................................................................. 64 Roller ................................................................ 66 Stabilizer - Rear ................................................ 70 Track Group - Rubber ......................................

62 Anchor Systems Anchor .............................................................. 96 Anchor Drive - Left ............................................. 92 Anchor Drive - Right .......................................... 90 Anchor Valve/Cover Mount .............................. 84 Auger Anchor Base .......................................... 82 Flange Hex Driver ............................................ 94 Front Pipe Guide - (JT4020AT) ............................ 86 Front Pipe Guide - (JT4020M1) ........................... 88 Carriage Chain ............................................... 120 Clamp Assembly ............................................

146 Drill Frame - Covers/Locks/Switches .................... 150 Gearbox - Rotation (JT42M1/JT42T2) ................... 136 Gearbox - Rotation Drive (AT4020) - Begins ........... 128 Gearbox - Rotation Drive (AT4020) - Ends ............. 124 Gearbox - Rotation Drive (JT42M1) ...................... 132 Grease Cylinder ............................................. 152 Hose Track..................................................... 144 Hydraulic Cylinder (4.5” x 2.25” x 2.75”) ............... 154 Outer Spindle Drive Case Drain ..................... 142 Pivot ............................................................... 112 Spindle Drive ..................................................

140 Thrust Drive ................................................... 114 Thrust Idler ..................................................... 122 Wrench Pipe Guide ........................................ 148 Pipe Loader System Gripper Cylinder ............................................. 168 Guard Lock Pin .............................................. 180 Pipe Box - (AT Pipe) ......................................... 174 Pipe Box - (JT Pipe) .......................................... 176 Pipe Loader Gripper ....................................... 166 Pipe Loader Lifters ......................................... 160 Pipe Loader Shuttle - Front ..............................

162 Pipe Loader Shuttle - Rear .............................. 164 Pipe Loader Shuttle Drive .............................. 158 Shuttle Guard ................................................. 178 Shuttle Stop .................................................... 170 Shuttle Stop Indicator ..................................... 172 Fluid System Antifreeze Tank .............................................. 200 Fluid Pump - 70 GPM ....................................... 192 Fluid Pump - 120 GPM ..................................... 190 Fluid Pump - Power - (L1122 - L1622) ................... 198 Fluid Pump - Power End ...................................

194 Mud Pump Plumbing - 70 GPM ........................ 186 Mud Pump Plumbing - 120 GPM ...................... 184 Mud System Plumbing ................................... 188 Pump Mount ................................................... 196 Wash Wand ................................................... 202 Hydraulics 2-Speed Track/Thrust .................................... 242 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 - Anchor Thrust - Left ............................. 296 Cylinder - Anchor Thrust - Right ........................... 294 Frame Tilt Hydraulics ..................................... 306 Greaser Hydraulics ........................................ 316 Lubricator Applicator ....................................................... 106 Auto-Luber ...................................................... 102 Grease Pump ................................................. 104 Grease Pump Mounting ................................. 100 Selector Valve ................................................

108 Drill Frame Carriage (AT42M1/AT42T2) ................................. 118 Carriage (JT42M1/JT42T2) .................................. 116 Continued ID0135178

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