The Charles Machine Works, Inc. JT3020 Mach 1 All Terrain Tier 3 User Manual (EN)

Contents

1 JT3020 Mach 1 All Terrain Tier 3 ISSUE NO. 10PL-06/11 For Replacement Copy Order P/N 053-1149 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 JT3020 Mach 1 All Terrain Tier 3 Directional Drilling System This manual contains information concerning the following models: Copyright 2007, 2008, 2009, 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. ID0184852

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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/JT3020 ......................... 8 Engine Components Battery - Begins .......................................... 54 Battery - Ends ............................................ 52 Battery Cables ......................................... 56 Cooling System - Deaeration ........................ 22 Cooling System - Fan Assembly .................... 20 Cooling System - Plumbing .......................... 24 Electrical Mounting Center ....................... 44 Engine Diagnostic Port ............................ 48 Engine Grid Heater .................................. 50 Engine Mounts .........................................

42 Engine Oil Drain & Filter........................... 16 Engine Service Parts ............................... 14 Engine Skid Covers ................................. 38 Engine Skid Mounting .............................. 36 ESID/Radio Module Mounting .................. 46 Exhaust System ....................................... 26 Front Hood Assembly .............................. 30 Front Hood Support ................................. 28 Fuel System ............................................. 58 Intake System .......................................... 18 Rear Controls ........................................... 40 Rear Fixed Hood ......................................

34 Rear Opening Hood ................................. 32 Frame Components Assisted Make-up .................................... 62 Carriage ................................................... 64 Carriage Stops ......................................... 66 Drill Frame Proximity Switches ............... 128 Fuel Tank Assembly .............................. 110 Grease Cylinder ..................................... 118 Hose Track ............................................ 120 Idler Assembly ....................................... 116 Idler Roller Parts .................................... 114 Jaw Inserts .............................................

108 Pipe Guide ............................................. 102 Pipe Restraint ........................................ 130 Pipe Sensor Sub .................................... 132 Pivot ....................................................... 126 Rotating Wrench .................................... 104 Rotation Gearbox (AT) - Begins .................. 86 Rotation Gearbox (AT) - Ends .................... 90 Rotation Gearbox (AT) - Ends/Begins ........... 94 Rotation Gearbox (JT) - Begins/Ends ............ 78 Rotation Gearbox (JT) - Ends/Begins ............ 82 Spindle Drive Assembly (AT) - Begins ........ 74 Frame Components Continuted Spindle Drive Assembly (AT) - Ends ..........

72 Spindle Drive Assembly (JT) - Begins ......... 70 Spindle Drive Assembly (JT) - Ends ........... 68 Stabilizer Cylinder Locks ........................ 124 Stabilizers .............................................. 122 Stationary Wrench ................................. 106 Thrust Drive ............................................. 98 Thrust Drive Gearbox ............................. 100 Track Group ........................................... 112 Water Swivel ............................................ 76 Work Lights ............................................ 134 Operator’s Station Electrical Strike System..........................

152 Gauges .................................................. 150 Ground Drive Control ............................. 154 Left Console ........................................... 142 Left Console – AT/JT Control Panel ................ 144 Operator Station Floor ............................ 140 Operator Station Seat ............................ 138 Right Console & Joystick ........................ 148 Weather Covers ..................................... 146 Hydraulics Anchor Hydraulics .................................. 246 Anchor Valve - Begins/Ends ........................ 244 Anchor Valve - Ends ................................. 242 Auxiliary Pump Hydraulics ......................

206 Centering Cylinder Hydraulics ................ 240 Charge Pressure Hydraulics .................. 212 Charge Pressure Valve .......................... 210 Filter & Reservoir Hydraulics .................. 158 Fluid Pump Hydraulics - Begins ................ 264 Fluid Pump Hydraulics - Ends .................. 262 Front Tilt Relief - Begins ............................ 222 Front Wrench Hydraulics ........................ 234 Gripper Hydraulics ................................. 252 Ground Drive Brake Hydraulics .............. 218 Ground Drive Hydraulics ........................ 216 Hose Track Hydraulics (AT) ................... 168 Hose Track Hydraulics ...........................

166 Hose Track Mount Hydraulics ................ 164 Hydraulic Cylinder (2.0x1.0) ....................... 268 Hydraulic Cylinder (2.0x1.0x9.0) .................. 276 Hydraulic Cylinder (2.0x1.25) ...................... 270 Hydraulic Cylinder (2.0x1.25x40.25) .............. 278 Hydraulic Cylinder (2.5x1.25) ...................... 272 Hydraulic Cylinder (4.0x2.0) ....................... 274 CONTINUED ID0184854

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