JT2020 Mach 1 Tier 3 Operator’s Manual CMW® Issue 3.
JT2020 Mach 1 Operator’s Manual Overview - 1 Overview Chapter Contents Serial Number Location . . . . . . . . . . . . . . . . . . . . . . 2 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Equipment Modification . . . . . . . . . . . . . . . . . . . . . . 3 Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Operator Orientation. . . . . . . . . . . . . . . . . . . . . . . . . 5 About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . .
JT2020 Mach 1 Operator’s Manual Overview - 2 Serial Number Location Serial Number Location Record serial numbers and date of purchase in spaces provided. Drilling unit serial number is located as shown.
JT2020 Mach 1 Operator’s Manual Overview - 3 Intended Use Intended Use The JT2020 Mach 1 is a self-contained horizontal directional drilling unit designed to install buried cable and pipe at distances to 400’ (122 m) depending on soil conditions. The unit is designed for operation in temperatures typically experienced in earth moving and construction work environments. Provisions may be required to operate in extreme temperatures. Contact your Ditch Witch dealer.
JT2020 Mach 1 Operator’s Manual Overview - 4 Unit Components Unit Components 1 2 3 9 4 8 6 6 7 j10om001h.eps 1. Operator’s station 6. Pipeloader 2. Spindle 7. Tracks 3. Carriage 8. Vise wrenches 4. Drill frame 9. Anchoring system 5.
JT2020 Mach 1 Operator’s Manual Overview - 5 Operator Orientation Operator Orientation IMPORTANT: Top view of unit is shown. 1. Front of unit 2. Right side of unit 3. Rear of unit 4. Left side of unit About This Manual This manual contains information for the proper use of this machine. See the beige Operation Overview pages for basic operating procedures. Cross references such as “See page 50” will direct you to detailed procedures.
Overview - 6 JT2020 Mach 1 Operator’s Manual About This Manual CMW
JT2020 Mach 1 Operator’s Manual Foreword - 7 Foreword This manual is an important part of your equipment. It provides safety information and operation instructions to help you use and maintain your Ditch Witch equipment. Read this manual before using your equipment. Keep it with the equipment at all times for future reference. If you sell your equipment, be sure to give this manual to the new owner. If you need a replacement copy, contact your Ditch Witch dealer.
Foreword - 8 JT2020 Mach 1 Operator’s Manual JT2020 Mach 1 (Tier 3) Operator’s Manual Issue number 3.0/OM-4/11 Part number 053-1361 Copyright 2009, 2010, 2011 by The Charles Machine Works, Inc. , Ditch Witch, CMW, AutoCrowd, Jet Trac, Roto Witch, Subsite, Fluid Miser, Power Pipe, Super Witch, Pierce Airrow, The Underground, The Underground Authority Worldwide, and Zahn are registered trademarks of The Charles Machine Works, Inc. This product is covered by one or more of the following patents: U.S.
JT2020 Mach 1 Operator’s Manual Contents - 9 Contents Overview 1 Foreword 7 Safety 11 Controls 21 Operation Overview 59 Prepare 63 Drive 79 Transport 83 Conduct a Bore 91 Systems and Equipment 113 Complete the Job 153 Service 159 machine serial number, information about the type of work this machine is designed to perform, basic machine components, and how to use this manual part number, revision level, and publication date of this manual, and factory contact information machine sa
Contents - 10 JT2020 Mach 1 Operator’s Manual Specifications 193 Support 153 Service Record 201 machine specifications including weights, measurements, power ratings, and fluid capacities the warranty policy for this machine, and procedures for obtaining warranty consideration and training a record of major service performed on the machine CMW
JT2020 Mach 1 Operator’s Manual Safety - 11 Safety Chapter Contents Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Safety Alert Classifications . . . . . . . . . . . . . . . . . . 13 Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Emergency Procedures . . . . . . . . . . . . . . . . . . . . . 17 • Electric Strike Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 • If an Electric Line is Damaged . . . . . . .
Safety - 12 JT2020 Mach 1 Operator’s Manual Guidelines Guidelines Follow these guidelines before operating any jobsite equipment: • Complete proper training and read operator’s manual before using equipment. • Contact your local One-Call (811 in USA) or the One-Call referral number (888-258-0808 in USA and Canada) to have underground utilities located before digging. Also contact any utilities that do not participate in the One-Call service.
JT2020 Mach 1 Operator’s Manual Safety - 13 Safety Alert Classifications Safety Alert Classifications These classifications and the icons defined on the following pages work together to alert you to situations which could be harmful to you, jobsite bystanders or your equipment. When you see these words and icons in the book or on the machine, carefully read and follow all instructions. YOUR SAFETY IS AT STAKE. Watch for the three safety alert levels: DANGER, WARNING and CAUTION.
JT2020 Mach 1 Operator’s Manual Safety - 14 Safety Alerts Safety Alerts Turning shaft will kill you or crush arm or leg. Stay away. Electric shock. Contacting electric lines will cause death or serious injury. Know location of lines and stay away. Deadly gases. Lack of oxygen or presence of gas will cause sickness or death. Provide ventilation. Moving tools will kill or injure. Shut off drill string power when anyone can be struck by moving or thrown tools. Never use pipe wrenches on drill string.
JT2020 Mach 1 Operator’s Manual Safety - 15 Safety Alerts Explosion possible. Serious injury or equipment damage could occur. Follow directions carefully. Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly. Improper control function could cause death or serious injury. If control does not work as described in instructions, stop machine and have it serviced. Looking into fiber optic cable could result in permanent vision damage.
JT2020 Mach 1 Operator’s Manual Safety - 16 Safety Alerts Hot pressurized cooling system fluid could cause serious burns. Allow to cool before servicing. Flying objects may cause injury. Wear hard hat and safety glasses. Hot parts may cause burns. Do not touch until cool. Exposure to high noise levels may cause hearing loss. Wear hearing protection. Fall possible. Slips or trips may result in injury. Keep area clean. Battery acid may cause burns. Avoid contact.
JT2020 Mach 1 Operator’s Manual Safety - 17 Emergency Procedures Emergency Procedures Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. Before operating any equipment, review emergency procedures and check that all safety precautions have been taken. EMERGENCY SHUTDOWN - Turn ignition switch to stop position or push remote engine stop button (if equipped). Electric Strike Description Electric shock.
Safety - 18 JT2020 Mach 1 Operator’s Manual Emergency Procedures If an Electric Line is Damaged If you suspect an electric line has been damaged and you are on drilling unit or bonded equipment, DO NOT MOVE. Remain on drilling machine or mats and take the following actions. The order and degree of action will depend on the situation. • Warn people nearby that an electric strike has occurred. • Have someone contact electric company. • Reverse drilling direction and try to break contact.
JT2020 Mach 1 Operator’s Manual Safety - 19 Emergency Procedures If a Gas Line is Damaged Fire or explosion possible. Fumes could ignite and cause burns. No smoking, no flame, no spark. Explosion possible. Serious injury or equipment damage could occur. Follow directions carefully. If you suspect a gas line has been damaged, take the following actions. The order and degree of action will depend on the situation. • Immediately shut off engine(s), if this can be done safely and quickly.
Safety - 20 JT2020 Mach 1 Operator’s Manual Emergency Procedures If a Fiber Optic Cable is Damaged Do not look into cut ends of fiber optic or unidentified cable. Vision damage can occur. If Machine Catches on Fire Perform emergency shutdown procedure and then take the following actions. The order and degree of action will depend on the situation. • Immediately move battery disconnect switch (if equipped) to disconnect position.
JT2020 Mach 1 Operator’s Manual Controls - 21 Controls Chapter Contents Set-Up Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Tethered Ground Drive Controller . . . . . . . . . . . . 25 Left Control Console . . . . . . . . . . . . . . . . . . . . . . . 27 • Pipeloading controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 • Drilling/Operation controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Gauge Cluster . . . . . . .
JT2020 Mach 1 Operator’s Manual Controls - 22 Set-Up Console Set-Up Console 1. Tracker control key 5. Right track switch 2. Cold start wait indicator 6. Right stabilizer control 3. Ignition switch 7. Frame tilt control 4. Left track switch 8. Left stabilizer control Item Description Notes 1. Tracker control key To allow tracker operator to stop thrust and rotation, move key to enable position (up). IMPORTANT: Remove key and keep in tracker operator’s possession.
JT2020 Mach 1 Operator’s Manual Controls - 23 Set-Up Console Item Description 2. Cold start wait indicator Lights when intake air preheater is operating. Notes Wait until light goes off before starting engine. 3. Ignition switch To start engine, insert key and turn clockwise. IMPORTANT: • Restart engine with ignition switch after it has been turned off with remote engine stop switch.
JT2020 Mach 1 Operator’s Manual Controls - 24 Set-Up Console Item Description 7. Frame tilt control To raise front end of drill frame, pull up. Notes To lower front end of drill frame, push down. 8. Left stabilizer control To raise, pull up. To lower, push down. IMPORTANT: Lower left and right stabilizers to the ground to stabilize unit and then adjust for side-to-side stability. After unit is level, adjust for entry angle. NOTICE: Stand clear of stabilizer to avoid crushing your foot.
JT2020 Mach 1 Operator’s Manual Controls - 25 Tethered Ground Drive Controller Tethered Ground Drive Controller 1 5 2 4 3 j10om016h.eps 1. Speed/direction control 4. Operator presence switch 2. Power mode switch 5. Throttle switch 3. Remote engine stop Item Description Notes 1. Speed/direction control To move forward, push. IMPORTANT: To move backward, pull. • Operator presence switch must be pressed and operator seat must be empty for control to work.
JT2020 Mach 1 Operator’s Manual Controls - 26 Tethered Ground Drive Controller Item Description 2. Power mode switch To select normal driving mode (high), push. Notes To select loading and unloading mode (low), pull. To disable controller, return to center. c00ic146h.eps 3. Remote engine stop To stop engine, press red button. 4. Operator presence switch To operate ground drive with tethered controller, press. IMPORTANT: To restart engine, turn ignition switch off and then back on.
JT2020 Mach 1 Operator’s Manual Controls - 27 Left Control Console Left Control Console Pipeloading Controls 1. Add pipe/manual/remove pipe switch 6. Pipe lift switch 2. Set/Resume switch 7. Pipe shuttle switch 3. Pipe box switch 8. Two-speed rotation switch 4. Resume switch 9. Pipe gripper switch 5. Wrench control 10. Pipe lubricator switch IMPORTANT: Switch 1 will not function unless unit is equipped with pipeloader automation option.
JT2020 Mach 1 Operator’s Manual Controls - 28 Left Control Console Item Description Notes 1. Add pipe/manual/ remove pipe switch To select “add pipe” automated pipeloader function, press top. See “Add Pipe” on page 102. To use manual pipeloader controls, move to center. 2. Set/Resume switch RESUME SET / / To select “remove pipe” automated pipeloader function, press bottom. See “Remove Pipe” on page 109. To resume operation or increase operation levels, press top.
JT2020 Mach 1 Operator’s Manual Controls - 29 Left Control Console Item Description 5. Wrench control To clamp front wrench, move to right. Notes To unclamp front wrench, move to left. To clamp and rotate rear (rotating) wrench, push. To unclamp rear (rotating) wrench, pull. 6. Pipe lift switch To raise, press top. To lower, press bottom. 7. Pipe shuttle switch To move toward pipe box, press top. To move toward spindle, press bottom. 8.
JT2020 Mach 1 Operator’s Manual Controls - 30 Left Control Console Item Description 9. Pipe gripper switch To close, press top. To open, press bottom. 10. Pipe lubricator switch To fill applicator at back of pipeloader, press top. To apply joint compound to threads at wrenches, press bottom. c00ic150h.
JT2020 Mach 1 Operator’s Manual Controls - 31 Left Control Console Drilling/Operation Controls 1. Engine throttle switch 6. Console/Work light switch 2. Drilling fluid pressure gauge 7. Fluid pump speed switch 3. Thrust pressure gauge 8. Fluid pump indicator 4. Rotation pressure gauge 9. Fluid flow control 5. Remote engine start switch Item Description Notes 1. Engine throttle switch To increase speed, press top. Return switch to center when desired speed is reached.
JT2020 Mach 1 Operator’s Manual Controls - 32 Left Control Console Item Description 2. Drilling fluid pressure gauge Displays drilling fluid pressure supplied by drilling fluid pump. Notes c00ic157h.eps 3. Thrust pressure gauge Displays hydraulic fluid pressure to thrust motor during thrust and pullback. Estimates thrust and pullback force on lines outside gauge. 4. Rotation pressure gauge Displays hydraulic fluid pressure to rotation motor when spindle is turned clockwise.
JT2020 Mach 1 Operator’s Manual Controls - 33 Left Control Console Item Description 6. Console/Work light switch To turn on, press top. Notes To turn off, press bottom. c00ic151h.eps 7. Fluid pump speed switch 8. Fluid pump indicator For high speed, press top. High speed delivers more flow at lower pressure. For low speed, press bottom. Low speed delivers less flow at higher pressure. If fluid pump is on, light should be on. If fluid pump is off, light should be off. 9.
Controls - 34 JT2020 Mach 1 Operator’s Manual Gauge Cluster Gauge Cluster Unit Status Indicators 1. Diagnostic light (red) 5. Operator presence indicator 2. Hydraulic fluid temperature indicator 6. Cold start wait indicator 3. Hydraulic filter service indicator 7. Water in fuel indicator 4. Fluid pump status indicator 8.
JT2020 Mach 1 Operator’s Manual Controls - 35 Gauge Cluster Item Description 1. Diagnostic light (red) If system is OK, light should be off. Notes If system may not be getting power, light should be on. If a non-essential diagnostic code is recorded, light should flash on and off for 10 seconds. See “Interpret Diagnostic Codes” on page 147. If an essential diagnostic code is recorded, light should flash on for three seconds and off for half a second. 2.
JT2020 Mach 1 Operator’s Manual Controls - 36 Gauge Cluster Item Description Notes 5. Operator presence indicator Indicates operator is seated in operator’s station. Thrust and rotation will not operate unless light is on. 6. Cold start wait indicator Lights when intake air preheater is operating. Wait until light goes off before starting engine. 7. Water in fuel indicator Indicates the presence of water in the fuel. 8. Battery charging indicator Indicates battery is not charging.
JT2020 Mach 1 Operator’s Manual Controls - 37 Gauge Cluster Pipeloading Status Indicators 1. Control cycle light (green) 5. Rear stop status indicator 2. Front wrench status indicator 6. Pipe lift status indicator 3. Shuttle home status indicator 7. Front pipe box status indicator 4. Carriage home status indicator 8. Rear pipe box status indicator Item Description 1. Control cycle light (green) If nothing is being controlled, light should be off.
JT2020 Mach 1 Operator’s Manual Controls - 38 Gauge Cluster Item Description 2. Front wrench status indicator If front wrench is closed, light should be on. If front wrench is open, light should be off. 3. Shuttle home status indicator If shuttle is retracted, light should be on. If shuttle is not completely retracted, light should be off. 4. Carriage home status indicator If carriage is in the home zone at either end of drill frame, light should be on.
JT2020 Mach 1 Operator’s Manual Controls - 39 Gauge Cluster Item Description 6. Pipe lift status indicator If pipe lifter is lifted fully and lift pressure switch is engaged, light should be on. Notes If pipe lift pressure switch is not engaged, light should be off. 7. Front pipe box status indicator If active pipe column contains pipe, light should be on. IMPORTANT: • Check pipe box status lights to see when active column of pipe box is empty. See “Shift Pipe Box” on page 141.
JT2020 Mach 1 Operator’s Manual Controls - 40 Gauge Cluster Gauges 1. Voltmeter 4. Engine oil pressure gauge 2. Tachometer/Hourmeter 5. Fuel gauge 3. Engine coolant temperature gauge Item Description Notes 1. Voltmeter Displays system voltage. Should show 13-14V with engine running.
JT2020 Mach 1 Operator’s Manual Controls - 41 Gauge Cluster Item Description Notes 2. Tachometer/Hourmeter Displays engine rpm. Full load reading should be 2600 rpm. Displays engine operating time. Use these times to schedule service. 3. Engine coolant temperature gauge Displays engine coolant temperature. Normal coolant temperature is 160°-212° F (71°-100° C). 4. Engine oil pressure gauge Displays engine oil pressure. Full load reading should be 35-65 psi (2.4-4.5 bar).
JT2020 Mach 1 Operator’s Manual Controls - 42 Right Control Console Right Control Console 1. Drilling fluid pump switch 4. Drilling fluid quick fill switch 2. Dual speed carriage control 5. Remote engine stop switch 3. Carriage control Item Description 1. Drilling fluid pump switch To turn on, press once. To turn off, press once.
JT2020 Mach 1 Operator’s Manual Controls - 43 Right Control Console Item Description Notes 2. Dual speed carriage control To engage high carriage travel speed, push and hold. Use during bore or pullback when no pipe is in spindle to save time. To return to normal carriage speed, release. IMPORTANT: Overriding assisted makeup mode puts pipe threads in jeopardy. If frequent overriding is necessary, see your Ditch Witch dealer for pipeloader adjustment.
JT2020 Mach 1 Operator’s Manual Controls - 44 Anchoring System Console Anchoring System Console 1 2 3 4 j10om015h.eps 1. Left rotation control 3. Right rotation control 2. Left thrust control 4. Right thrust control Item Description Notes 1. Left rotation control To drive anchor, push down. IMPORTANT: Stand on platform when operating anchor controls. To remove anchor, pull up.
JT2020 Mach 1 Operator’s Manual Controls - 45 Anchoring System Console Item Description Notes 2. Left thrust control To move anchor down, push down. IMPORTANT: Stand on platform when operating anchor controls. To move anchor up, pull up. 3. Right rotation control To drive anchor, push down. IMPORTANT: Stand on platform when operating anchor controls. To remove anchor, pull up. 4. Right thrust control To move anchor down, push down. IMPORTANT: Stand on platform when operating anchor controls.
JT2020 Mach 1 Operator’s Manual Controls - 46 Seat/Armrest Seat/Armrest 1. Armrest adjustment 3. Seat slide control 2. Seat recline control Item Description 1. Armrest adjustment To adjust armrest position, unscrew knob, move armrest to new position, and screw knob in. 2. Seat recline control To recline or raise seatback, lift. To lock seatback in position, release.
JT2020 Mach 1 Operator’s Manual Controls - 47 Seat/Armrest Item Description 3. Seat slide control To slide forward or backward, move left. Notes To lock seat in position, move right.
JT2020 Mach 1 Operator’s Manual Controls - 48 Battery Battery 1. Battery disconnect switch Item Description 1. Battery disconnect switch To connect, move clockwise. To disconnect, move counterclockwise.
JT2020 Mach 1 Operator’s Manual Controls - 49 Engine Compartment Controls Engine Compartment Controls 1. High/auto fan speed switch Item Description Notes 1. High/auto fan speed switch For high speed, press top. IMPORTANT: If switch is on high speed, fan will run at full speed all the time. If switch is on auto speed, fan speed will vary in relation to engine temperature. For automatic speed, press bottom.
JT2020 Mach 1 Operator’s Manual Controls - 50 ESID ESID 2 3 1 4 5 6 7 8 j07om042h.eps 1. Alphanumeric display 5. Current problem indicator 2. Strike indicator 6. OK indicator 3. Alarm interrupt button 7. Electrical power supply indicator 4. Voltage problem indicator 8. Self test button Item Description 1. Alphanumeric display Displays amount of current and voltage being detected as a percentage of strike condition.
JT2020 Mach 1 Operator’s Manual Controls - 51 ESID Item Description Notes 3. Alarm interrupt button To turn off strike alarm at drilling unit, press. 4. Voltage problem indicator Blinking red light indicates a voltage indicator problem. See “Troubleshoot Strike System” on page 118. 5. Current problem indicator Blinking red light indicates a current indicator problem. See “Troubleshoot Strike System” on page 118. 6. OK indicator Green light means system self test detected no problems.
JT2020 Mach 1 Operator’s Manual Controls - 52 ESID Item Description 7. Electrical power supply indicator Green light means control box has sufficient electrical power for operation. Notes Strike system is ready to operate if OK indicator is also on. 8. Self test button CMW To start manual self test, press. Checks all systems and circuits. To reset system after a strike has been detected, press. NOTICE: See “If an Electric Line is Damaged” on page 18.
JT2020 Mach 1 Operator’s Manual Controls - 53 Ditch Witch Electronics 750/752 Display Ditch Witch Electronics 750/752 Display Indicators 1. Beacon temperature display 5. Depth estimate 2. Pitch/slope indicator and percentage indicator 6. Display battery status indicator 3. Roll indicator 7. Beacon battery status indicator 4. Target indentifier indicator 8. Beacon temperature indicator IMPORTANT: Some items operate differently depending where data is being saved.
JT2020 Mach 1 Operator’s Manual Controls - 54 Ditch Witch Electronics 750/752 Display Item Description Notes 2. Pitch/slope indicator and percentage indicator Indicates pitch beacon percent of grade. Internal: shows pipe label and stored pitch. 3. Roll indicator Indicates beacon roll angle. 4. Target identifier indicator Indicates approximate beacon location. Only one set of arrows is active at a time. 5. Depth estimate Indicates beacon depth estimate.
JT2020 Mach 1 Operator’s Manual Controls - 55 Ditch Witch Electronics 750/752 Display Item Description Notes 6. Display battery status indicator Indicates display power from drilling unit. If all five bars are not showing, check display power connections. 7. Beacon battery status indicator Indicates beacon battery status. See beacon instruction sheet. 8. Beacon temperature indicator Indicates beacon temperature. See beacon instruction sheet.
JT2020 Mach 1 Operator’s Manual Controls - 56 Ditch Witch Electronics 750/752 Display Controls 1. Delete button 4. Roll stop button 2. On/Off button 5. Recall button 3. Channel select button 6. Store button IMPORTANT: Some items operate differently depending where data is being saved. Internal refers to pipe data being saved to 750 Display memory. External refers to pipe data being sent to a properly connected laptop computer running a version of Trac Management System software.
JT2020 Mach 1 Operator’s Manual Controls - 57 Ditch Witch Electronics 750/752 Display Item Description 2. On/Off button To turn on, press. Notes To turn off, press again. 3. Channel select button To display current channel, press and release. Unit defaults to last channel used each time unit is turned on. To switch channels, press and hold. IMPORTANT: Make sure display and tracker are set to the same channel. Second function: To start a new job, press with Recall button.
JT2020 Mach 1 Operator’s Manual Controls - 58 Ditch Witch Electronics 750/752 Display Item Description Notes 6. Store button To display serial number, press and hold while pressing on/off button. Pipe number will appear in numeric display when data is stored. To store current pipe data, press. IMPORTANT: Pipe data cannot be stored without a valid depth estimate.
JT2020 Mach 1 Operator’s Manual Operation Overview - 59 Operation Overview Chapter Contents Planning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Setting Up at Jobsite . . . . . . . . . . . . . . . . . . . . . . . 60 Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Backreaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Leaving Jobsite. . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Storing Equipment . . . . . . . . . .
Operation Overview - 60 JT2020 Mach 1 Operator’s Manual Planning Planning 1. Gather information about jobsite. See page 65. 2. Inspect jobsite. See page 66. 3. Classify jobsite. See page 68. 4. Plan bore path. See page 71. 5. Check supplies and prepare equipment. See page 76. 6. Load equipment. See page 85. Setting Up at Jobsite 1. Prepare jobsite. See page 76. 2. Unload drilling unit from trailer. See page 88. 3. Assemble drill string. See page 97. 4. Position drilling unit and drill frame. See page 93.
JT2020 Mach 1 Operator’s Manual Operation Overview - 61 Drilling Drilling 1. Start system. See page 93. 2. Engage tracker control if desired. See page 127. 3. Drill first pipe. See page 100. 4. Record bore path. See page 105. 5. Enable automated pipeloader system. See page 105. 6. Add pipe. See page 102. 7. Drill remaining pipes in pipe box. • Correct direction. See page 104. • Engage cruise control. See page 146. • Shift pipe box. See page 141. 8.
Operation Overview - 62 JT2020 Mach 1 Operator’s Manual Backreaming Backreaming 1. Assemble backream string. See page 107. 2. Start drilling unit and adjust throttle. 3. Set drilling fluid flow. Check that fluid flows through all nozzles. See page 122. 4. Remove pipe from bore. See page 109. 5. Remove up to a single column of drill pipe from full box (see page 137) to complete backream. 6. Remove pullback device. See page 111. Backreaming Tips • Plan backreaming job before drilling.
JT2020 Mach 1 Operator’s Manual Prepare - 63 Prepare Chapter Contents Gather Information . . . . . . . . . . . . . . . . . . . . . . . . . 65 • Review Job Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 • Notify One-Call Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 • Examine Pullback Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 • Arrange for Traffic Control. . . . . . . . . . . . .
Prepare - 64 JT2020 Mach 1 Operator’s Manual Prepare Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 • Mark Bore Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 • Prepare Entry Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Check Supplies and Prepare Equipment . . . . . . . 77 • Check Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JT2020 Mach 1 Operator’s Manual Prepare - 65 Gather Information Gather Information A successful job begins before the bore. The first step in planning is reviewing information already available about the job and jobsite. Review Job Plan Review blueprints or other plans and make sure you have taken bore enlargement during backreaming and pullback into account. Check for information about existing or planned structures, elevations, or proposed work that may be taking place at the same time.
JT2020 Mach 1 Operator’s Manual Prepare - 66 Inspect Site Inspect Site Inspect jobsite before transporting equipment. Check for the following: • overall grade or slope • changes in elevation such as hills or open trenches • obstacles such as buildings, railroad crossings, or streams • signs of utilities (See “Inspect Jobsite” on page 68.) • traffic • access • soil type and condition • water supply • sources of locator interference (rebar, railroad tracks, etc.
JT2020 Mach 1 Operator’s Manual Prepare - 67 Inspect Site Select Start and End Points Select one end to use as a starting point. Consider the following when selecting a starting point: Slope Fluid system should be parked on a level site. Consider how slope will affect drilling unit setup, bending pipe, and fluid flow out of hole. Traffic Vehicle and pedestrian traffic must be a safe distance from drilling equipment. Allow at least 10’ (3 m) buffer zone around equipment.
Prepare - 68 JT2020 Mach 1 Operator’s Manual Classify Jobsite Classify Jobsite Inspect Jobsite • Follow U.S. Department of Labor regulations on excavating and trenching (Part 1926, Subpart P) and other similar regulations. • Contact your local One-Call (811 in USA) or the One-Call referral number (888-258-0808 in USA and Canada) to have underground utilities located before digging. Also contact any utilities that do not participate in the One-Call service.
JT2020 Mach 1 Operator’s Manual Prepare - 69 Classify Jobsite Apply Precautions Once classified, precautions appropriate for jobsite must be taken. Electric Jobsite Precautions Electric shock. Contacting electric lines will cause death or serious injury. Know location of lines and stay away. In addition to using a directional drilling system with an electric strike system, use one or both of these methods. • Expose line by careful hand digging or soft excavation. Use beacon to track bore path.
JT2020 Mach 1 Operator’s Manual Prepare - 70 Classify Jobsite Crystalline Silica (Quartz) Dust Precautions Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. NOTICE: Cutting, drilling or working materials such as, concrete, sand or rock containing quartz may result in exposure to silica dust. Use water spray or other means to control dust. If workers are exposed to dust they must wear appropriate breathing protection.
JT2020 Mach 1 Operator’s Manual Prepare - 71 Plan Bore Path Plan Bore Path Plan the bore path, from entry to end, before drilling begins. The Ditch Witch Trac Management System Plus is available for planning your bore path. This special software can be run in the field using a laptop computer equipped with Windows® 95 or higher operating system. See your Ditch Witch dealer for details.
Prepare - 72 JT2020 Mach 1 Operator’s Manual Plan Bore Path Recommended Bend Limits Ditch Witch drill pipes are designed to bend slightly during operation. Slight bending allows for steering and correcting direction. Bending beyond recommended limits will cause damage that might not be visible. This damage adds up and will later lead to sudden drill pipe failure. IMPORTANT: Consider recommended bend limits during any bend, not just during bore entry.
JT2020 Mach 1 Operator’s Manual Prepare - 73 Plan Bore Path Pipe-By-Pipe Bend Limits Pipe (C) Forward (B) Deflection (A) Pipe (C) Forward (B) Deflection (A) 1 10 ft 0 in (3.0 m) 0 ft 5 in (0.1 m) 12 103 ft 8 in (31.6 m) 51 ft 7 in (15.7 m) 2 19 ft 11 in (6.1 m) 1 ft 6 in (0.5 m) 13 109 ft 5 in (33.3 m) 59 ft 9 in (18.2 m) 3 29 ft 9 in (9.1 m) 3 ft 5 in (1.1 m) 14 1114 ft 6 in (34.9 m) 68 ft 5 in (20.8 m) 4 39 ft 4 in (12.0 m) 6 ft 1 in (1.9 m) 15 118 ft 10 in (36.
Prepare - 74 JT2020 Mach 1 Operator’s Manual Plan Bore Path Entry Pitch Entry pitch is the slope of the drill frame compared with the slope of the ground. Determine entry pitch one of two ways: 1. With Pitch Beacon • Lay pitch beacon on the ground and read pitch. • Lay pitch beacon on drill frame and read pitch. • Subtract ground pitch from drilling unit pitch. 2. With Measurements • Measure from the ground to front end of drill frame (H1). • Measure from the ground to back end of frame (H2).
JT2020 Mach 1 Operator’s Manual Prepare - 75 Plan Bore Path Minimum Depth Because you must bend pipe gradually, entry pitch and bend limits determine how deep the pipe will be when it becomes horizontal. This is called the minimum depth. • To reduce minimum depth (D1), reduce entry pitch. This also decreases setback. • To increase minimum depth (D2), increase entry pitch. This also increases setback.
JT2020 Mach 1 Operator’s Manual Prepare - 76 Prepare Jobsite Prepare Jobsite Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. NOTICE: • If jobsite classification is in question or if the possibility of unmarked electric utilities exists, classify jobsite as electric. • Cutting high voltage cable can cause electrocution. Expose lines by hand before digging. • All vegetation near operator’s station must be removed.
JT2020 Mach 1 Operator’s Manual Prepare - 77 Check Supplies and Prepare Equipment Check Supplies and Prepare Equipment Check Supplies • receiver/transmitter or tracker with spare batteries • beacons with new and spare batteries • two-way radios with new and spare batteries • quick wrench (see page 135) • transition sub • anchoring equipment and accessories • bits, screens, nozzles (see page 130) • adapters, pipe, beacon housings • marking flags or paint • water and additional hoses •
Prepare - 78 JT2020 Mach 1 Operator’s Manual Prepare Equipment Fluid Levels • fuel • hydraulic fluid • engine coolant • battery charge • engine oil Condition and Function • filters (air, oil, hydraulic) • fluid pump • couplers • tires and tracks • pumps and motors • drilling fluid mixer • hoses and valves • water tanks Assemble Accessories Fire Extinguisher If required, mount a fire extinguisher near the power unit but away from possible points of ignition.
JT2020 Mach 1 Operator’s Manual Drive - 79 Drive Chapter Contents Start Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Steer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Shut Down Unit . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive - 80 JT2020 Mach 1 Operator’s Manual Start Unit Start Unit 1. Insert key. 2. Turn key clockwise. See page 23 for more information. 3. Run engine at low throttle for 5 minutes. Steer Unit To steer drilling unit while using tethered ground drive controller, follow instructions for type of steering desired. To steer while moving forward, push forward and then move to left or right. Drilling unit will gradually turn to left or right.
JT2020 Mach 1 Operator’s Manual Drive - 81 Shut Down Unit Shut Down Unit 1. Stop track movement. 2. Lower drill frame and stabilizers to the ground. IMPORTANT: If frame and stabilizers cannot be lowered, use cylinder locks or other suitable material to block the tracks and frame. Remove cylinder locks or chocks before driving unit. 3. Run engine at low throttle for 3 minutes to cool. 4. Turn key to the stop position. 5. Remove key.
Drive - 82 JT2020 Mach 1 Operator’s Manual Shut Down Unit CMW
JT2020 Mach 1 Operator’s Manual Transport - 83 Transport Chapter Contents Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Haul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 • Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 • Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 • Unload . . . . . . . . . . . . . . . . . .
Transport - 84 JT2020 Mach 1 Operator’s Manual Lift Lift This machine is not configured for lifting. If the machine must be lifted, load machine into a container or onto a platform appropriate for lifting. See “Specifications” for weight of machine.
JT2020 Mach 1 Operator’s Manual Transport - 85 Haul Haul Load Crushing weight. If load falls or moves it could kill or crush you. Use proper procedures and equipment or stay away. NOTICE: • Load and unload trailer on level ground. • Verify that trailer wheels are blocked. • Incorrect loading can cause trailer swaying. • Attach trailer to vehicle before loading or unloading. • Ten to fifteen percent of total vehicle weight (equipment plus trailer) must be on tongue to help prevent trailer sway.
JT2020 Mach 1 Operator’s Manual Transport - 86 Haul Tie Down Points Tiedown points are identified by tiedown decals. Securing to trailer at other points is unsafe and can damage machinery. Procedure Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly. NOTICE: Wrenches can open after engine shutdown. Ensure that any downhole tool or pipe in tool joint vises is attached to spindle or removed before transport.
JT2020 Mach 1 Operator’s Manual Transport - 87 Haul Without Tiedown Kit Loop tiedowns around unit at tiedown points. Make sure tiedowns are tight before transporting.
JT2020 Mach 1 Operator’s Manual Transport - 88 Haul Unload Crushing weight. If load falls or moves it could kill or crush you. Use proper procedures and equipment or stay away. NOTICE: • Load and unload trailer on level ground. • Ensure trailer wheels are blocked. • Attach trailer to vehicle before loading or unloading. With Tiedown Kit 1. Lower ramps. 2. Remove tiedowns. 3. Start drilling unit engine. 4. Using tethered ground drive controller, pull power mode switch into low position.
JT2020 Mach 1 Operator’s Manual Transport - 89 Tow Tow Under normal conditions, drilling unit should not be towed. If unit breaks down and towing is necessary: • Attach chains to indicated tow points facing towing vehicle. • Open bypass valves. • Open selector valves. • Tow for short distances at less than 1 mph (1.6 km/h). • Use maximum towing force of 1.5 times unit weight. To open bypass valves for towing, rotate valve stems (shown) two full revolutions.
Transport - 90 JT2020 Mach 1 Operator’s Manual Tow To open selector valves for towing, loosen jam nut and tighten valve screw (shown) until it is fully threaded. To close selector valves and return to normal operation, unthread valve screw and tighten jam nut. To attach chains to tow points, determine which points are facing towing vehicle. To attach chains to tow points, determine which points are facing towing vehicle.
JT2020 Mach 1 Operator’s Manual Conduct a Bore - 91 Conduct a Bore Chapter Contents Position Equipment . . . . . . . . . . . . . . . . . . . . . . . . 93 Connect Fluid System . . . . . . . . . . . . . . . . . . . . . . 93 Start System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Prime Drilling Fluid Pump . . . . . . . . . . . . . . . . . . . 94 Operate Carriage Control . . . . . . . . . . . . . . . . . . . 95 Clamp Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conduct a Bore - 92 JT2020 Mach 1 Operator’s Manual Record Bore Path . . . . . . . . . . . . . . . . . . . . . . . . . 105 Surface Drill Head . . . . . . . . . . . . . . . . . . . . . . . . 106 Assemble Backream String . . . . . . . . . . . . . . . . 107 Remove Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Remove Pullback Device . . . . . . . . . . . . . . . . . . .
JT2020 Mach 1 Operator’s Manual Conduct a Bore - 93 Position Equipment Position Equipment 1. Review bore plan and select drilling unit position and fluid unit position. See “Select Start and End Points” on page 67. 2. Move equipment into selected positions. Connect Fluid System Electric shock. Contacting electric lines will cause death or serious injury. Know location of lines and stay away.
JT2020 Mach 1 Operator’s Manual Conduct a Bore - 94 Prime Drilling Fluid Pump Prime Drilling Fluid Pump Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly. NOTICE: Failure to prime the drilling fluid pump will cause flow fluctuations, which will make it difficult to control the washwand. Pressurized fluid or air could pierce skin and cause injury or death. Stay away. Prime drilling fluid pump each time tank is changed. To prime the pump: 1.
JT2020 Mach 1 Operator’s Manual Conduct a Bore - 95 Operate Carriage Control Operate Carriage Control The thrust/rotation control has eight positions which allow the four basic functions to be combined. The chart below summarizes functions that occur when control is put at a combined position. Operator must be in seat for control to function.
JT2020 Mach 1 Operator’s Manual Conduct a Bore - 96 Clamp Pipe Clamp Pipe Turning shaft can kill you or crush arm or leg. Stay away. NOTICE: Clamping anywhere else on the pipe will weaken the pipe. Pipe can later break, even when operating under normal loads. Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly. NOTICE: Wrenches can open after engine shutdown.
JT2020 Mach 1 Operator’s Manual Conduct a Bore - 97 Assemble Drill String Assemble Drill String Prepare Beacon Housing 1. Select nozzles and bit. IMPORTANT: A variety of nozzles and bits are available to suit your particular job conditions. See “Downhole Tools” on page 130 for more information, or contact your Ditch Witch dealer. 2. Insert nozzle into beacon housing. 3. Attach bit (2) to beacon housing (1). 4.
Conduct a Bore - 98 JT2020 Mach 1 Operator’s Manual Assemble Drill String Attach Transition Sub Moving tools will kill or injure. Shut off drill string power when anyone can be struck by moving or thrown tools. Never use pipe wrenches on drill string. Use either machine torque or quick wrench to attach transition sub (2) to beacon housing (1). Machine Torque 1. Pull beacon housing into front wrench. 2. Close wrench. 3. Lube joints. 4. Slowly make up joint. 5.
JT2020 Mach 1 Operator’s Manual Conduct a Bore - 99 Assemble Drill String Connect Drill Pipe 1. Start drilling unit engine. 2. Align drill pipe in front wrench. 3. Clamp tool joint in front wrench. See “Clamp Pipe” on page 96. 4. Load pipe: • Make sure pipe box is positioned correctly. • Lower pipe lifters. • Close grippers. • Lubricate pipe threads (pipe loader end). • Lubricate pipe threads (front wrench end). • Move pipe to spindle. • Raise pipe lifters. 5.
Conduct a Bore - 100 JT2020 Mach 1 Operator’s Manual Drill First Pipe Drill First Pipe Turning shaft can kill you or crush arm or leg. Stay away. NOTICE: • Keep everyone at least 10’ (3 m) away from turning drill string. • Push rod or pipe slowly. Forcing can bend string. Do not use bent rod or pipe. Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. 1. Turn on drilling fluid. 2.
JT2020 Mach 1 Operator’s Manual Conduct a Bore - 101 Enable Automated Pipeloader System Enable Automated Pipeloader System Add Pipe Remove Pipe 1. Make sure pipe box is properly positioned. See “Shift Pipe Box” on page 141. 1. Make sure pipe box is properly positioned. See “Shift Pipe Box” on page 141. IMPORTANT: Carriage MUST be in center of drill frame. IMPORTANT: Carriage MUST be in center of drill frame. 2. Open front wrench, retract shuttles, and grip pipe for add pipe function to work. 2.
Conduct a Bore - 102 JT2020 Mach 1 Operator’s Manual Add Pipe Add Pipe IMPORTANT: If gripper switch is not in the grip position when using optional pipeloader automation, grippers will open when automation is stopped and gripped pipe could be dropped. To return a dropped pipe to the drill string, see “Correct Dropped Pipe” on page 141. 1. Press top of drilling unit throttle switch until engine is at full throttle. 2. Enable automated pipeloader system (automated pipeloader control only).
JT2020 Mach 1 Operator’s Manual Conduct a Bore - 103 Add Pipe 5. Connect new pipe to drill string: Manual Pipeloader Controls Automated Pipeloader Control • Move carriage forward until pipe joints meet at front wrench. • Move carriage forward until pipe joints meet at front wrench. • Rotate spindle clockwise. Carriage will move forward as pipe threads tighten. • Rotate spindle clockwise. Carriage will move forward as pipe threads tighten.
Conduct a Bore - 104 JT2020 Mach 1 Operator’s Manual Correct Direction Correct Direction Correcting direction is a skill operators gain with experience and knowledge of equipment and soil conditions. These instructions cover only basic procedures. For information about specific equipment or jobsites, contact your Ditch Witch dealer. To track progress and make corrections, one crew member locates the drill head and sends instructions to the operator.
JT2020 Mach 1 Operator’s Manual Conduct a Bore - 105 Record Bore Path Drill Head Position The drill head position is determined by reading beacon roll. Roll is displayed as a clock face position. 1. Read beacon roll. 2. Slowly rotate pipe until locator displays desired beacon roll. To change direction: 1. Rotate pipe to clock position you intend to travel. 2. Push pipe into ground. To move forward without changing direction: Rotate pipe into ground.
JT2020 Mach 1 Operator’s Manual Conduct a Bore - 106 Surface Drill Head Surface Drill Head Moving tools will kill or injure. Shut off drill string power when anyone can be struck by moving or thrown tools. Never use pipe wrenches on drill string. Turning shaft will kill you or crush arm or leg. Stay away. NOTICE: • Tracker operator and drill operator should maintain two-way communication. • Keep everyone clear of the exposed drill string.
JT2020 Mach 1 Operator’s Manual Conduct a Bore - 107 Assemble Backream String Assemble Backream String Sometimes it is necessary to enlarge the pilot hole to accommodate larger product. As a general rule, the final hole should be 1.5 times larger than the diameter of the product being installed. The number of passes needed depends on soil conditions. Do not try to increase hole size too much in one pass. Several passes using successively larger reamers will save wear on machine.
Conduct a Bore - 108 JT2020 Mach 1 Operator’s Manual Assemble Backream String 1. Select backreaming devices. See “Backreamers” on page 132. 2. Determine fluid rate requirements and install appropriate nozzles to provide sufficient flow. See “Backream Fluid Requirements” on page 133 and “Nozzles” on page 130. 3. Attach backreamer to backream beacon housing if tracking backream. 4. Install beacon, following beacon instructions for: • battery replacement • beacon positioning 5.
JT2020 Mach 1 Operator’s Manual Conduct a Bore - 109 Remove Pipe Remove Pipe IMPORTANT: If gripper switch is not in the grip position when using optional pipeloader automation, grippers will open when automation is stopped and gripped pipe could be dropped. To return a dropped pipe to the drill string, see “Correct Dropped Pipe” on page 141. NOTICE: If engine is shut off during backreaming, drill pipe clamped by wrenches but not connected to saver sub can be pulled downhole as vise wrenches loosen. 1.
Conduct a Bore - 110 JT2020 Mach 1 Operator’s Manual Remove Pipe 9. Break rear joint. • Engage rear wrench. • Slowly rotate spindle counterclockwise until joint is loosened. Do not fully separate joint. • Disengage rear wrench. • Move carriage back until front end of pipe is positioned inside front end of pipe box. • Rotate spindle counterclockwise until saver sub is separated from pipe. • Stop rotation and move carriage to back of frame. 10. Ensure pipe box is positioned correctly. 11.
JT2020 Mach 1 Operator’s Manual Conduct a Bore - 111 Remove Pullback Device Remove Pullback Device The pullback device can be removed when the last pipe is on the frame. It can also be removed when a target pit along the bore path has been reached. Remaining pipe is then pulled back and removed. Moving tools will kill or injure. Shut off drill string power when anyone can be struck by moving or thrown tools. Never use pipe wrenches on drill string. 1.
Conduct a Bore - 112 JT2020 Mach 1 Operator’s Manual Remove Pullback Device CMW
JT2020 Mach 1 Operator’s Manual Systems and Equipment - 113 Systems and Equipment Chapter Contents Anchor System . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 • Drive Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 • Remove Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Electric Strike System . . . . . . . . . . . . . . . . . . . . . 116 • FCC Statement . . . . . . . . . . . . . . . . . . . . .
Systems and Equipment - 114 JT2020 Mach 1 Operator’s Manual Downhole Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 130 • Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 • Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 • Beacon Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 • Backreamers . . . . . . . . . . . . . . . . . .
JT2020 Mach 1 Operator’s Manual Systems and Equipment - 115 Anchor System Anchor System Crushing weight. If load falls or moves, it could kill or crush you. Use proper procedures and equipment or stay away. NOTICE: • Drive anchors properly before drilling. • Stand on platform when operating anchor controls. • Wear high-top protective boots with legs of pants completely tucked inside. • Wear protective gloves.
Systems and Equipment - 116 JT2020 Mach 1 Operator’s Manual Electric Strike System Remove Anchors 1. Use anchor rotation and thrust controls to slowly remove anchor shaft from ground. 2. Repeat process for other anchor. Electric Strike System Any time you drill in an electric jobsite, electric strike system must be properly set up, tested, and used.
JT2020 Mach 1 Operator’s Manual Systems and Equipment - 117 Electric Strike System Assemble Voltage Detector 1. Drive voltage stake into ground at least 6’ (2 m) away from any part of system. 2. Clip voltage limiter to voltage stake. Test Strike System If system fails any part of this test, see “Troubleshoot Strike System” on page 118 on the following page. Do not drill until test is completed successfully. 1. Turn on drilling unit. 2.
JT2020 Mach 1 Operator’s Manual Systems and Equipment - 118 Electric Strike System Troubleshoot Strike System When strike system detects a problem, an error code will be displayed. Anytime this happens, press self test button to retest. If error code is still displayed and does not appear in this chart, have control module checked or replaced. Other problem situations and their possible causes and solutions are listed in the chart below.
JT2020 Mach 1 Operator’s Manual Systems and Equipment - 119 Electric Strike System Problem Possible cause Possible solution Strobe light on drilling unit does not work during total test Improper connections with control module Check connections and wiring harness Defective strobe light 1. Disconnect strobe and connect to external 12V power source. 2. If strobe does not work, replace it.
JT2020 Mach 1 Operator’s Manual Systems and Equipment - 120 Electric Strike System Problem Possible cause Possible solution EV2 code displays and voltage problem indicator is on Improper connections with control module Check cable connection on control module Defective voltage limiter Have voltage limiter checked or replaced Defective control module Have control module checked or replaced Use Electric Strike Simulator Use the Electric Strike Simulator (p/n 259-506) to test voltage and current se
JT2020 Mach 1 Operator’s Manual Systems and Equipment - 121 Electric Strike System To test for current at strike levels: 1. Put two or three loops through current transformer. 2. Follow steps above to test. 3. Display should show the following: • All lights should turn on. • Alarm and strobe should turn on. With two loops, • Current "A" should be 80-110%. • Strike indication might go on and off. With three loops, • Current should be 130-160%. • Strike indication should be continuous.
JT2020 Mach 1 Operator’s Manual Systems and Equipment - 122 Drilling Fluid Drilling Fluid For productive drilling and equipment protection, use these recommended Baroid® products, available from your Ditch Witch dealer.
JT2020 Mach 1 Operator’s Manual Systems and Equipment - 123 Drilling Fluid Bentonite Bentonite is a dry powder. When properly mixed with water, it forms a thin cake on bore walls, lubricating the bore, keeping it open, and holding fluid in the bore. Some things to remember when mixing bentonite: • Use clean water free of salt, calcium, or excessive chlorine. • Use water with pH level between 9 and 10. • Use water with hardness of less than 120 ppm. • Do not use bentonite containing sand.
Systems and Equipment - 124 JT2020 Mach 1 Operator’s Manual Drilling Fluid Basic Fluid Recipes Soil type Mixture/100 gal (378 L) of water fine sand 35 lb (16 kg) Bore-Gel coarse sand 35 lb (16 kg) Bore-Gel .5 lb (225 g) No-Sag Add .5 lb (225 g) of Quik-Trol for additional filtrate control fine sand below water table 40 lb (18 kg) Bore-Gel .75 lb (340 g) Quik-Trol Add .5 - 1 gal (2-4 L) of Dinomul in high torque situations coarse sand below water table 40 lb (18 kg) Bore-Gel .
JT2020 Mach 1 Operator’s Manual Systems and Equipment - 125 Drilling Fluid Drilling Fluid Requirements 1. Determine drilling conditions and choose appropriate drilling fluid mix. 2. Estimate amount of supplies needed and check availability. • Drilling fluid • Water supply. If more water than can be carried with the unit will be needed, arrange to transport additional water. • Bentonite and/or polymer 3. Check water quality. • Use meter or pH test strips to test pH of water. If pH is below 9.
Systems and Equipment - 126 JT2020 Mach 1 Operator’s Manual Drilling Fluid Funnel Viscosity Viscosity is the measure of internal resistance of a fluid to flow; the greater the resistance, the higher the viscosity. Viscosity of drilling fluids must be controlled. To determine viscosity, you will need a Marsh funnel (p/n 259-267) and a measuring cup, available from your Ditch Witch dealer.
JT2020 Mach 1 Operator’s Manual Systems and Equipment - 127 Tracker Control Tracker Control Overview Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly. This mode allows the 750 Tracker operator to disable hydraulic power to drilling unit thrust and rotation. NOTICE: This mode does not disable thrust and rotation immediately. Functions are disabled within 16 seconds.
Systems and Equipment - 128 JT2020 Mach 1 Operator’s Manual Tracker Control 4. Turn on 750/752 Tracker and check four-digit code. If codes on tracker and display match, thrust and rotation hydraulics on the drilling unit are enabled. If codes on tracker and display do not match, adjust tracker code: • Press and hold fore/aft/left/right button while making the following adjustments. • Use ON/OFF to advance first two digits (1). Use DEPTH to lower first two digits.
JT2020 Mach 1 Operator’s Manual Systems and Equipment - 129 Tracker Control Disable Thrust and Rotation 1. When drill head enters target pit or exits the ground, turn off tracker. After 8-16 seconds, green tracker control light (shown), located on drilling unit anchoring console, will come on. Hydraulic power to thrust and rotation will be disabled.
JT2020 Mach 1 Operator’s Manual Systems and Equipment - 130 Downhole Tools Downhole Tools Nozzles Nozzles control fluid flow from the pipe to the bore. Select nozzles that will supply at least the amount of fluid per minute needed for the flow and pressure you will be using. A nozzle that will supply more fluid per minute is recommended. See your Ditch Witch dealer for nozzle recommendations. Bits Selection These charts are meant as a guideline only. No one bit works well in all conditions.
JT2020 Mach 1 Operator’s Manual Systems and Equipment - 131 Downhole Tools Soil Description sandy soil sugar sand, blow sand, or other soils where sand is the predominant component soft soil sandy loam medium soil loams, loamy clays hard soil packed clays, gumbo, all compacted soils rocky soil chunk rock, glacial till, cobble, rip rap, gravel soft rock soft limestone, sandstone, shale, coral, caliche hard rock granite, schist, marble, hard limestone Installation Remove all paint from mati
JT2020 Mach 1 Operator’s Manual Systems and Equipment - 132 Downhole Tools Backreamers A backreamer enlarges the hole as pipe is pulled back through the bore. No one backreamer works well in all conditions. These charts are meant as a guideline only. See your local Ditch Witch dealer for soil conditions and backreamer recommendations for your area. Also see our interactive Downhole Tool Selector at www.ditchwitch.com.
JT2020 Mach 1 Operator’s Manual Systems and Equipment - 133 Downhole Tools Backream Fluid Requirements Backreaming is only successful when enough fluid reaches the bore. The amount of fluid needed depends on size of bore and soil condition. Follow these steps to find the minimum amount of fluid needed in perfect conditions. IMPORTANT: Use more fluid than recommended or the backream might be dry and unsuccessful. Instructions Example 1. Find amount of fluid needed for your size of backreamer.
JT2020 Mach 1 Operator’s Manual Systems and Equipment - 134 Downhole Tools Backream Fluid Requirements Backreamer/product diameter Gal/ft L/m Backreamer/product diameter Gal/ft L/m .5 in 13 mm 0.01 0.13 13.5 in 343 mm 7.44 92.35 1 in 25 mm 0.04 0.51 14 in 356 mm 8.00 99.31 1.5 in 38 mm 0.09 1.14 14.5 in 368 mm 8.58 106.54 2 in 51 mm 0.16 2.03 15 in 381 mm 9.18 114.01 2.5 in 64 mm 0.25 3.17 15.5 in 394 mm 9.80 121.74 3 in 76 mm 0.37 4.56 16 in 406 mm 10.
JT2020 Mach 1 Operator’s Manual Systems and Equipment - 135 Quick Wrench Quick Wrench To attach or remove downhole tools, use quick wrench to join or break the joint. Moving tools will kill or injure. Shut off drill string power when anyone can be struck by moving or thrown tools. Never use pipe wrenches on drill string. IMPORTANT: Apply TJC to threads and hand-tighten joint before attaching quick wrench components to tighten joint. Attach quick wrench in either the join or break position.
Systems and Equipment - 136 JT2020 Mach 1 Operator’s Manual Quick Wrench To Join 1. Scribe straight line across joint on both sides of separating line (A). 2. Scribe second line (B) on moveable side of joint in the opposite direction of tightening action .25” (6 mm) away from first line. A B 3. Turn handle until second line (B) meets first (A). A B 4. Turn handle opposite direction two turns to relieve pressure. A 5. Remove quick wrench components. j07om071h.eps To Break 1.
JT2020 Mach 1 Operator’s Manual Systems and Equipment - 137 Drill Pipe Drill Pipe Perform Regular Drill Pipe Care Precondition New Pipe Repeat this procedure three times for each piece of pipe before it is used the first time: 1. Hand-lubricate entire surface of threads and shoulders of both ends of pipe with copper base tool joint compound. See page 163 for correct lubricant. 2. Join pipe and tighten joint. 3. Break joint. 4. Move pipe back to box.
Systems and Equipment - 138 JT2020 Mach 1 Operator’s Manual Drill Pipe Use Caps and Plugs Before transporting in dusty conditions or prolonged storage, install caps and plugs to male and female ends of pipe and to saver sub. Replace Worn Saver Sub Because each pipe comes in contact with the saver sub, check saver sub regularly for wear. Replace it when it is worn, or it will damage your drill pipe. See page 191 for replacement procedure. Precondition a new saver sub the same way you do new pipe.
JT2020 Mach 1 Operator’s Manual Systems and Equipment - 139 Drill Pipe Use Drill Pipe Correctly Align the Joints Always carefully align the male and female ends of pipe before connecting them together. Poor alignment can damage the threads and destroy the usefulness of the joint. j07om034c.eps Clamp Pipe Correctly Clamp on pipe when joint is centered between wrenches. Clamp only on the tool joint of the drill pipe as shown.
Systems and Equipment - 140 JT2020 Mach 1 Operator’s Manual Drill Pipe Make Up and Break Out Joints Correctly Assisted Makeup protects threads by automatically matching carriage movement speed to rotation during makeup and breakout. • To connect pipes together and fully torque joint, slowly rotate pipe until spindle stops turning and full pressure is developed. Improperly torqued joints will damage the shoulder faces and threads, and will cause joints to leak or break while drilling or backreaming.
JT2020 Mach 1 Operator’s Manual Systems and Equipment - 141 Pipeloader Pipeloader Shift Pipe Box IMPORTANT: Lift arms must be fully raised for pipe box to move. Drilling 1. Shift pipe box when both pipe box status lights are off. 2. Release pipe box switch when box hits mechanical stops, then move back to align mechanical pointer in center of cutout (shown) for new column. Backreaming 1. Shift pipe box when active column is full (8 pipes). 2.
Systems and Equipment - 142 JT2020 Mach 1 Operator’s Manual Pipeloader Correct Misaligned or Jammed Pipe One pipe box status light on and one light off indicates a misaligned or jammed pipe. Turn off engine and inspect pipe in active column. • If one end of a drill pipe is jammed and will not drop correctly from pipe box, inspect pipe box position.
JT2020 Mach 1 Operator’s Manual Systems and Equipment - 143 Pipeloader Add/Remove Single Pipe Load a single drill pipe or up to a whole column of drill pipe into an empty column of pipe box to finish bore without changing pipe boxes. Electric shock. Contacting electric lines will cause death or serious injury. Know location of lines and stay away. NOTICE: • Do not attempt to load and unload pipe while drilling or backreaming. Unprotected worker can be injured by electric strike.
Systems and Equipment - 144 JT2020 Mach 1 Operator’s Manual Pipeloader Add Single Pipe 1. Place grid mats on the ground on pipe box side of drilling unit. 2. Connect mats. 3. Connect bonding cable to drilling unit (shown in inset). 4. Position entire drill pipe box on mat (shown). 5. Ensure pipe box is positioned properly. See “Shift Pipe Box” on page 141. 6. Move shuttles out fully. Crushing weight. If load falls or moves it could kill or crush you. Use proper procedures and equipment or stay away. 7.
JT2020 Mach 1 Operator’s Manual Systems and Equipment - 145 Pipeloader Remove Single Pipe Unload all drill pipe loaded with auxiliary pipe loaders. 1. Lift, rotate, and lock pipe positioning aid (3) into stowed position. 2. Ensure pipe box is positioned properly. See “Shift Pipe Box” on page 141. 3. Move shuttles out fully. 4. Pull pin (2) on shuttle, rotate auxiliary pipe loader (1) down, and install pin. 5. Repeat process for other shuttle. 6. Raise pipe. 7. Move pipe to auxiliary pipe loaders.
Systems and Equipment - 146 JT2020 Mach 1 Operator’s Manual Cruise Control Cruise Control During the bore, you can set the desired thrust, pullback, and rotation speeds to match ground conditions. Cruise control enables the unit to maintain these settings hands-free. You can engage, disengage, override, and resume these settings at any time. IMPORTANT: In order for cruise control to function, front wrench must be open and shuttles must be under pipe box.
JT2020 Mach 1 Operator’s Manual Systems and Equipment - 147 Interpret Diagnostic Codes Override • To override settings, move joystick out of neutral and beyond current setting. Unit will increase to new setting. • To return to previous setting, release joystick. Disengage To disengage cruise control, move joystick out of neutral and in opposite direction of carriage travel. Green control cycle light will go off. Resume 1. Position joystick out of neutral in forward or backward direction.
Systems and Equipment - 148 JT2020 Mach 1 Operator’s Manual Interpret Diagnostic Codes Review Modes IMPORTANT: Do not turn off ignition. Diagnostic codes are cleared each time ignition is turned off. View All Codes View Codes Individually 1. Ensure that engine is running and no one is sitting in operator’s seat. 1. Ensure that engine is running and no one is sitting in operator’s seat. 2. Press and hold the resume button for two seconds. 2. Press and hold the set button for two seconds. 3.
JT2020 Mach 1 Operator’s Manual Systems and Equipment - 149 Interpret Diagnostic Codes Diagnostic Codes The following table lists the attributes of each diagnostic code. Information presented includes: code number, condition causing code to be sent, result, and level of severity.
Systems and Equipment - 150 JT2020 Mach 1 Operator’s Manual Interpret Diagnostic Codes Code Condition Result Severity 63 no continuity to auxiliary dump valve add pipe or remove pipe aborted and code is stored nonessential 65 no continuity to thrust/right track neutral valve cruise control is blocked essential 71 no continuity to drive selector valve drive is blocked essential 73 no continuity to throttle up solenoid code is stored nonessential 74 no continuity to throttle down soleno
JT2020 Mach 1 Operator’s Manual Systems and Equipment - 151 Interpret Diagnostic Codes Code Condition Result Severity 163 no continuity to pipe up switch pipe box movement is blocked and code is stored nonessential 164 no continuity to tracker control input code is stored nonessential 166 no continuity to thrust rear stop switch code is stored nonessential 171 no continuity to pipe grip rocker switch code is stored nonessential 172 no continuity to pipe shuttle rocker switch code is
Systems and Equipment - 152 JT2020 Mach 1 Operator’s Manual Interpret Diagnostic Codes Code Condition Result Severity 255 undefinable diagnostic code reported code is stored nonessential CMW
JT2020 Mach 1 Operator’s Manual Complete the Job - 153 Complete the Job Chapter Contents Antifreeze Drilling Unit . . . . . . . . . . . . . . . . . . . . 154 • Add Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 • Reclaim Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Rinse Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 156 Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Complete the Job - 154 JT2020 Mach 1 Operator’s Manual Antifreeze Drilling Unit Antifreeze Drilling Unit Your drilling unit can be left overnight in freezing conditions by circulating a polypropylene-based antifreeze (p/n 265-644) through optional antifreeze system before shutdown. Add Antifreeze 1. Fill antifreeze tank with 3 gal (11 L) of approved antifreeze. 2. Move carriage to front of drill frame. 3. Position 3-gal (11-L) bucket under spindle. 4.
JT2020 Mach 1 Operator’s Manual Complete the Job - 155 Antifreeze Drilling Unit Reclaim Antifreeze 1. Connect remote fluid system. See page 93. 2. Turn on remote fluid system engine. 3. Start drilling unit and run at low throttle. 4. Move carriage to front of drill frame. 5. Position 3-gal (11-L) bucket under spindle. 6. Turn drilling fluid pump on low speed. 7. Turn drilling fluid pump off when drilling fluid comes out of spindle. 8. Open hood and pour antifreeze into tank.
JT2020 Mach 1 Operator’s Manual Complete the Job - 156 Rinse Equipment Rinse Equipment Using Washwand Connect the washwand at quick connect (1) at rear of unit. Open valve (2) to start water flow. Close valve to stop water flow. Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly. NOTICE: Failure to prime the drilling fluid pump will cause flow fluctuations, which will make it difficult to control the washwand.
JT2020 Mach 1 Operator’s Manual Complete the Job - 157 Disconnect Disconnect Disconnect and store the following hoses and cables (if used): • electric strike system voltage stake • fluid hose Stow Tools Make sure all quick wrenches, bits, pullback devices, and other tools are loaded and properly secured on trailer.
Complete the Job - 158 JT2020 Mach 1 Operator’s Manual Stow Tools CMW
JT2020 Mach 1 Operator’s Manual Service - 159 Service Chapter Contents Service Precautions . . . . . . . . . . . . . . . . . . . . . . . 161 • Welding Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 • Washing Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 • Working Under Drilling Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Recommended Lubricants/Service Key . . . . . .
JT2020 Mach 1 Operator’s Manual Service - 160 Service Precautions Service Precautions Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly. NOTICES: • Unless otherwise instructed, all service should be performed with engine off. • Refer to engine manufacturer’s manual for engine maintenance instructions. Welding Precaution NOTICE: Welding can damage electronics. • Disconnect battery to prevent damage to battery.
JT2020 Mach 1 Operator’s Manual Service - 161 Service Precautions Working Under Drilling Unit Crushing weight could cause death or serious injury. Use proper procedures and equipment or stay away. Before working under area of drilling unit supported by a stabilizer, make sure drilling unit is parked on hard surface. 1. Remove cylinder locks from storage at rear of pipe box and place over extended cylinder rods (shown) with curved ends toward stabilizer shoes. 2.
Service - 162 JT2020 Mach 1 Operator’s Manual Service Precautions Opening/Closing Front Hood To open: 1. Unlock hood at handles (1, 2) if hood is locked. 2. Unlatch handles (1) and rotate handle (2) counterclockwise. 3. Grasp upper and lower (2, 4) handles. 4. Lift hood upward and outward. 5. Continue lifting hood and push inward until up-latch (5, below) engages. To close: 1. Disengage the up-latch (5) by holding it up as the hood is pulled outward using the lower handle (4). 2.
JT2020 Mach 1 Operator’s Manual Service - 163 Recommended Lubricants/Service Key Recommended Lubricants/Service Key Item Description DEO Diesel engine oil meeting or exceeding Cummins CES 20078, API CI-4, ACEA E-5, JAMA DH-1, or Global DHD-1. API American Petroleum Institute, ACEA European Automobile Manufacturer’s Association, JAMA Japanese Automobile Manufacturer’s Association. Use viscosity grade SAE 15W40 unless ambient temperatures below 5° F (-15° C) are expected.
Service - 164 JT2020 Mach 1 Operator’s Manual Recommended Lubricants/Service Key For more information on engine lubrication and maintenance, see your engine manual. NOTICE: • Use only genuine Ditch Witch parts, filters, approved lubricants, TJC, and approved coolants to maintain warranty. • Use the “Service Record” on page 159 to record all required service to your machine. Approved Fuel This engine is designed to run on diesel fuel. Use only high quality fuel meeting ASTM D975 No.
JT2020 Mach 1 Operator’s Manual Service - 165 Startup/10 Hour Startup/10 Hour Location Task DRILLING UNIT Check fuel filter water separator Notes Check air filter indicator and clean dust trap Check engine oil level DEO Check engine coolant level DEAC Check hydraulic hoses Check hydraulic fluid level THF Check fluid pump oil level NDO Test control switches Check pipe lube applicator Check pipe auto lubricator spray nozzle Check pipe auto lubricator TJC level TJC Check drilling fluid y-stra
Service - 166 JT2020 Mach 1 Operator’s Manual Startup/10 Hour Check Air Filter Indicator and Clean Dust Trap Check air filter indicator (1) and inspect dust trap (2) for cracks every 10 hours. Change filter elements when indicator reaches the red zone. See “Change Air Filter” on page 190. NOTICE: Only open the air filter canister when air restriction is indicated. Change the elements, do not attempt to clean them. • Compressed air or water may damage filter elements.
JT2020 Mach 1 Operator’s Manual Service - 167 Startup/10 Hour Check Engine Coolant Level Check coolant level, with engine cool, at expansion tank before startup and every 10 hours of operation. Maintain coolant level at halfway point on sight glass. If low, add DEAC. IMPORTANT: See “Approved Fuel” on page 164 for information on approved coolants.
Service - 168 JT2020 Mach 1 Operator’s Manual Startup/10 Hour Check Hydraulic Hoses j10om024h.eps Check hydraulic hoses for leaks before startup and every 10 hours of operation. Fluid or air pressure could pierce skin and cause injury or death. Stay away. NOTICE: Escaping pressurized fluid can cause injury or pierce skin and poison. • Before disconnecting a hydraulic line, turn engine off and operate all controls to relieve pressure. Lower, block, or support any raised component with a hoist.
JT2020 Mach 1 Operator’s Manual Service - 169 Startup/10 Hour Check Hydraulic Fluid Level Check hydraulic fluid level before startup and every 10 hours of operation. Maintain fluid level at halfway point on sight glass (2), when engine is off and fluid is cool. Refill with THF at hydraulic fluid fill (1). Check Fluid Pump Oil Level Check fluid pump oil level at fill plug (1) before startup and every 10 hours of operation. Maintain fluid level at fill plug. Add NDO at fill plug (1) as needed.
Service - 170 JT2020 Mach 1 Operator’s Manual Startup/10 Hour Test Control Switches Check control proximity switches before startup and every 10 hours of operation and clean or replace as needed. 1. front pipe box switch 4. rear home switch 2. rear pipe box switch 5. shuttle position switch 3. rear stop switch 6. front home switch To test: 1. Turn ignition switch to the on position. Do not start engine. 2. Place metal object above target on each switch. 3.
JT2020 Mach 1 Operator’s Manual Service - 171 Startup/10 Hour Check Pipe Lube Applicator Check pipe lube applicator before startup and every 10 hours of operation. Replace if damaged or badly worn. Check Pipe Auto Lubricator Spray Nozzle Check pipe auto lubricator spray nozzle before startup and every 10 hours of operation. Ensure that nozzle is free of obstructions and operates properly. Clean as needed.
Service - 172 JT2020 Mach 1 Operator’s Manual Startup/10 Hour Check Pipe Auto Lubricator TJC Level Check pipe auto lubricator TJC level before startup and every 10 hours of operation. Change pail as needed. See “Change Auto Lubricator TJC Pail” on page 186 for procedure. NOTICE: Ditch Witch tool joint compound is specially formulated to work with Ditch Witch pipe lubrication system. Use of other tool joint compounds will clog system.
JT2020 Mach 1 Operator’s Manual Service - 173 50 Hour 50 Hour Location Task Notes DRILLING UNIT Change fluid pump oil Initial service, NDO Check radiator Change hydraulic filter Initial service Check ground drive gearbox oil level 2 gearboxes, MPL Check rotation gearbox oil level MPL Lube rotation gearbox sliding output shaft EPS Inspect thrust rollers Drilling Unit Change Fluid Pump Oil (Initial Service) Change fluid pump oil after first 50 hours and every 1000 hours thereafter.
Service - 174 JT2020 Mach 1 Operator’s Manual 50 Hour Check Radiator Check radiator for dirt, grass, and other debris every 50 hours. Check more often if operating in dusty or grassy conditions. Clean as needed. To clean: • Clean fins with compressed air or spray wash. • Open rear hood and spray through radiator toward engine. • If grease and oil are present on radiator, spray with solvent and allow to soak overnight. IMPORTANT: Be careful not to damage fins with high pressure air or water.
JT2020 Mach 1 Operator’s Manual Service - 175 50 Hour Check Ground Drive Gearbox Oil Level Check oil level in both ground drive gearboxes every 50 hours. To check: Open check plug (2). If oil does not come out, open fill plug (1) and add MPL until level with check plug (2). IMPORTANT: • Drilling unit must be on level ground for accurate reading. • Use helper to assist in positioning gearbox plugs for checking and adding oil. • Do not overfill.
Service - 176 JT2020 Mach 1 Operator’s Manual 50 Hour Lube Rotation Gearbox Sliding Output Shaft Lube rotation gearbox sliding output shaft with EPS every 50 hours. To lube: • Stop engine and turn battery disconnect switch to the off position. • Clean exposed portion of sliding output shaft with pressure washer to remove grime. • Blow dry with compressed air. • Apply EPS spray lube to all exposed shaft surfaces while manually moving the shaft in and out.
JT2020 Mach 1 Operator’s Manual Service - 177 250 Hour 250 Hour Location Task DRILLING UNIT Inspect air intake system Change engine oil and filter Notes DEO Drilling Unit Inspect Air Intake System Inspect intake piping for cracked hoses, loose clamps, or punctures. Tighten or replace parts as necessary. Change Engine Oil and Filter Change engine oil and filter every 250 hours for normal service. Drain oil (3), change filter (2), and add 8.5 qt (8 L) of DEO at fill (1).
JT2020 Mach 1 Operator’s Manual Service - 178 500 Hour 500 Hour Location Task Notes DRILLING UNIT Change hydraulic fluid and filter Normal conditions Change fuel filter Check batteries Drilling Unit Change Hydraulic Fluid and Filter (Normal Conditions) Change hydraulic filter every 500 hours. Change filter more often if indicated by filter indicator. Change Fuel Filter Replace fuel filter every 500 hours. See parts manual or contact your Ditch Witch dealer for correct replacement filter.
JT2020 Mach 1 Operator’s Manual Service - 179 500 Hour Check Battery Check battery every 500 hours. Keep batteries clean and terminals free of corrosion. To clean: 1. Turn battery disconnect switch to the off position. 2. Ensure that no ignition sources are near batteries. 3. Loosen and remove battery cable clamps carefully, negative (-) cable first. 4. Clean cable clamps and terminals with wire brush or battery cleaning tool to remove dull glaze. 5. Check for signs of internal corrosion in cables. 6.
JT2020 Mach 1 Operator’s Manual Service - 180 750 Hour 750 Hour Location Task Notes DRILLING UNIT Change fluid pump oil NDO Drilling Unit Change Fluid Pump Oil Change fluid pump oil after first 50 hours and every 750 hours thereafter. Drain at plug (2) and fill with NDO engine oil at plug (1). Maintain fluid level at fill plug. Capacity for pump is 1 qt (0.9 L).
JT2020 Mach 1 Operator’s Manual Service - 181 1000 Hour 1000 Hour Location Task Notes DRILLING UNIT Change ground drive gearbox oil 2 gearboxes, MPL Lube rotation gearbox internal splines EPG Change rotation gearbox oil MPL Drilling Unit Change Ground Drive Gearbox Oil Change oil in both ground drive gearboxes every 1000 hours. To change: Drain MPL at plug (3). Add MPL at plug (1) until level with check plug (2). IMPORTANT: • Drill unit must be parked on level surface for accurate reading.
Service - 182 JT2020 Mach 1 Operator’s Manual 1000 Hour Lube Rotation Gearbox Internal Splines Lube rotation gearbox internal splines with EPG every 1000 hours. To lube: • Turn battery disconnect switch to the off position. • Clean rotation gearbox area with pressure washer to remove grime. • Disconnect hose and remove water swivel. • Using special socket, remove thrust locknut, tang lock washer, and nut. • Remove sliding shaft from front side of gearbox. Clean and dry all components.
JT2020 Mach 1 Operator’s Manual Service - 183 1000 Hour Change Rotation Gearbox Oil Drain oil at gearbox oil drain (2) every 1000 hours. Replace drain plug. Fill with MPL at fill plug (1). Replace fill plug. IMPORTANT: Drill frame must be level for accurate reading.
JT2020 Mach 1 Operator’s Manual Service - 184 2000 Hour 2000 Hour Location Task Notes DRILLING UNIT Change engine coolant DEAC Drilling Unit Change Engine Coolant Drain cooling system at drain (2) every two years or 2000 hours. Refill according to instructions below with approved coolant. See “Specifications” on page 193 for coolant capacity. NOTICE: • The use of non-approved coolant may lead to engine damage or premature engine failure and will void engine warranty.
JT2020 Mach 1 Operator’s Manual Service - 185 As Needed As Needed Location Task Notes DRILLING UNIT Change pipe auto lubricator pail TJC Change hydraulic filter Any time system is opened Check pipeloader pads Check front pipe guide inserts Check fluid pump ball valve Check track tension and condition Change/Adjust engine drive belt Change air filter Check saver sub Replace fuses CMW
Service - 186 JT2020 Mach 1 Operator’s Manual As Needed Drilling Unit Change Auto Lubricator TJC Pail Check pipe auto lubricator TJC level and change pail as needed. To change pail: 1. Remove wingnuts and bolts attaching base ring (4) to pail cover (1). 2. Rotate base ring slightly to clear hooks on cover and remove pail from cover. 3. Remove follower plate (3) from empty pail and install into new pail. Press firmly on follower plate until TJC comes up in center opening. 4.
JT2020 Mach 1 Operator’s Manual Service - 187 As Needed Change Hydraulic Filter (Anytime System Opened) Change hydraulic filter anytime system is opened for repair. Change filter and refill with THF at hydraulic oil fill. Check Pipeloader Inserts Check pipeloader inserts at indicated areas for wear. Flip gripper inserts for longer wear, or replace as needed. See your Ditch Witch dealer for replacement parts. 1. wear pad 3. shuttle gripper pad 2. shuttle wear pad 4.
Service - 188 JT2020 Mach 1 Operator’s Manual As Needed Check Front Pipe Guide Inserts Check front pipe guide inserts (3) for wear. Rotate inserts for longer wear, or replace as needed. See your Ditch Witch dealer for replacement parts. To replace: 1. Remove lynch pins (1, one on each side). 2. Remove guide inserts (3). 3. Remove pin (2) and open pipe guide. 4. Remove guide inserts (3). 5. Replace in reverse order. Check Fluid Pump Ball Valve Check ball valve for leaks. Tighten stem packing as needed.
JT2020 Mach 1 Operator’s Manual Service - 189 As Needed Check Track Tension and Condition Check track tension and condition, and adjust or replace as needed. See your Ditch Witch dealer for replacement parts. To adjust: 1. Pump MPG into fitting (A) until dimension (B) is 21 7/8” (555 mm). 2. Drive straight forward one machine length and check tension again. Change/Adjust Drive Belt Change or adjust engine drive belt as needed. To adjust: 1. Turn off engine and remove key. 2.
Service - 190 JT2020 Mach 1 Operator’s Manual As Needed Change Air Filter Change air filter when red band on air filter service indicator pops up. To change: 1. Disengage clasps (1) and remove end cup. 2. Remove primary element (3). 3. Remove secondary element (2), if dirty. 4. Wipe inside of housing and wash end cup (4). 5. Install new element(s). 6. Install end cup and engage clasps. 7. Reset air filter service indicator (5).
JT2020 Mach 1 Operator’s Manual Service - 191 As Needed Check Saver Sub Check saver sub and replace as needed. See your Ditch Witch dealer for replacement parts. To replace: 1. Remove eight bolts that attach saver sub to spindle. Do not remove indexing dowels from spindle. 2. Remove and replace o-ring, if necessary. 3. Install in reverse order and torque eight bolts in a cross pattern to 47 ft•lb (64 N•m). Apply Loctite® 242 to bolts before installation. Replace Fuses Change fuses as needed.
Service - 192 JT2020 Mach 1 Operator’s Manual As Needed CMW
JT2020 Mach 1 Operator’s Manual Specifications - 193 Specifications Dimensions U.S. Metric L, overall machine length (per SAE J2022) 207 in 5.26 m W, overall machine width (per SAE J2022) 51.5 in 1.31 m H, overall machine height (per SAE J2022) 90 in 2.39 m Entry angle (per SAE J2022) 10-14° 10-14° Entry angle 18-24% 18-24% Angle of approach 18° 18° Angle of departure 18° 18° Operating weight (per SAE J2022) 11,600 lb 5260 kg Power Pipe U.S.
Specifications - 194 JT2020 Mach 1 Operator’s Manual Operational U.S. Metric Maximum spindle speed (per SAE J2022) 225 rpm 225 rpm Maximum spindle torque (per SAE J2022) 2200 ft•lb 2980N•m Thrust force (per SAE J2022) 17,000 lb 75.
JT2020 Mach 1 Operator’s Manual Specifications - 195 Drilling Fluid System (Onboard) U.S. Metric Maximum drilling fluid pressure (per SAE J2022) 1500 psi 103 bar Fluid Capacities U.S. Metric Fuel tank * 30 gal 114 L Hydraulic reservoir 19 gal 72 L Engine oil, including filter 8.5 qt 8L Cooling system 4.4 gal 17 L * Under normal operating conditions, a full tank of fuel will last 10 hours.
Specifications - 196 CMW JT2020 Mach 1 Operator’s Manual
JT2020 Mach 1 Operator’s Manual Support - 155 Procedure Support Procedure Notify your dealer immediately of any malfunction or failure of Ditch Witch equipment. Always give model, serial number, and approximate date of your equipment purchase. This information should be recorded and placed on file by the owner at the time of purchase. Return damaged parts to dealer for inspection and warranty consideration if in warranty time frame.
JT2020 Mach 1 Operator’s Manual Warranty - 156 Warranty 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 SK5 attachments).
JT2020 Mach 1 Operator’s Manual Service Record - 159 Service Record Service Performed Date Hours CMW
Service Record - 160 Service Performed CMW JT2020 Mach 1 Operator’s Manual Date Hours
