JT922 Tier 4i Operator’s Manual CMW® Issue 2.
JT922 Operator’s Manual Overview - 1 Overview Chapter Contents Serial Number Location . . . . . . . . . . . . . . . . . . . . . . 2 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Operator Orientation. . . . . . . . . . . . . . . . . . . . . . . . . 5 About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 5 • Bulleted Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JT922 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.
JT922 Operator’s Manual Overview - 3 Intended Use Intended Use The JT922 Mach 1 is a self-contained horizontal directional drilling unit designed to install buried cable and pipe at distances to 300’ (90 m) depending on soil conditions and is intended for operation in ambient temperatures from 0° to 115°F (-18° to 46°C). Use in any other way is considered contrary to the intended use. The JT922 Mach 1 can be used with Ditch Witch drilling fluid units and Ditch Witch locating equipment.
JT922 Operator’s Manual Overview - 4 Unit Components Unit Components 1. Operator’s station 6. Drill frame 2. Spindle 7. Tracks 3. Carriage 8. Vise wrenches 4. Drill pipe box 9. Anchoring system 5.
JT922 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 JT922 Operator’s Manual About This Manual CMW
JT922 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.
JT922 Operator’s Manual Foreword - 8 JT922 Tier 4i Operator’s Manual Issue number 2.0/OM-04/11 Part number 053-1298 Copyright 2008, 2011 by The Charles Machine Works, Inc. , Ditch Witch, CMW, AutoCrowd, Jet Trac, Roto Witch, Subsite, Fluid Miser, Power Pipe, Super Witch, Pierce 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.
JT922 Operator’s Manual Contents - 9 Contents Overview 1 machine serial number, information about the type of work this machine is designed to perform, basic machine components, and how to use this manual Foreword 7 part number, revision level, and publication date of this manual, and factory contact information Safety 11 machine safety alerts and emergency procedures Controls 21 machine controls, gauges, and indicators and how to use them Operation Overview 45 an overview for completing a j
Contents - 10 JT922 Operator’s Manual Specifications 149 machine specifications including weights, measurements, power ratings, and fluid capacities Support 153 the warranty policy for this machine, and procedures for obtaining warranty consideration and training Service Record a record of major service performed on the machine CMW 157
JT922 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 JT922 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.
JT922 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. Learn what each level means.
JT922 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.
JT922 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.
JT922 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.
JT922 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 JT922 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.
JT922 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 JT922 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.
JT922 Operator’s Manual Controls - 21 Controls Chapter Contents Set-Up Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Left Control Console . . . . . . . . . . . . . . . . . . . . . . . 24 Gauge Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Right Control Console . . . . . . . . . . . . . . . . . . . . . . 30 Anchoring System Console . . . . . . . . . . . . . . . . . 31 Seat/Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Battery . . . . . . . .
JT922 Operator’s Manual Controls - 22 Set-Up Console Set-Up Console 1. left track control 4. Tracker control key 2. Right track control 5. Engine throttle control 3. Stabilizer and frame tilt control Item Description 1. Left track control To move forward, push. To move backward, pull. To stop, move to center. c00ic147h.
JT922 Operator’s Manual Controls - 23 Set-Up Console Item Description 2. Right track control To move forward, push. Notes To move backward, pull. To stop, move to center. c00ic148h.eps 3. Stabilizer and frame tilt control To raise stabilizer and increase frame tilt, push. Note: Stabilizer control lowers the front of the drill frame along with the stabilizer. To lower stabilizer and decrease frame tilt, pull. 4.
JT922 Operator’s Manual Controls - 24 Left Control Console Left Control Console Drilling/Operation Controls 1. Auxiliary outlet 4. Wrench control 2. Ignition switch 5. Fluid flow control 3. Engine throttle control Item Description Notes 1. Auxiliary outlet Provides power for other equipment. Power output is 12V, 5A.
JT922 Operator’s Manual Controls - 25 Left Control Console Item Description 2. Ignition switch To start engine, insert key and turn clockwise. Notes To stop engine, turn key counterclockwise. 3. Engine throttle control To increase engine speed, push up. To decrease engine speed, pull down. 4. Wrench control To clamp front wrench and shut off drilling fluid, move toward pipe box. To unclamp front wrench, move away from pipebox.
Controls - 26 JT922 Operator’s Manual Gauge Cluster Gauge Cluster 1. Drilling fluid pressure gauge 6. Hydraulic fluid temperature indicator 2. Thrust pressure gauge 7. Hydraulic filter service indicator 3. Rotation pressure gauge 8. Hourmeter 4. High temperature indicator 9. Fuel gauge 5. Engine oil pressure indicator 10.
JT922 Operator’s Manual Controls - 27 Gauge Cluster Item Description 1. Drilling fluid pressure gauge Displays drilling fluid pressure supplied by drilling fluid pump. Notes c00ic157h.eps 2. Thrust pressure gauge Displays hydraulic fluid pressure to thrust motor during thrust and pullback. Estimates thrust and pullback force on lines outside gauge. 3. Rotation pressure gauge Displays hydraulic fluid pressure to rotation motor when spindle is turned clockwise.
JT922 Operator’s Manual Controls - 28 Gauge Cluster Item Description Notes 5. Engine oil pressure indicator Indicates engine oil pressure is too low. IMPORTANT: Alarms will sound when engine oil pressure is too low. Stop engine and check oil level. 6. Hydraulic fluid temperature indicator Indicates hydraulic fluid is overheating. • Check hydraulic fluid level. • Check cooler for debris. See page 137. 7. Hydraulic filter service indicator Indicates hydraulic fluid filter needs replacing.
JT922 Operator’s Manual Controls - 29 Gauge Cluster Item Description Notes 9. Fuel gauge Displays fuel level in tank. NOTICE: Use low sulfur or ultra low sulfur fuel only. Refer to engine operator’s manual for cold weather fuel recommendations. Tank holds 19 gal (72 L). 10. Cold start wait indicator Lights when intake air preheater is operating. Wait until light goes off before starting engine.
JT922 Operator’s Manual Controls - 30 Right Control Console Right Control Console 1. Carriage control 2. Pipe lubricator button (optional) Item Description 1. Carriage control To move carriage forward, push. To move carriage backward, pull. To rotate spindle counterclockwise (breakout), move right. To rotate spindle clockwise (makeup), move left. 2. Pipe lubricator button (optional) CMW To apply joint compound to threads at wrenches, press button.
JT922 Operator’s Manual Controls - 31 Anchoring System Console Anchoring System Console 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.
JT922 Operator’s Manual Controls - 32 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. To move anchor up, pull up.
JT922 Operator’s Manual Controls - 33 Seat/Armrest Seat/Armrest 1. Seat tilt latch 2. Seat leveling wheel Item Description 1. Seat tilt latch To tilt seat forward for transport, push knob. Notes To lower seat for operation, pull knob. 2. Seat leveling wheel To level seat when the unit is set up on a side slope, turn wheel.
JT922 Operator’s Manual Controls - 34 Battery Battery 1. Battery disconnect switch Item Description 1. Battery disconnect switch To disable battery power, move switch to the disconnect position. To enable battery power, move switch to the connect position.
JT922 Operator’s Manual Controls - 35 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 Display amount of current and voltage being detected as a percentage of strike condition.
JT922 Operator’s Manual Controls - 36 ESID Item Description 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 97. 5. Current problem indicator Blinking red light indicates a current indicator problem. See “Troubleshoot Strike System” on page 97. 6. OK indicator Green light means system self test detected no problems.
JT922 Operator’s Manual Controls - 37 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 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.
JT922 Operator’s Manual Controls - 38 750/752 Display 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. Internal refers to pipe data being saved to 750 Display memory.
JT922 Operator’s Manual Controls - 39 750/752 Display Item Description Notes 2. Pitch/slope indicator and percentage indicator Indicates pitch beacon percent of grade. Internal: shows pipe label and stored pitch. External: shows desired 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.
JT922 Operator’s Manual Controls - 40 750/752 Display Item Description Notes 6. Display battery status indicator Indicates display power from drilling unit. If all 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.
JT922 Operator’s Manual Controls - 41 750/752 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. Item Description Notes 1.
JT922 Operator’s Manual Controls - 42 750/752 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. “Init” and job number will be displayed. 4.
JT922 Operator’s Manual Controls - 43 750/752 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. Second function: To download all jobs stored in internal logging memory: • Press with Recall button • Connect display to PC running Trac Management System software.
Controls - 44 JT922 Operator’s Manual 750/752 Display CMW
JT922 Operator’s Manual Operation Overview - 45 Operation Overview Chapter Contents Planning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Setting Up at Jobsite . . . . . . . . . . . . . . . . . . . . . . . 46 Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Backreaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Leaving Jobsite. . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Storing Equipment . . . . . . . . . . . . . .
Operation Overview - 46 JT922 Operator’s Manual Planning Planning 1. Gather information about jobsite. See page 51. 2. Inspect jobsite. See page 52. 3. Classify jobsite. See page 54. 4. Plan bore path. See page 57. 5. Check supplies and prepare equipment. See page 63. 6. Load equipment. See page 70. Setting Up at Jobsite 1. Prepare jobsite. See page 62. 2. Unload drilling unit from trailer. See page 73. 3. Position drilling unit and frame. See page 77. 4. Assemble strike system. See page 95. 5.
JT922 Operator’s Manual Operation Overview - 47 Backreaming Backreaming 1. Assemble backream string. See page 87. 2. Start drilling unit and adjust throttle. 3. Set drilling fluid flow. Check that fluid flows through all nozzles. 4. Remove pipe from bore. See page 89. 5. Remove pullback device. See page 90. Backreaming Tips • Plan backreaming job before drilling. Plan bore path as straight as possible. Check bend limits of pullback material. Check that appropriate pullback devices are on hand.
Operation Overview - 48 JT922 Operator’s Manual Storing Equipment CMW
Manual Prepare - 49 Prepare Chapter Contents Gather Information . . . . . . . . . . . . . . . . . . . . . . . . . 51 • Review Job Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 • Notify One-Call Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 • Examine Pullback Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 • Arrange for Traffic Control. . . . . . . . . . . . . . . . . . . . . . . . . .
Prepare - 50 Prepare Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 • Mark Bore Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 • Prepare Entry Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Check Supplies and Prepare Equipment . . . . . . . 63 • Check Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 • Prepare Equipment . . . . . . . . . . . . .
Manual Prepare - 51 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.
Manual Prepare - 52 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 54.) • traffic • access • soil type and condition • water supply • sources of locator interference (rebar, railroad tracks, etc.
Manual Prepare - 53 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.
Manual Prepare - 54 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.
Manual Prepare - 55 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.
Manual Prepare - 56 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.
Manual Prepare - 57 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 - 58 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. Pipe Pitch Ditch Witch drill pipe is tested to bend at a maximum percent pitch.
Manual Prepare - 59 Plan Bore Path Pipe-By-Pipe Bend Limits Pipe (C) Forward (B) Deflection (A) Pipe (C) Forward (B) Deflection (A) 1 6 ft 0 in (1.8 m) 0 ft 2 in (0.1 m) 15 79 ft 5 in (24.3 m) 36 ft 3 in (11.1 m) 2 12 ft 0 in (3.7 m) 0 ft 8 in (0.2 m) 16 83 ft 2 in (25.4 m) 40 ft 11 in (12.5 m) 3 17 ft 11 in (5.5 m) 1 ft 6 in (0.5 m) 17 86 ft 8 in (26.2m) 45 ft 9 in (13.9 m) 4 23 ft 9 in (7.2 m) 2 ft 9 in (0.8 m) 18 89 ft 11 in (27.4m) 50 ft 10 in (15.
Prepare - 60 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). • Subtract (H1) from (H2).
Manual Prepare - 61 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. Bore Path Calculator Entry pitch, setback, and minimum depth work together with bend limits to determine the bore path.
Manual Prepare - 62 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.
Manual Prepare - 63 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 114) • transition sub • anchoring equipment and accessories • bits, screens, nozzles (see page 109) • adapters, pipe, beacon housings • marking flags or paint • water and additional hoses • fuel (Use low sulfur or
Prepare - 64 Manual Prepare Equipment Fluid Levels • fuel (Use low sulfur or ultra low sulfur fuel only.) • hydraulic fluid • 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.
JT922 Operator’s Manual Drive - 65 Drive Chapter Contents Start Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Steer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Shut Down Unit . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive - 66 JT922 Operator’s Manual Start Unit Start Unit 1. Insert key. 2. Turn key clockwise. See page 25 for more information. 3. Run engine at low throttle for 5 minutes. Steer Unit To steer drilling unit, follow instructions for type of steering desired. See page 22 for more information. To steer while moving forward, move one control slightly more than the other to turn in the desired direction. Drilling unit will gradually turn to left or right.
JT922 Operator’s Manual Drive - 67 Shut Down Unit Shut Down Unit 1. Stop track movement. 2. Lower drill frame and stabilizer to the ground. IMPORTANT: If frame and stabilizer cannot be lowered, use cylinder locks or other suitable material to block the tracks. Remove cylinder locks or chocks before driving unit. 3. Run engine at low throttle for 3 minutes to cool. 4. Turn key to STOP. 5. Remove key.
Drive - 68 JT922 Operator’s Manual Shut Down Unit CMW
JT922 Operator’s Manual Transport - 69 Transport Chapter Contents Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Haul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 • Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 • Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 • Unload . . . . . . . . . . . . . . . . . . . . . .
JT922 Operator’s Manual Transport - 70 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. 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.
JT922 Operator’s Manual Transport - 71 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.
Transport - 72 JT922 Operator’s Manual Haul Attach chains at front and rear tie-down points (shown). Make sure chains are tight before transporting unit. IMPORTANT: Drill frame must be lowered to trailer floor before attaching chains.
JT922 Operator’s Manual Transport - 73 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. 1. Lower ramps. 2. Remove tiedowns. 3. Start drilling unit engine. 4. Raise stabilizers. 5. Raise drill frame. 6. Slow engine to low throttle and slowly back unit down trailer or ramps.
Transport - 74 JT922 Operator’s Manual Tow Tow Under normal conditions, drilling unit should not be towed. If unit breaks down and towing is necessary: • Tow for short distances at less than 1 mph (1.6 kph). • Attach chains to indicated tow points facing towing vehicle. • Use maximum towing force of 1.5 times unit weight. • disengage power to tracks. IMPORTANT: When hydraulics are disengaged, unit has no brakes. To disengage track hydraulics: 1. Loosen locknut (B). 2.
JT922 Operator’s Manual Conduct a Bore - 75 Conduct a Bore Chapter Contents Position Equipment . . . . . . . . . . . . . . . . . . . . . . . . 77 Start System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Prime Drilling Fluid Pump . . . . . . . . . . . . . . . . . . . 77 Operate Carriage Control . . . . . . . . . . . . . . . . . . . 78 Clamp Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Assemble Drill String . . . . . . . . . . . . . . . . . . . . . . .
Conduct a Bore - 76 JT922 Operator’s Manual Record Bore Path . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Surface Drill Head . . . . . . . . . . . . . . . . . . . . . . . . . 86 Assemble Backream String . . . . . . . . . . . . . . . . . 87 Remove Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Remove Pullback Device . . . . . . . . . . . . . . . . . . . .
JT922 Operator’s Manual Conduct a Bore - 77 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 53. 2. Move equipment into selected positions. Start System 1. Start drilling unit and remote fluid unit. Allow both engines to warm up. IMPORTANT: Ensure that mixture of drilling fluid matches drilling conditions. 2. Enable tracker control mode if desired. See “Tracker Control” on page 106. 3.
JT922 Operator’s Manual Conduct a Bore - 78 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.
JT922 Operator’s Manual Conduct a Bore - 79 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.
Conduct a Bore - 80 JT922 Operator’s Manual 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 109 for more information, or contact your Ditch Witch dealer. 2. Insert nozzle into beacon housing. 3. Attach bit (2) to beacon housing (1). 4. Install beacon, following beacon instructions for: • battery replacement • beacon positioning 5.
JT922 Operator’s Manual Conduct a Bore - 81 Assemble Drill String Connect Drill Pipe 1. Start drilling unit engine. 2. Align transition sub (3) in front wrench. 3. Clamp tool in front wrench. See “Clamp Pipe” on page 79. 4. Lift pipe box latches. NOTICE: If drilling unit is set up in a side-slope, the rear pipe box latch should be left latched to help ensure that upper rows of drill pipe do not fall. 5. Load pipe (4). • Lubricate upper pipe threads. • Move pipe to spindle.
JT922 Operator’s Manual Conduct a Bore - 82 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. Visually check for drilling fluid flow. 3.
JT922 Operator’s Manual Conduct a Bore - 83 Add Pipe Add Pipe 1. Set engine throttle to full speed. 2. Clamp pipe joint. See “Clamp Pipe” on page 79. 3. Locate drill head. 4. Engage front wrench until pipe is clamped and pressure develops. 5. Slowly rotate spindle counterclockwise. Move carriage back as threads unscrew. 6. After threads are fully unscrewed, stop rotation and move carriage to back of frame, slowing down as carriage approaches rear end. 7. Connect Pipe. See “Connect Drill Pipe” on page 81.
Conduct a Bore - 84 JT922 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.
JT922 Operator’s Manual Conduct a Bore - 85 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. Record Bore Path Locate drill head every half-length of pipe.
JT922 Operator’s Manual Conduct a Bore - 86 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.
JT922 Operator’s Manual Conduct a Bore - 87 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. Moving tools will kill or injure.
Conduct a Bore - 88 JT922 Operator’s Manual Assemble Backream String 1. Select backreaming devices. See “Backreamers” on page 111. 2. Determine fluid rate requirements and install appropriate nozzles to provide sufficient flow. See “Backream Fluid Requirements” on page 112 and “Nozzles” on page 109. 3. Attach backreamer to backream beacon housing if tracking backream. 4. Install beacon, following beacon instructions for: • battery replacement • beacon positioning 5. Install beacon housing lid.
JT922 Operator’s Manual Conduct a Bore - 89 Remove Pipe Remove Pipe 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. Stop carriage when pipes are aligned in wrenches. 2. Clamp pipe in front wrench. See page 79. 3. Clamp and rotate rear wrench to break front joint. See “Wrench control” on page 25. 4. Disengage rear wrench. 5. Unscrew front joint.
Conduct a Bore - 90 JT922 Operator’s Manual 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. Turn off drilling fluid. 2.
JT922 Operator’s Manual Systems and Equipment - 91 Systems and Equipment Chapter Contents Anchor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 • Drive Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 • Remove Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Electric Strike System . . . . . . . . . . . . . . . . . . . . . . 95 • FCC Statement . . . . . . . . . . . . . . . . . . . . . . . .
Systems and Equipment - 92 JT922 Operator’s Manual Downhole Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 109 • Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 • Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 • Beacon Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 • Backreamers . . . . . . . . . . . . . . . . . . . . . .
JT922 Operator’s Manual Systems and Equipment - 93 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 - 94 JT922 Operator’s Manual Anchor System Drive Anchors IMPORTANT: Carefully time anchor rotation with anchor movement. Properly driven anchors should thread into soil and should not auger up soil. 1. Use anchor rotation and thrust controls to drive anchor into ground. 2. Anchor is set when cap top plate (1) rests firmly on centering tube (2). 3. Repeat process for other anchor. Remove Anchors 1. Use anchor rotation and thrust controls to slowly remove anchor shaft from ground. 2.
JT922 Operator’s Manual Systems and Equipment - 95 Electric Strike System Electric Strike System Any time you drill in an electric jobsite, electric strike system must be properly set up, tested, and used. You must wear protective boots and gloves meeting the following standards: • Boots must have high tops and meet the electric hazard protection requirements of ASTM F2413 when tested at 14,000 volts. Tuck legs of pants completely inside boots.
Systems and Equipment - 96 JT922 Operator’s Manual 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 97 on the following page. Do not drill until test is completed successfully. 1. Turn on drilling unit. 2.
JT922 Operator’s Manual Systems and Equipment - 97 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.
JT922 Operator’s Manual Systems and Equipment - 98 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.
JT922 Operator’s Manual Systems and Equipment - 99 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 sensors on
Systems and Equipment - 100 JT922 Operator’s Manual 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. Voltage Test 1.
JT922 Operator’s Manual Systems and Equipment - 101 Drilling Fluid Drilling Fluid For productive drilling and equipment protection, use these recommended Baroid® products, available from your Ditch Witch dealer.
Systems and Equipment - 102 JT922 Operator’s Manual 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.
JT922 Operator’s Manual Systems and Equipment - 103 Drilling Fluid Basic Fluid Recipes Soil type Mixture/100 gal (378 L) of water Notes 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 .
Systems and Equipment - 104 JT922 Operator’s Manual 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.
JT922 Operator’s Manual Systems and Equipment - 105 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.
Systems and Equipment - 106 JT922 Operator’s Manual Tracker Control Tracker Control Overview Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly. This mode allows the 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.
JT922 Operator’s Manual Systems and Equipment - 107 Tracker Control 4. Turn on 750 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. • Use up arrow to advance last two digits (2).
Systems and Equipment - 108 JT922 Operator’s Manual 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. 2. Turn engine off.
JT922 Operator’s Manual Systems and Equipment - 109 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.
Systems and Equipment - 110 JT922 Operator’s Manual 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 mating surfac
JT922 Operator’s Manual Systems and Equipment - 111 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.
JT922 Operator’s Manual Systems and Equipment - 112 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.
JT922 Operator’s Manual Systems and Equipment - 113 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 10.44 129.
Systems and Equipment - 114 JT922 Operator’s Manual 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.
JT922 Operator’s Manual Systems and Equipment - 115 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. 3. Turn handle until second line (B) meets first (A). 4. Turn handle opposite direction two turns to relieve pressure. 5. Remove quick wrench components. To Break 1. Turn handle until joint is broken. 2.
Systems and Equipment - 116 JT922 Operator’s Manual 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 130 for correct lubricant. 2. Join pipe and tighten joint. 3. Break joint. NOTICE: Failure to follow this procedure could result in fused joints.
JT922 Operator’s Manual Systems and Equipment - 117 Drill Pipe Use Caps and Plugs Install plug on saver sub before transporting. Cap and plug male and female ends of drill pipe during prolonged storage. 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 147 for replacement procedure. Precondition a new saver sub the same way you do new pipe.
Systems and Equipment - 118 JT922 Operator’s Manual Drill Pipe Use Drill Pipe Correctly Align the Joints Always carefully align the male and female ends of pipe before screwing them together. Poor alignment can damage the threads and destroy the usefulness of the joint. IMPORTANT: The first pipe drilled must be in a straight line with the unit. A misaligned pipe can damage threads on each pipe that is added. Clamp Pipe Correctly Clamp on pipe when joint is centered between wrenches.
JT922 Operator’s Manual Systems and Equipment - 119 Drill Pipe Make Up and Break Out Joints Correctly • Make up and break out joints slowly. Do not ram pipes together during makeup or force them apart during breakout. Carefully time rotation with carriage travel speed, and always connect and disconnect joints slowly and deliberately. This will help prevent thread crossing, galling, and shoulder swelling. • Torque joints fully.
Systems and Equipment - 120 JT922 Operator’s Manual Drill Pipe CMW
JT922 Operator’s Manual Complete the Job - 121 Complete the Job Chapter Contents Antifreeze Drilling Unit . . . . . . . . . . . . . . . . . . . . 122 • Add Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 • Reclaim Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Rinse Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 124 Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Complete the Job - 122 JT922 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 fluid system before shutdown. Add Antifreeze 1. Drain remaining water from the onboard tank. 2. Pour 3 gal (11 L) of approved antifreeze into the onboard tank. 3. Move carriage to front of drill frame. 4. Position 3-gal (11-L) bucket under spindle. 5.
JT922 Operator’s Manual Complete the Job - 123 Antifreeze Drilling Unit Reclaim Antifreeze 1. Start drilling unit and run at low throttle. 2. Move carriage to front of drill frame. 3. Position 3-gal (11-L) bucket under spindle. 4. Turn drilling fluid pump on low speed. 5. Turn drilling fluid pump off when drilling fluid comes out of spindle. 6. Pour antifreeze into onboard tank.
JT922 Operator’s Manual Complete the Job - 124 Rinse Equipment Rinse Equipment Using Optional 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. Procedure See “Prime Drilling Fluid Pump” on page 77. Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly.
JT922 Operator’s Manual Complete the Job - 125 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 - 126 JT922 Operator’s Manual Stow Tools CMW
JT922 Operator’s Manual Service - 127 Service Chapter Contents Service Precautions . . . . . . . . . . . . . . . . . . . . . . . 128 Recommended Lubricants/Service Key . . . . . . 130 Startup/10 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . 132 50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 250 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 500 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 750 Hour . . . . . . .
JT922 Operator’s Manual Service - 128 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.
JT922 Operator’s Manual Service - 129 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 yellow cylinder lock from storage at rear of pipe box and place over extended cylinder rod (shown) with curved ends toward stabilizer shoe. 2.
JT922 Operator’s Manual Service - 130 Recommended Lubricants/Service Key Recommended Lubricants/Service Key Item Description DEO Diesel engine oil meeting API service classification CF-4 or E1-96 and SAE viscosity recommended by engine manufacturer (SAE 15W40) SAE SAE 30 MPG Multipurpose grease. Use polyurea based NLGI GC-LB Grade 1.5 or lithium based NLGI GC-LB Grade 2.
JT922 Operator’s Manual Service - 131 Recommended Lubricants/Service Key Engine Oil Temperature Chart Temperature range anticipated before next oil change Approved Fuel This engine is designed to run on diesel fuel. Use only high quality fuel meeting ASTM D975 No. 2D, EN590, or equivalent. At temperatures below 32° F (0° C) winter fuel blends are acceptable. See the engine operation manual for more information. IMPORTANT: For machines operated in the U.S.
JT922 Operator’s Manual Service - 132 Startup/10 Hour Startup/10 Hour Location Task DRILLING UNIT Check engine air filter service indicator Check engine oil level Notes DEO Check hydraulic hoses Check hydraulic fluid level THF Check pipe lube applicator Check pipe auto lubricator spray nozzle Check pipe auto lubricator TJC level Check drilling fluid filter Drilling Unit Check Engine Air Filter Service Indicator Check air filter service indicator before startup and every 10 hours of operation.
JT922 Operator’s Manual Service - 133 Startup/10 Hour Check Engine Oil Level While engine oil is warm, check oil level at dipstick (1) before startup and every 10 hours of operation. Add DEO at fill (2) as necessary to keep oil level at highest line on dipstick. Check Hydraulic Hoses Pressurized fluid or air could pierce skin and cause injury or death. Stay away. NOTICE: Escaping pressurized fluid can cause injury or pierce skin and poison.
Service - 134 JT922 Operator’s Manual 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) as necessary. IMPORTANT: If hydraulic system must be opened for repair, install new filter (p/n 153-791) for first 50 hours of operation.
JT922 Operator’s Manual Service - 135 Startup/10 Hour Check Pipe Auto Lubricator TJC Level (Optional) 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 146 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.
JT922 Operator’s Manual Service - 136 50 Hour 50 Hour Location Task Notes DRILLING UNIT Check fluid pump oil level SAE 30 Change fluid pump oil level (initial) SAE 30 Check oil cooler Change hydraulic filter Initial service Check ground drive gearbox oil level 2 gearboxes, MPL Check rotation gearbox oil level MPL Inspect thrust rollers Lubricate rotation gearbox sliding output shaft Check and adjust belt tension Clean alternator cooler turbine Drilling Unit Check Fluid Pump Oil Level Check
JT922 Operator’s Manual Service - 137 50 Hour Change Fluid Pump Oil (Initial Service) Change fluid pump oil after first 50 hours and every 750 hours thereafter. Drain at plug (2) and fill with SAE 30 at plug (1). Maintain fluid level at fill plug. Check Oil Cooler Check oil cooler for dirt, grass, and other foreign matter 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.
Service - 138 JT922 Operator’s Manual 50 Hour Check Rotation Gearbox Oil Level Check rotation gearbox oil level every 50 hours. Fill through plug (1) with MPL as needed. IMPORTANT: Drill frame must be level for accurate reading. Inspect Thrust Rollers Inspect thrust rollers every 50 hours. Clean or replace if they do not turn freely. Lubricate Rotation Gearbox Sliding Output Shaft Lube rotation gearbox sliding output shaft with EPS every 50 hours.
JT922 Operator’s Manual Service - 139 50 Hour Check and Adjust Engine Belt Tension Check belt tension every 50 hours. Belt is properly tensioned when it moves about 3/8” (10 mm) when pushed at the long span (A). To adjust belt, move tensioner pulley: Note: Boltheads are hidden. Use an 8 mm hex wrench, 17 mm open end wrench, and a 1/2” prybar for this procedure. 1. Loosen socket bolt (2) and bolt (1). 2. Use a prybar in slots (3) to move pulley. 3. Tighten socket bolt (2) and bolt (1). 4. Check tension.
JT922 Operator’s Manual Service - 140 250 Hour 250 Hour Location Task DRILLING UNIT Inspect air intake system Drilling Unit Inspect Air Intake System Inspect intake piping for cracked hoses, loose clamps, or punctures. Tighten or replace parts as necessary.
JT922 Operator’s Manual Service - 141 500 Hour 500 Hour Location Task DRILLING UNIT Check fuel filter strainer Notes Change fuel filter Change engine oil and filter DEO Change hydraulic fluid and filter Normal conditions Drilling Unit Check Fuel Filter Strainer Check fuel filter strainer every 10 hours. Clean fuel filter strainer: 1. Close fuel shut-off valve. 2. Unscrew nut (1). 3. Remove fuel strainer cover (2). 4. Clean fuel strainer (2) with diesel fuel. Replace if necessary. 5.
Service - 142 JT922 Operator’s Manual 500 Hour Change Engine Oil & Filter (Normal Service) Change engine oil and filter every 500 hours for normal service. Drain oil (3), change filter (2), and add 9 qt (8.5 L) of DEO at fill (1). IMPORTANT: Use oil specified in temperature chart found in “Recommended Lubricants/ Service Key” on page 130. Change Hydraulic Fluid and Filter Change hydraulic fluid and filter every 500 hours.
JT922 Operator’s Manual Service - 143 750 Hour 750 Hour Location Task Notes DRILLING UNIT Change fluid pump oil SAE 30 Drilling Unit Change Fluid Pump Oil Change fluid pump oil every 750 hours. Drain at plug (2) and fill with SAE 30W oil at plug (1). Maintain fluid level at fill plug. Capacity for pump is 1 qt (0.9 L).
JT922 Operator’s Manual Service - 144 1000 Hour 1000 Hour Location Task Notes DRILLING UNIT Change rotation gearbox oil MPL Drilling Unit 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.
JT922 Operator’s Manual Service - 145 As Needed As Needed Location Task DRILLING UNIT Clean engine cooling system Notes Change pipe auto lubricator pail TJC Change hydraulic filter Any time system is opened Check front pipe guide inserts Check track tension and condition Change air filter Check saver sub Inspect muffler Replace fuses CMW
Service - 146 JT922 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.
JT922 Operator’s Manual Service - 147 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 the length of the compressed spring, dimension (B), is 15.25” (387.35 mm). 2. Drive straight forward one machine length and check tension again. Change Air Filter To change: 1. Remove air filter cover (4) and remove primary (3) and secondary (2) elements. 2.
Service - 148 JT922 Operator’s Manual As Needed Inspect Muffler Inspect muffler for looseness as needed. Replace Fuses Change fuses as needed. Refer to decal inside panels to identify fuses.
JT922 Operator’s Manual Specifications - 149 Specifications Dimensions U.S. Metric L, overall machine length (per SAE J2022) 146 in 3.7 m W, overall machine width (per SAE J2022) 48 in 1.2 m H, overall machine height (per SAE J2022) 74 in 1.
Specifications - 150 JT922 Operator’s Manual Operational U.S.
JT922 Operator’s Manual Specifications - 151 Drilling Fluid System (Onboard) U.S. Metric Maximum drilling fluid flow (per SAE J2022) 9 gpm 34 L/min Maximum drilling fluid pressure (per SAE J2022) 750 psi 52 bar Fluid Capacities U.S. Metric Fuel tank * 19 gal 72 L Hydraulic reservoir 18 gal 68 L Engine oil, including filter 11.6 qt 11 L * Under normal operating conditions, a full tank of fuel will last 10 hours.
Specifications - 152 CMW JT922 Operator’s Manual
JT922 Operator’s Manual Support - 239 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.
JT922 Operator’s Manual Warranty - 240 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).
JT922 Operator’s Manual Service Record - 157 Service Record Service Performed Date Hours CMW
Service Record - 158 Service Performed CMW JT922 Operator’s Manual Date Hours
