Ditch Witch JT1220 Mach 1 Operator's Manual

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JT1220 Mach 1

Operator’s Manual

CMW

Issue 2.1

054- 114

JT1220 Mach 1 Operator’s Manual Overview - 1

Overview

Chapter Contents

Serial Number Location . . . . . . . . . . . . . . . . . . . . . . 2

Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Operator Orientation. . . . . . . . . . . . . . . . . . . . . . . . . 4

About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 4

• Bulleted Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

• Numbered Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

• “Continued” Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

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Overview - 2 JT1220 Mach 1 Operator’s Manual

Serial Number Location

Record serial numbers and date of purchase in spaces provided. Drilling unit serial number is located as shown.

Item

date of manufacture date of purchase drilling unit serial number trailer serial number engine serial number

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JT1220 Mach 1 Operator’s Manual Overview - 3

Intended Use

The JT1220 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 and is intended for oper ation 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 JT1220 Mach 1 can be used with Ditch Witch drilling fluid units and Ditch Witch Subsite locating equipment. It should be operated, serviced, and repaired only by persons familiar with its particular characteristics and acquainted with the relevant safety procedures.

Unit Components

j10om001h.eps

1. Operator’s station

2. Spindle

6. Pipeloader

7. Tracks

3. Carriage

4. Drill frame

5. Stabilizer

8. Vise wrenches

9. Anchoring system

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Overview - 4 JT1220 Mach 1 Operator’s Manual

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.

Bulleted Lists

Bulleted lists provide helpful or important information or contain procedures that do not have to be performed in a specific order.

Numbered Lists

Numbered lists contain illustration callouts or list steps that must be performed in order.

“Continued” Indicators

indicates that a procedure is continued on the next page.

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JT1220 Mach 1 Operator’s Manual Foreword - 5

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 equipmen t 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. If you need assistance in locating a dealer, visit our website at www.ditchwitch.com or write to the following address:

The Charles Machine Works, Inc. Attn: Marketing Department PO Box 66 Perry, OK 73077-0066 USA

The descriptions and specifications in this manual are subject to change without notice. The Charles Machine Works, Inc. reserves the right to improve equipment. Some product improvements may have taken place after this manual was publishe d. For the latest information on Ditch Witch equipment, see your Ditch Witch dealer.

Thank you for buying and using Ditch Witch equipment.

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Foreword - 6 JT1220 Mach 1 Operator’s Manual

JT1220 Mach 1

Operator’s Manual

Issue number 2.1/OM-3/06

Part number 054-114

by The Charles Machine Works, Inc.

, Ditch Witch, CMW, AutoCrowd, Modularmatic, Jet Trac, Roto Witch, Subsite, Fluid Miser, Perma-Soil, Power Pipe, Super Witch, Super Witch II, Pierce Airrow, The Underground, and The Underground Authority Worldwide are r egistered trademarks of The Charles Machine Works, Inc.

This product is covered by one or more of the following patents: U.S. B1 4,858,704; 4,953,638; 5,148,880; 5,242,026; 5,341,887; 5,490,569; 5,684,466; 5,713,423; 5,794,719; 5,880,680; 5,941,322; 6,085,852; 6,109,371; 6,179,065; 6,216,803; 6,250,403; 6,250,404; 6,290,606; 6,311,790; 6,411,094; 6,543,551; 6,550,547; 6,672,409; 6,739,413; 6,761,231; 6,776,246; 6,808,210; 6,827,158; 6,848,506; 6,871,712; RE37,450; RE37,923; RE37,975; RE38,418; AU 689,533; 706,544; 718,034; 755,862; CA 2,156,398; 2,217,899; DE 694 17 019; 695 29 634; 297 01 406; EP 0683845; 0674093; 0817901; 0846841; 0927892; FR 674,093; GB 2,309,239; 2,312,006; EP674,093; EP846,841; JP 3,458,247; other U.S. and foreign patents pending.

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JT1220 Mach 1 Operator’s Manual Contents - 7

Overview

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

part number, revision level, and publication date of this manual, and factory contact information

Safety

machine safety alerts and emergency procedures

Controls

machine controls, gauges, and indicators and how to use them

Operation Overview

an overview for completing a job with this machine: planning, setting up, installing product, and restoring the jobsite; with cross references to deta iled procedures

Prepare

procedures for inspecting and classifying the jobsite, planning the installation path, and preparing the jobsite for work

Drive

procedures for startup, cold start, driving, and shutdown

Transport

procedures for lifting, hauling, and towing

Conduct a Bore

procedures for drilling and backreaming

Systems and Equipment

downhole tools and drill pipe, anchor, electric strike, tracker control, and fluid systems

Complete the Job

procedures for restoring the jobsite and rinsing and storing equipment

Service

service intervals and instructions for this machine including lubrication, replacement of wear items, and basic maintenance

107

147

153

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Contents - 8 JT1220 Mach 1 Operator’s Manual

Specifications

machine specifications including weights, measurements, power ratings, and fluid capacities

Support

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

185

189

193

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JT1220 Mach 1 Operator’s Manual Safety - 9

Safety

Chapter Contents

Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Safety Alert Classifications . . . . . . . . . . . . . . . . . . 11

Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Emergency Procedures . . . . . . . . . . . . . . . . . . . . . 15

• Electric Strike Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

• If an Electric Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

• If a Gas Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

• If a Fiber Optic Cable is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

• If Machine Catches on Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

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Safety - 10 JT1220 Mach 1 Operator’s Manual

Guidelines

Follow these guidelines before operating any jobsite equipment:

• Complete proper training and read operator’s manual before using equipment.

• Contact One-Call (888-258-0808) and any utility companies which do not subscribe to One-Call. Have

all underground pipes and cables located and marke d before operating equipment. If you damage a utility, contact utility company.

• Classify jobsite based on its hazards and use correct tools and machin ery, safety equipment, and work

methods for jobsite.

• Mark jobsite clearly and keep spectators away.

• Wear personal protective equipment.

• Review jobsite hazards, safety and emergency procedures, and individual responsibilities with all

personnel before work begins. Safety videos are available from your Ditch Witch dealer.

• Replace missing or damaged safety shields and safety signs.

• Use equipment carefully. Stop operation and investigate anything that does not look or feel right.

• Do not operate unit where flammable gas is present.

• Contact your Ditch Witch dealer if you have any question about operation, ma intenance, or equipmen t

use.

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JT1220 Mach 1 Operator’s Manual Safety - 11

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.

indicates an imminently hazardous situation which, if not avoided, will result in death or

serious injury.

indicates a potentially hazardous situation which, if not avoided, could result in death or

serious injury.

indicates a potentially hazardous situation which, if not avoided, may result in minor or

moderate injury.

Watch for two other words: NOTICE and IMPORTANT. NOTICE can keep you from doing something that might damage the machine or someone's property. It

can also alert you against unsafe practices.

IMPORTANT can help you do a better job or make your job easier in some way.

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Safety - 12 JT1220 Mach 1 Operator’s Manual

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.

Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment.

Crushing weight could cause death or seriou s injur y. Use

proper procedures and equipment or stay away.

Moving parts could cut off ha nd or foot. Stay away.

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JT1220 Mach 1 Operator’s Manual Safety - 13

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. Do

not look into ends of fiber optic or unidentified cable.

Pressurized fluid or air could pierce skin a nd cause injur y or

death. Stay away.

Fire or explosion possible. Fumes could ignite and cause burns. No

smoking, no flame, no spark.

Moving traffic - hazardous situation. Death or serious injury could result.

Avoid moving vehicles, wear high visibility clothing, post appropriate warning signs.

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Safety - 14 JT1220 Mach 1 Operator’s Manual

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.

Improper handling or use of chemicals may result in illness, injury, or equipment damage. Follow instructions on labels and in material safety da ta sheets (MSDS).

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JT1220 Mach 1 Operator’s Manual Safety - 15

Emergency Procedures

Before operating any equipment, review emergency proc edures and check that all safety precau tions have been taken.

EMERGENCY SHUTDOWN - Turn ignition switch to stop position or push remote e ngine stop button ( if equipped).

Electric Strike Description

When working near electric cables, remember the following:

• Electricity follows all paths to ground, not just path of least resistance.

• Pipes, hoses, and cables will conduct electricity back to all equipment.

• Low voltage current can injure or kill. Almost one-third of work-related electrocutions result from contact with less than 440 volts.

Most electric strikes are not noticeable, but indications of a strike include:

• power outage

•smoke

•explosion

• popping noises

• arcing electricity

If any of these occur, or if strike alarm sounds or flashes, assume an electric strike has occurred.

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Safety - 16 JT1220 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 ground mats, 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. Do not touch drill pipe with hands or hand-held tools.

• Press electric strike system status button.

• If alarm sounds again, stay where you are and wa it for electric company to shut off power.

• If alarm does not sound and there is no other indication of a strike, wait at least one full minute

before moving away from equipment. Utility might use automatic reclosers which will restart current flow. If alarm sounds again while waiting, stay where you are until electric company shuts off power.

• If alarm does not sound but all light s in strike indicator are on , assume strike is continuing and sta y

where you are until electric company shuts off power.

• Do not resume drilling or allow anyone into area until given permission by electric company.

If you suspect an electric line has been damaged and you are off drilling unit or bonded ground mats, DO NOT TOUCH ANY EQUIPMENT connected to drilling unit. Take the following actions. The order and degree of action will depend on the situation.

• St ay wher e you are unless you ar e we aring ele ctric insulating b oot s. If you leave, do not retur n to area or allow anyone into area until given permission by electric company.

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JT1220 Mach 1 Operator’s Manual Safety - 17

Emergency Procedures

If a Gas Line is Damaged

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.

• Remove any ignition source(s), if this can be done safely and quickly.

• Warn others that a gas line has been cu t and that they sh ould leave the area.

• Leave jobsite as quickly as possible.

• Immediately call your local emergency phone number and utility company.

• If jobsite is along street, stop traffic from driving near jobsite .

• Do not return to jobsite until given permission by emergency personnel and utility company.

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.

• If fire is small and fire extinguisher is available, attempt to extinguish fire.

• If fire cannot be extinguished, leave area as quickly as possible and contact emergency personnel.

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Safety - 18 JT1220 Mach 1 Operator’s Manual

Emergency Procedures

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JT1220 Mach 1 Operator’s Manual Controls - 19

Controls

Chapter Contents

Set-Up Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Tethered Ground Drive Controller . . . . . . . . . . . . 23

Left Control Console . . . . . . . . . . . . . . . . . . . . . . . 25

• Pipeloading controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

• Drilling/Operation controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Gauge Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

• Unit status indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

• Pipeloading status indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

• Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Right Control Console . . . . . . . . . . . . . . . . . . . . . . 39

Anchoring System Console . . . . . . . . . . . . . . . . . 41

Seat/Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

ESID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Ditch Witch Electronics 750/752 Display . . . . . . . 49

• Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

• Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

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Controls - 20 JT1220 Mach 1 Operator’s Manual

Set-Up Console

1. Tracker control key

2. Ignition switch

3. Left track switch

4. Right track switch

Item Description Notes

1. Tracker control key To allow tracker operator to

stop thrust and rotation, move key to enable position (up).

To override tracker control mode, move key to disable position (right).

5. Right stabilizer control

6. Frame tilt control

7. Left stabilizer control

IMPORTANT: Remove key and keep in tracker operator’s possession.

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JT1220 Mach 1 Operator’s Manual Controls - 21

Set-Up Console

Item Description Notes

2. Ignition switch T o star t engine, insert key and

turn clockwise. To stop engine, turn key

counterclockwise.

3. Left track switch To move forward, press top. To move backward, press

bottom.

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4. Right track switch To move forward, press top. To move backward, press

bottom.

IMPORTANT:

• Restart engine with ignition switch after it has been turned off with remote engine stop switch.

• If wrenches are engaged when engine is stopped with ignition switch, wrenches will release and then engage when unit is started.

IMPORTANT: Use track switches only if tethered control is inoperable.

c00ic148h.eps

5. Right stabilizer control To raise, pull up. To lower, push down.

6. Frame tilt control To raise front end of drill frame, pull up.

To lower front end of drill frame, 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: St and clear of right st abilizer to avoid crushing your foot.

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Controls - 22 JT1220 Mach 1 Operator’s Manual

Set-Up Console

Item Description Notes

7. 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.

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JT1220 Mach 1 Operator’s Manual Controls - 23

Tethered Ground Drive Controller

j10om016h.eps

1. Speed/direction control

2. Power mode switch

3. Remote engine stop

Item Description Notes

1. Speed/direction control To move forward, push.

To move backward, pull. To steer, move left or right.

c00ic145h.eps

4. Operator presence switch

5. Throttle switch

IMPORTANT:

• Operator presence switch must

• See “Steer Unit” on page 76 for

be pressed and operator seat must be empty for control to work.

more information.

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Controls - 24 JT1220 Mach 1 Operator’s Manual

Tethered Ground Drive Controller

Item Description Notes

2. Power mode switch T o select normal driving mode

(high), push. 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.

To disable controller, release.

5. Throttle switch To increase engine speed, push.

To decrease engine speed, pull.

IMPORTANT: To restart engine, turn ignition switch off and then back on.

IMPORTANT: Throttle switch at operator’s station must be in center position for this switch to control speed.

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JT1220 Mach 1 Operator’s Manual Controls - 25

Left Control Console

Pipeloading Controls

1. Add pipe/manual/remove pipe switch

2. Set/Resume switch

3. Pipe box switch

4. Wrench control

IMPORTANT: Switch 1 will not function unless unit is equipped with pipeloader automation option.

Item Description Notes

1. Add pipe/manual/

remove pipe switch

To select “add pipe” automated pipeloader function, press top.

To use manual pipeloader controls, move to center.

To select “remove pipe” automated pipeloader function, press bottom.

5. Pipe lift switch

6. Pipe shuttle switch

7. Pipe gripper switch

8. Pipe lubricator switch

See “Add Pipe” on page 97.

See “Remove Pipe” on page 103.

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Controls - 26 JT1220 Mach 1 Operator’s Manual

Left Control Console

Item Description Notes

2. Set/resume switch To resume operation or

increase operation levels,

RESUME /

press top. To set operating conditions or

reduce operation levels, press bottom.

SET /

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3. Pipe box switch To shift pipe box toward operator, press left side.

To shift pipe box away from operator, press right side.

4. Wrench control To clamp front wrench, move to right.

To unclamp front wrench, move to left.

See “Cruise Control” on page 140.

IMPORTANT: See “Shift Pipe Box” on page 135.

To clamp and rotate rear (rotating) wrench, push.

To unclamp rear (rotating) wrench, pull.

5. Pipe lift switch To raise, press top. To lower, press bottom.

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JT1220 Mach 1 Operator’s Manual Controls - 27

Left Control Console

Item Description Notes

6. Pipe shuttle switch To move toward pipe box,

press top. To move toward spindle,

press bottom.

7. Pipe gripper switch To close, press top. To open, press bottom.

8. Pipe lubricator switch To fill applicator at back of pipeloader, press top.

To apply joint compound to threads at wrenches, press bottom.

c00ic150h.eps

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Controls - 28 JT1220 Mach 1 Operator’s Manual

Left Control Console

Drilling/Operation Controls

1. Engine throttle switch

2. Drilling fluid pressure gauge

3. Thrust pressure gauge

4. Rotation pressure gauge

Item Description Notes

1. Engine throttle switch To increase speed, press top.

Return switch to center when desired speed is reached.

To enable autothrottle mode, press top and leave switch in top position.

To decrease speed, press bottom.

To disable autothrottle mode, return switch to center after desired speed is reached.

5. Remote engine start switch

6. Console/Work light switch

7. Fluid pump indicator

8. Fluid flow control

Autothrottle mode slows the engine to low throttle after 15 seconds of inactivity involving thrust, rotation, drilling fluid flow, or pipeloader functions. To return to high speed, activate thrust, rotation, drilling fluid, or an add/remove cycle.

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JT1220 Mach 1 Operator’s Manual Controls - 29

Left Control Console

Item Description Notes

2. Drilling fluid pressure

gauge

Displays drilling fluid pressure supplied by drilling fluid pump.

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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.

5. Remote engine start

switch

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Estimates rotational torque on lines outside gauge.

To start engine from operator’s station, push button.

Release when engine starts.

IMPORTANT: This button works only when key on set-up console is on, operator is in seat, and battery disconnect switch is closed.

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Controls - 30 JT1220 Mach 1 Operator’s Manual

Left Control Console

Item Description Notes

6. Console/Work light

To turn on, press top.

switch

To turn off, press bottom.

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7. Fluid pump indicator If fluid pump is on, light should be on.

If fluid pump is off, light should be off.

8. Fluid flow control To increase flow, turn clockwise.

To decrease flow, turn counterclockwise.

To stop flow, turn all the way counterclockwise.

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JT1220 Mach 1 Operator’s Manual Controls - 31

Gauge Cluster

Unit Status Indicators

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1. Water in fuel indicator

5. Coolant high temperature indicator

2. Battery charging indicator

3. Hydraulic filter service indicator

4. Hydraulic oil high temperature indicator

Item Description Notes

1. Water in fuel indicator Indicates the presence of

water in the fuel.

6. Engine oil pressure indicator

7. Operator presence indicator

8. Diagnostic light (red)

Drain water from fuel filter. See page 159.

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Controls - 32 JT1220 Mach 1 Operator’s Manual

Gauge Cluster

Item Description Notes

2. Battery charging

indicator

3. Hydraulic filter service

indicator

4. Hydraulic fluid

temperature indicator

Indicates battery is not charging.

Indicates hydraulic fluid filter needs replacing.

Indicates hydraulic fluid is overheating.

Change filter when indicator lights continuously and as indicated on page 168.

• Check hydraulic fluid level.

• Check cooler for debris. See page 168.

5. Coolant high temperature indicator

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Indicates coolant is overheating.

IMPORTANT: Alarms will sound when coolant overheats.

Stop engine and let cool. Check coolant level.

JT1220 Mach 1 Operator’s Manual Controls - 33

Gauge Cluster

Item Description Notes

6. Engine oil pressure indicator

7. Operator presence indicator

8. Diagnostic light (red) If system is OK, light should

Indicates engine oil pressure is too low.

Indicates operator is seated in operator’s station.

be off.

IMPORTANT: Alarms will sound when engine oil pressure is too low.

Stop engine and check oil level.

Thrust and rotation will not operate unless light is on.

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.

If an essential diagnostic code is recorded, light should flash on for three seconds and off for half a second.

See “Interpret Diagnostic Codes” on page 141.

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Controls - 34 JT1220 Mach 1 Operator’s Manual

Gauge Cluster

Pipeloading Status Indicators

1. Control cycle light (green)

2. Rear stop status indicator

3. Carriage home status indicator

4. Front wrench status indicator

Item Description Notes

1. Control cycle light (green)

If nothing is being controlled, light should be off.

If system is waiting for an action before starting cycle, light should flash on and off.

If something is being controlled, light should be on.

If control cycle is interrupted, light should flash twice quickly.

5. Shuttle home status indicator

6. Front pipe box status indicator

7. Rear pipe box status indicator

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JT1220 Mach 1 Operator’s Manual Controls - 35

Gauge Cluster

Item Description Notes

2. Rear stop status indicator

3. Carriage home status indicator

4. Front wrench status indicator

If carriage is at very back of drill frame, light should be on.

If carriage is away from very back of drill frame, light should be off.

If carriage is in the home zone at either end of drill frame, light should be on.

If carriage is out of the home zone at either end of drill frame, light should be off.

If front wrench is closed, light should be on.

5. Shuttle home status indicator

If front wrench is open, light should be off.

If shuttle is retracted, light should be on.

If shuttle is not completely retracted, light should be off.

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Controls - 36 JT1220 Mach 1 Operator’s Manual

Gauge Cluster

Item Description Notes

6. Front pipe box status indicator

7. Rear pipe box status indicator

If active pipe column contains pipe, light should be on.

If active pipe column does not contain pipe, light should be off.

If active pipe column contains pipe, light should be on.

If active pipe column does not contain pipe, light should be off.

IMPORTANT:

• Check pipe box status lights to see when active column of pipe box is empty. See “Shift Pipe Box” on page 135.

• One light on and one light off indicates a jammed pipe. See “Correct Misaligned or Jammed Pipe” on page 136.

IMPORTANT:

• Check pipe box status lights to see when active column of pipe box is empty. See “Shift Pipe Box” on page 135.

• One light on and one light off indicates a jammed pipe. See “Correct Misaligned or Jammed Pipe” on page 136..

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JT1220 Mach 1 Operator’s Manual Controls - 37

Gauge Cluster

Gauges

j10om009h.eps

1. Voltmeter

4. Engine oil pressure gauge

2. Tachometer/Hourmeter

3. Engine coolant temperature gauge

Item Description Notes

1. Voltmeter Displays system voltage. Should show 13 to 14 volts with

5. Fuel gauge

engine running.

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Controls - 38 JT1220 Mach 1 Operator’s Manual

Gauge Cluster

Item Description Notes

2. Tachometer/Hourmeter Displays engine rpm.

Displays engine operating time.

3. Engine coolant temperature gauge

4. Engine oil pressure gauge

Displays engine coolant temperature.

Displays engine oil pressure. Full load reading should be 35-65 psi

Full load reading should be 2200 rpm. Use these times to schedule service.

Normal coolant temperature is 190°-212° F (88°-100° C).

(2.4-4.5 bar). At idle, reading should not drop below

12 psi (0.8 bar).

5. Fuel gauge Displays fuel level in tank. Use only #2 diesel fuel.

Refer to engine operator’s manual for cold weather fuel recommendations.

Tank holds 19 gal (72 L).

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JT1220 Mach 1 Operator’s Manual Controls - 39

Right Control Console

1. Drilling fluid pump switch

2. Dual speed carriage control

3. Carriage control

Item Description Notes

1. Drilling fluid pump switch

To turn on, press once. To turn off, press once.

4. Drilling fluid quick fill switch

5. Remote engine stop switch

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Controls - 40 JT1220 Mach 1 Operator’s Manual

Right Control Console

Item Description Notes

2. Dual speed carriage control

3. Carriage control To move carriage forward,

To engage high carriage travel speed, push and hold.

To return to normal carriage speed, release.

To override assisted makeup mode, push and hold.

push. To move carriage backward,

pull. To rotate spindle

counterclockwise (breakout), move right.

To rotate spindle clockwise (makeup), move left.

Use during bore or pullback when no pipe is in spindle to save time.

Use during pipe makeup when pipe ends are misaligned.

IMPORTANT: Overriding assisted makeup mode puts pipe threads in jeopardy. If frequent overriding is necessary, see your Ditch Witch dealer for pipeloader adjustment.

IMPORTANT: See “Operate Carria ge Control” on page 91 for more information.

4. Drilling fluid quick fill switch

5. Remote engine stop switch

To override fluid control setting for full pump flow, press and hold.

To return fluid flow to flow control setting, release.

To stop engine, press. To restart engine, turn ignition

off and then back to start.

IMPORTANT:

• If this switch is used to stop drilling unit, be sure to turn ignition switch off if machine will be left unattended for long periods of time. Battery discharge can occur.

• If wrenches are engaged when remote stop is pressed, wrenches will remain engaged but could gradually open.

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JT1220 Mach 1 Operator’s Manual Controls - 41

Anchoring System Console

j10om015h.eps

1. Left rotation control

2. Left thrust control

Item Description Notes

1. Left rotation control To drive anchor, push down.

To remove anchor, pull up.

3. Right rotation control

4. Right thrust control

IMPORTANT: S tand on plat form when operating anchor controls.

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Controls - 42 JT1220 Mach 1 Operator’s Manual

Anchoring System Console

Item Description Notes

2. Left thrust control To move anchor down, push

down. To move anchor up, pull up.

3. Right rotation control To drive anchor, push down. To remove anchor, pull up.

4. Right thrust control To move anchor down, push down.

IMPORTANT: S tand on plat form when operating anchor controls.

To move anchor up, pull up.

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JT1220 Mach 1 Operator’s Manual Controls - 43

Seat/Armrest

1. Armrest adjustment

3. Seat slide control

2. Seat recline control

Item Description Notes

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.

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Controls - 44 JT1220 Mach 1 Operator’s Manual

Seat/Armrest

Item Description Notes

3. Seat slide control To slide forward or backward,

move left. To lock seat in position, move

right.

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JT1220 Mach 1 Operator’s Manual Controls - 45

Battery

1. Battery disconnect switch

Item Description Notes

1. Battery disconnect

switch

To connect, move left. To disconnect, move right.

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Controls - 46 JT1220 Mach 1 Operator’s Manual

ESID

j07om042h.eps

1. Alphanumeric display

2. Strike indicator

3. Alarm interrupt button

4. Voltage problem indicator

Item Description Notes

1. Alphanumeric display Display amount of current

and voltage being detected as a percentage of strike condition.

5. Current problem indicator

6. OK indicator

7. Electrical power supply indicator

8. Self test button

5 6

The line with the “V” shows voltage reading and the line with the “A” shows current reading.

2. Strike indicator Red lights come on as values in display increase.

Light in triangle represents strike warning condition and will trigger alarm(s) and strobe(s).

Remember that system can go from one or two lights to an electric strike immediately.

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NOTICE: The ESID does not indicate

proximity to electric lines. System will activate only when voltage and/or amperage detected at the drilling unit are above threshold minimum limits.

JT1220 Mach 1 Operator’s Manual Controls - 47

ESID

Item Description Notes

3. Alarm interrupt button To turn off strike alarm at

drilling unit, press.

4. Voltage problem

indicator

5. Current problem

indicator

6. OK indicator Green light means system

Blinking red light indicates a voltage indicator problem.

Blinking red light indicates a current indicator problem.

self test detected no problems.

See “Troubleshoot Strike System” on page 112.

Strike system is ready to operate.

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Controls - 48 JT1220 Mach 1 Operator’s Manual

ESID

Item Description Notes

7. Electrical power supply

indicator

8. Self test button To start manual self test,

Green light means control box has sufficient electrical power for operation.

Strike system is ready to operate if OK indicator is also on.

press. To reset system after a strike

has been detected, press.

Checks all systems and circuits.

NOTICE: See “If an Electric Line is Damaged” on page 16.

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JT1220 Mach 1 Operator’s Manual Controls - 49

Ditch Witch Electronics 750/752 Display

Indicators

1. Beacon temperature display

2. Pitch/slope indicator and percentage indicator

3. Roll indicator

4. Target indentifier indicator

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. Beacon temperature

display

Shows beacon temperature readings in degrees Farenheit and degrees Centigrade.

5. Depth estimate

6. Display battery status indicator

7. Beacon battery status indicator

8. Beacon temperature indicator

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Controls - 50 JT1220 Mach 1 Operator’s Manual

Ditch Witch Electronics 750/752 Display

Item Description Notes

2. Pitch/slope indicator

and percentage indicator

3. Roll indicator Indicates beacon roll angle.

4. Target identifier

indicator

Indicates pitch beacon percent of grade.

Indicates approximate beacon location.

Internal: shows pipe label and stored pitch.

External: shows desired pitch.

Only one set of arrows is active at a time.

5. Depth estimate Indicates beacon depth estimate.

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Internal: shows job number and

stored depth. External: shows desired depth.

JT1220 Mach 1 Operator’s Manual Controls - 51

Ditch Witch Electronics 750/752 Display

Item Description Notes

6. Display battery status

indicator

7. Beacon battery status

indicator

8. Beacon temperature

indicator

Indicates display power from drilling unit.

Indicates beacon battery status.

Indicates beacon temperature.

If all five bars are not showing, check display power connections.

See beacon instruction sheet.

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Controls - 52 JT1220 Mach 1 Operator’s Manual

Ditch Witch Electronics 750/752 Display

Controls

1. Delete button

2. On/Off button

3. Channel select button

Item Description Notes

1. Delete button To delete current pipe, press.

Second function:

To delete all jobs in internal logging memory, press with Recall button.

4. Roll stop button

5. Recall button

6. Store button

Previous pipe number will appear in numeric display when data is deleted.

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JT1220 Mach 1 Operator’s Manual Controls - 53

Ditch Witch Electronics 750/752 Display

Item Description Notes

2. On/Off button To turn on, press.

To turn off, press again.

3. Channel select button To display current channel, press and release.

To switch channels, press and hold.

Second function:

To start a new job, press with Recall button.

“Init” and job number will be displayed.

4. Roll stop button This feature is not yet available.

Unit defaults to last channel used each time unit is turned on.

IMPORTANT: Make sure display and tracker are set to the same channel.

5. Recall button To see data about pipe, press and release.

Second function:

To access second functions, press with other buttons.

Internal: shows data about previous pipe.

External: shows data about next pipe.

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Controls - 54 JT1220 Mach 1 Operator’s Manual

Ditch Witch Electronics 750/752 Display

Item Description Notes

6. Store button To display serial number,

press and hold while pressing on/off button.

To store current pipe data, press.

Second function:

To download all jobs stored in internal logging memory:

• Press with Recall button

• Connect display to PC

running Trac Management System software.

Pipe number will appear in numeric display when data is stored.

IMPORTANT: Pipe data cannot be stored without a valid depth estimate.

CMW

JT1220 Mach 1 Operator’s Manual Operation Overview - 55

Operation Overview

Chapter Contents

Planning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Setting Up at Jobsite . . . . . . . . . . . . . . . . . . . . . . . 56

Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Backreaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Leaving Jobsite. . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Storing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 58

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Operation Overview - 56 JT1220 Mach 1 Operator’s Manual

Planning

1. Gather information about jobsite. See page 61.

2. Inspect jobsite. See page 62.

3. Classify jobsite. See page 64.

4. Plan bore path. See page 66.

5. Check supplies and prepare equipment. See page 72.

6. Load equipment. See page 81.

Setting Up at Jobsite

1. Prepare jobsite. See page 71.

2. Unload drilling unit from trailer. See page 84.

3. Assemble drill string. See page 93.

4. Position drilling unit and frame. See page 89.

5. Assemble strike system. See page 110.

6. Anchor drilling unit. See page 109.

7. Connect fluid system. See page 89.

8. Calibrate tracker with beacon that will be installed in beacon housing. See tracker operator’s manual.

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JT1220 Mach 1 Operator’s Manual Operation Overview - 57

Drilling

1. Start system. See page 90.

2. Prime drilling fluid pump. See page 90.

3. Engage tracker control if desired. See page 121.

4. Drill first pipe. See page 95.

5. Record bore path. See page 100.

6. Enable automated pipeloader system. See page 96.

7. Add pipe. See page 97.

8. Drill remaining pipes in pipe box.

• Correct direction. See page 99.

• Engage cruise control. See page 140.

• Shift pipe box. See page 135.

9. Add up to a single column of drill pipe to empty box (see page 135) to complete bore.

10. Surface drill head. See page 101.

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Operation Overview - 58 JT1220 Mach 1 Operator’s Manual

Backreaming

1. Assemble backream string. See page 102.

2. Start drilling unit and adjust throttle.

3. Set drilling fluid flow. Check that fluid flows through all nozzles. See page 116.

4. Remove pipe from bore. See page 103.

5. Remove up to a single column of drill pipe from full box (see page 131) to complete backream.

6. Remove pullback device. See page 105.

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.

• Keep all bends as gradual as possible.

• Drilling fluid quality is a key factor in backreaming success. Contact your Ditch Witch dealer for information on testing water, selecting additives, and mixing drilling fluid.

• Backreaming requires more fluid than drilling. Make sure enough fluid is used.

Leaving Jobsite

1. Remove downhole tools. See page 105.

2. Remove anchors. See page 109.

3. Rinse unit and downhole tools. See page 150.

4. Disassemble strike system and disconnect from fluid system. See page 151.

5. Stow tools. See page 151.

6. Load unit onto trailer. See page 81.

Storing Equipment

1. For cold weather storage, antifreeze drilling unit. See page 148.

2. For long-term storage, disconnect battery disconnect switch.

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JT1220 Mach 1 Operator’s Manual Prepare - 59

Prep are

Chapter Contents

Gather Information . . . . . . . . . . . . . . . . . . . . . . . . . 61

• Review Job Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

• Notify One-Call Services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

• Examine Pullback Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

• Arrange for Traffic Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

• Plan for Emergency Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Inspect Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

• Identify Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

• Select Start and End Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Classify Jobsite. . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

• Inspect Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

• Select a Classification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

• Apply Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Plan Bore Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

• Recommended Bend Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

• Entry Pitch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

• Minimum Setback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

• Minimum Depth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

• Bore Path Calculator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

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Prepare - 60 JT1220 Mach 1 Operator’s Manual

Prepare Jobsite. . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

• Mark Bore Path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

• Prepare Entry Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Check Supplies and Prepare Equipment . . . . . . . 72

• Check Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

• Prepare Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

• Assemble Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

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JT1220 Mach 1 Operator’s Manual Prepare - 61

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.

Notify One-Call Services

Call area One-Call or similar services and have existing lines located and marked. Call any utilities in your area that do not subscribe to One-Call.

Examine Pullback Material

Ask for a sample of the material you will be pulling back. Check its weight and stiffness. Contact the manufacturer for bend radius informa tion. Check that you have appropriate pullback devices.

Arrange for Traffic Control

If working near a road or other traffic area, contact local authorities about safety procedures and regulations.

Plan for Emergency Services

Have the telephone numbers for local emergency and medical facilities on hand. Check that you will have access to a telephone.

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Prepare - 62 JT1220 Mach 1 Operator’s Manual

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 64.)

•traffic

•access

• soil type and condition

• water supply

• sources of locator interference (rebar, railroad tracks, etc.)

Take soil samples from several locations along bore path to determine best bit and backreamer combinations.

Identify Hazards

Identify safety hazards and classify jobsite. See “Classify Jobsite” on page 64.

Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment.

NOTICE:

• Wear personal protective equipment including hard hat, safety eye wear, and hearing protection.

• Do not wear jewelry or loose clothing.

• Notify One-Call and companies which do not subscribe to One-Call.

• Comply with all utility notification regulations before digging or drilling.

• Verify location of previously marked underground hazards.

• Mark jobsite clearly and keep spectators away.

Remember, jobsite is classified by hazards in place -- not by line being installed.

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JT1220 Mach 1 Operator’s Manual Prepare - 63

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.

Space

Check that starting and ending points allow enough space for gradual pipe bending. See “Minimum Setback” on page 69.

Check that there is enough space to work and to set up electric strike system.

Comfort

Consider shade, wind, fumes, and other site features. Drill downhill when possible so fluid will flow away from drilling unit.

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Prepare - 64 JT1220 Mach 1 Operator’s Manual

Classify Jobsite

Inspect Jobsite

• Follow U.S. Department of Labor regulations on excavating and trenching (Part 1926, Subpart P) and other similar regulations.

• Contact One-Call (888-258-0808) and any utility companies which do not subscribe to One-Call.

• Inspect jobsite and perimeter for evidence of underground hazards, such as: – “buried utility” notices

– utility facilities without overhead lines – gas or water meters – junction boxes – drop boxes – light poles – manhole covers – sunken ground

• Have an experienced locating equipment operator sweep area within 20’ (6 m) to each side of bore path. Verify previously marked line and cable locations.

• Mark location of all buried utilities and obstructions.

• Classify jobsite.

Select a Classification

Jobsites are classified according to underground hazards present.

If working . . . then classify jobsite as . . .

within 10’ (3 m) of a buried electric line electric within 10’ (3 m) of a natural gas line natural gas in concrete, sand or granite which is capable of producing

crystalline silica (quartz) dust within 10’ (3 m) of any other hazard other

NOTICE: If you have any doubt about jobsite classification, or if jobsite might contain unmarked hazards, take steps outlined previously to identify hazards and classify jobsite before working.

crystalline silica (quartz) dust

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JT1220 Mach 1 Operator’s Manual Prepare - 65

Classify Jobsite

Apply Precautions

Once classified, precautions appropriate for jobsite must be taken.

Electric Jobsite Precautions

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.

• Have service shut down while work is in progress. Have electric company test lines before returning them to service.

Natural Gas Jobsite Precautions

In addition to using a directional drilling system and positioning equipment upwind from gas lines, use one or both of these methods.

• Expose lines by careful hand digging or soft excavation. Use beacon to track bore path.

• Have gas shut off while work is in progress. Have gas company test lines before returning them to service.

Crystalline Silica (Quartz) Dust Precautions

Follow OSHA or other guidelines for exposure to crystalline silica when trenching, sawing or drilling through material that might produce dust containing crystalline silica (quartz).

Other Jobsite Precautions

You may need to use different methods to safely avoid other underground hazards. Talk with those knowledgeable about hazards present at each site to determine which precautions should be taken or if job should be attempted.

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Prepare - 66 JT1220 Mach 1 Operator’s Manual

Plan Bore Path

Plan the bore path, from entry to end, before drilling begins. The Ditch Witch Subsite 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 details.

If not using Trac Management System Plus, mark the bore path on the ground with spray paint or flags, or record it on paper for operator reference.

For complicated bores, consult an engineer . Have the jobsite surveyed and bore pa th calculated. Be sure the engineer knows minimum entry pitch, bend limits of drill pipe, bend and tension limits of pullback material, pipe lengths, and location of all underground utilities.

For less complicated bores, plan the bore based on four measurements:

• recommended bend limit

• entry pitch

• minimum setback

95 or higher operating system. See your Ditch Witch dealer for

• minimum depth

IMPORTANT: See the following pages for more information about these measurements. If not using Trac Management System Plus, see “Bore Path Calcula tor” on page 70 and use these measurements to help plan your bore.

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JT1220 Mach 1 Operator’s Manual Prepare - 67

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. For JT1220 Mach 1 drill pipe, make sure pitch (A) changes no more than 9% over the full length

of each pipe.

NOTICE: Bending drill pipe more sharply than recommended will damage pipe and cause failure over time. Changes in pitch must be equally distributed over the length of a pipe. Maximum changes in pitch within 1-2’ (300-600 mm) of pipe create sharp bends that will damage pipe.

Monitor the pitch of each pipe with the 750 Display on the operator’s console. See page 49.

Bend Radius

JT1220 Mach 1 drill pipes have a tested minimum bend radius of 105’ (32 m). This means that a 90degree bend in the bore path:

• has a radius (A) of 105’ (32 m)

• requires approximately 165’ (50 m) of drill pipe

(B).

NOTICE: Bending drill pipe more sharply than recommended will damage the pipe and cause failure over time.

• If bend radius is reduced, drill pipe life is reduced.

• If bend radius is increased, drill pipe life is increased.

IMPORTANT: Use the charts on the next page to keep bends within safe limits.

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Prepare - 68 JT1220 Mach 1 Operator’s Manual

Plan Bore Path

Pipe-By-Pipe Bend Limits

Pipe

(C)

1 10 ft 0 in (3.0 m) 0 ft 6 in (0.1 m) 10 85 ft 6 in (26.1 m) 44 ft 1 in (13.4 m) 2 19 ft 10 in (6.1 m) 1 ft 11 in (0.6 m) 11 90 ft 11 in (27.7 m) 52 ft 6 in (16 m) 3 29 ft 7 in (9.0 m) 4 ft 3 in (1.3 m) 12 95 ft 6 in (29.1 m) 61 ft 5 in (18.7 m) 4 39 ft 0 in (11.9 m) 7 ft 6 in (2.3 m) 13 99 ft 3 in (30.3 m) 70 ft 8 in (21.5 m) 5 48 ft 1 in (14.6 m) 11 ft 8 in (3.6 m) 14 102 ft 0 in (31.1 m) 80 ft 3 in (24.5 m) 6 56 ft 9 in (17.3 m) 16 ft 8 in (5.1 m) 15 103 ft 11 in (31.7 m) 90 ft 1 in (27.5 m) 7 64 ft 11 in (19.8 m) 22 ft 5 in (6.8 m) 16 104 ft 10 in (31.9 m) 100 ft 0 in (30.5 m) 8 72 ft 5 in (22.1 m) 29 ft 0 in (8.8 m) 16.5 105 ft 0 in (32 m) 105 ft 0 in (32 m) 9 79 ft 4 in (24.2 m) 36 ft 3 in (11 m)

Forward (B) Deflection (A) Pipe

(C)

Forward (B) Deflection (A)

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Pipe 10 is illustrated.

JT1220 Mach 1 Operator’s Manual Prepare - 69

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). Record this number.

• Measure the distance between front and back points (C).

• Divide (H2-H1) by (C), then multiply by 100. This is your pitch.

IMPORTANT: A shallow entry pitch (A1) allows you to reach horizontal sooner and with less bending. Increasing entry pitch (A2) makes bore path longer and deeper.

Minimum Setback

Setback is the distance from the entry point to where pipe becomes horizontal (B1).

NOTICE: If setback is too small (B2), you will exceed bend limits and damage the pipe.

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Prepare - 70 JT1220 Mach 1 Operator’s Manual

Plan Bore Path

Minimum Depth

Because you must bend pipe gradually , en try 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 limit s to determine the bore p ath. To find the setback (B) and entry pitch (A) that will take you to the desired minimum depth (D), use the chart below.

Minimum depth (D) Entry pitch (A) Setback (B) Depth to begin steering (S)

3 ft 0 in (0.9 m) -18% 26 ft 0 in (7.9 m) 1 ft 5 in (0.43 m)

3 ft 7 in (1.1 m) -20% 28 ft 6 in (8.7 m) 1 ft 7 in (0.48 m) 4 ft 2 in (1.2 m) -22% 30 ft 6 in (9.3 m) 1 ft 9 in (0.52 m) 4 ft 9 in (1.4 m) -24% 32 ft 3 in (9.8 m) 1 ft 10 in (0.57 m)

IMPORTANT: Numbers in table based on 105’ (32 m) minimum bend radius, beacon housing, EZConnect, connector, transition sub, and 1/3 of first drill pipe (L, totaling 8’ [2.4 m]) in the ground before steering.

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JT1220 Mach 1 Operator’s Manual Prepare - 71

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. Contact with trees, shrubs, or weeds during electrical strike could result in electrocution.

Mark Bore Path

Mark your planned bore path and all located utility lines with flags or paint.

Prepare Entry Point

For bore to be successful, first pipe must be straight as it enters the ground.

To help ensure that the first pipe does not bend, dig a small starting hole so that the first pipe is drilled into a vertical surface.

To prevent bending or straining pipe, position drilling unit for straight entry.

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Prepare - 72 JT1220 Mach 1 Operator’s Manual

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 129)

• transition sub

• anchoring equipment and accessories

• bits, screens, nozzles (see page 124)

• adapters, pipe, beacon housings

• marking flags or paint

• water and additional hoses

•fuel

• drilling fluid additives (see page 116)

•spare fuses

•keys

• backreamers, swivels, pulling devices (see page 124)

• wash down hose and spray gun

•duct tape

• spray lubricant

• tool joint compound (see page 157)

• electrically insulating boots and gloves

• personal protective equipment, such as hard hat and safety glasses

• notepad and pencil

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JT1220 Mach 1 Operator’s Manual Prepare - 73

Check Supplies and Prepare Equipment

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. The fire extinguisher should always be classified for both oil and electric fires. It should meet legal and regulatory requirements.

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Prepare - 74 JT1220 Mach 1 Operator’s Manual

Check Supplies and Prepare Equipment

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JT1220 Mach 1 Operator’s Manual Drive - 75

Drive

Chapter Contents

Start Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Steer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Shut Down Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

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Drive - 76 JT1220 Mach 1 Operator’s Manual

Start Unit

1. Insert key.

2. Turn key clockwise. See page 21 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.

To steer while moving backward, pull back and then move to left or right. Drilling unit will gradually turn to left or right.

c00ic145h.eps

For tight steering in low speed, move control to center position and then to a corner. Tracks will counterrotate and turn drilling unit in a tight circle.

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. 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.

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JT1220 Mach 1 Operator’s Manual Transport - 77

Transport

Chapter Contents

Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

• Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

• Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

Haul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

• Inspect Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

• Hitch Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

• Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

• Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

• Unload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

• Unhitch Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

Tow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

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Transport - 78 JT1220 Mach 1 Operator’s Manual

Lift

Crushing weight. If load falls or moves it could kill or crush you. Use

proper procedures and equipment or stay away.

Points

Lifting points are identified by lifting decals. Lifting at other points is unsafe and can damage machinery.

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JT1220 Mach 1 Operator’s Manual Transport - 79

Lift

Procedure

Use a crane capable of supporting the equipment's size and weight. See “Specifications” on page 185 or measure and weigh equipment before lifting.

1. Attach chains to four lift points (two on each side of drilling unit).

2. Install spacer blocks (shown) between the chain and the drilling unit as shown above.

3. Attach each chain securely to cross members.

IMPORTANT: Length of spreader bars should be equal to width of drilling unit.

4. Bring chains together to a central pull point.

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Transport - 80 JT1220 Mach 1 Operator’s Manual

Haul

Inspect Trailer

• Check hitch for wear and cracks. Lubricate if needed.

• Check u-bolts and axles for wear. Replace if needed.

• Check fasteners for wear and tightness. Replace or tighten if needed.

• Check battery for 12V charge.

• Inspect lights for cleanliness and correct operation. Inspect reflectors and replace if needed.

• Check tire pressure. Check lug nut tightness with a torque wrench. Adjust if needed.

• Ensure trailer brakes are adjusted to come on in synchronization with tow vehicle brakes.

• Check ramps and trailer bed for cracks.

Hitch Trailer

1. Back tow vehicle to trailer.

2. Put manual transmission into first or reverse gear or automatic transmission into park. Turn off ignition. Set parking brake.

3. Connect trailer drawbar, lunette or coupler to tow vehicle hitch and lock in place with lock pin. If needed, adjust drawbar, lunette or coupler height to level load.

4. Connect safety chains to tow vehicle.

5. Connect breakaway switch cable to tow vehicle. Do not connect to pintle hook or hitch ball.

6. Plug trailer electrical connector into tow vehicle connector.

7. Use jack crank to raise jack base and stow.

8. Remove wheel blocks.

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JT1220 Mach 1 Operator’s Manual Transport - 81

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.

With Tiedown Kit

1. Start drilling unit engine.

2. Move drilling unit to rear of trailer and align with ramps.

3. Slow engine to low throttle and slowly drive unit onto trailer until track reaches chock.

4. Lower drill frame to drill frame rest.

5. Back unit until front of drill frame is seated in rest.

6. Lower stabilizers to trailer floor.

7. Stop engine.

8. Attach tiedowns at rear of unit where indicated on page 82.

Without Tiedown Kit

1. Start drilling unit engine.

2. Move drilling unit to rear of trailer and align with ramps.

3. Slow engine to low throttle and slowly drive unit onto trailer.

4. Lower stabilizers to trailer floor.

5. Lower drill frame to trailer floor.

6. Stop engine when unit is safely positioned on trailer bed.

7. Attach tiedowns to drilling unit where indicated on page 82.

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Transport - 82 JT1220 Mach 1 Operator’s Manual

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 af ter eng ine shut down. En sure that any do wnhole tool or pi pe in tool joint vises is attached to spindle or removed before transport.

With Tiedown Kit

Loop tiedowns around rear tiedown points. Make sure tiedowns are ti ght before transporting.

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JT1220 Mach 1 Operator’s Manual Transport - 83

Haul

Without Tiedown Kit

Loop tiedowns around unit at tiedown points. Make sure tiedowns are tight before transporting.

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Transport - 84 JT1220 Mach 1 Operator’s Manual

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. Raise stabilizers.

5. Move drilling unit forward until track meets chock.

6. Raise drill frame.

7. Slow engine to low throttle and slowly back unit down trailer or ramps.

Without Tiedown Kit

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.

Unhitch Trailer

1. Stop tow vehicle and trailer on level ground.

2. Put manual transmission into first or reverse gear or automatic transmission into park. Turn off ignition. Set parking brake.

3. Block trailer wheels.

4. Reverse “Hitch Trailer “ steps to unhitch trailer from tow vehicle.

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JT1220 Mach 1 Operator’s Manual Transport - 85

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.

NOTICE: Do not open valves more than two turns.

To close bypass valves and return to normal operation, torque valve stems (shown) to 7-10 ft•lb (9.5-14

N•m).

NOTICE: Do not over-tighten bypass valves.

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Transport - 86 JT1220 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. If back tow points are facin g towing vehicle, loop chains through e ach tow point and bring them together to

a central pull point.

If front tow points are facing towing vehicle, loop chain through tow point and pull straight forward.

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JT1220 Mach 1 Operator’s Manual Conduct a Bore - 87

Conduct a Bore

Chapter Contents

Position Equipment . . . . . . . . . . . . . . . . . . . . . . . . 89

Connect Fluid System . . . . . . . . . . . . . . . . . . . . . . 89

Start System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Prime Drilling Fluid Pump . . . . . . . . . . . . . . . . . . . 90

Operate Carriage Control . . . . . . . . . . . . . . . . . . . 91

Clamp Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Assemble Drill String . . . . . . . . . . . . . . . . . . . . . . . 93

• Prepare Beacon Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

• Attach Transition Sub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

• Connect Drill Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

Drill First Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Enable Automated Pipeloader System . . . . . . . . 96

Add Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Correct Direction . . . . . . . . . . . . . . . . . . . . . . . . . . 99

• Basic Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

• Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

• Drill Head Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

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Conduct a Bore - 88 JT1220 Mach 1 Operator’s Manual

Record Bore Path . . . . . . . . . . . . . . . . . . . . . . . . . 100

Surface Drill Head . . . . . . . . . . . . . . . . . . . . . . . . 101

Assemble Backream String . . . . . . . . . . . . . . . . 102

Remove Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Remove Pullback Device . . . . . . . . . . . . . . . . . . . 105

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JT1220 Mach 1 Operator’s Manual Conduct a Bore - 89

Position Equipment

1. Review bore plan and select drilling unit position and fluid unit position. See “Select Start and End Points” on page 63.

2. Move equipment into selected positions.

Connect Fluid System

1. Connect fluid hose from mixing system to drilling fluid pump. A 1.5” (38 mm) or larger, non-collapsible hose is required.

2. Install y-strainer between mixing unit and drilling fluid pump. Position strainer so that drilling fluid flows in the direction of the arrow. In most cases, positioning strainer at outlet of mixing unit gives best results.

IMPORTANT: Clean y-strainer regularly. See page 166.

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Conduct a Bore - 90 JT1220 Mach 1 Operator’s Manual

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 121.

3. Press top of drilling unit throttle switch until engine is at full throttle. If you do not want to use autothrottle mode, return switch to center position.

4. Press and hold quick fill fluid pump switch until pipe fills and fluid pressure begins to rise.

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. Fill drilling fluid hose and connect hose to unit.

2. Operate mixing/transfer pump at full speed for 1 - 3 minutes to discharge air from system.

3. Return mixing/transfer pump to normal operating speed and continue the bore.

4. If drilling fluid pressure surges are observed, repeat step 2.

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JT1220 Mach 1 Operator’s Manual Conduct a Bore - 91

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.

Carriage Movement Rotation Direction

forward clockwise (makeup)

reverse counterclockwise (breakout)

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Conduct a Bore - 92 JT1220 Mach 1 Operator’s Manual

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 af ter eng ine shut down. En sure that any do wnhole tool or pi pe in tool joint vises is attached to spindle or removed before transport.

Clamp on pipe when joint is centered between wrenches (1 and 2). Always clamp on the larger diameter areas on either side of the tool joint face.

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JT1220 Mach 1 Operator’s Manual Conduct a Bore - 93

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 124 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. Install beacon housing lid. See “Beacon Housings” on page 125.

6. Follow beacon instructions to check beacon operation.

7. Follow tracker instructions to calibrate beacon.

Attach Transition Sub

Use either machine torque or quick wrench to attach transition sub (2) to beacon housing (1).

Machine Torque

1. Pull transition sub into front wrench.

2. Close wrench.

3. Lube joints.

4. Slowly make up joint.

5. Use full machine torque to tighten joint fully.

Quick Wrench

1. Lube joints with TJC.

2. Attach quick wrench to the joint in the join position and tighten joint. See “Quick Wrench” on p age 129.

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Conduct a Bore - 94 JT1220 Mach 1 Operator’s Manual

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 92.

4. Load pipe (4).

• Make sure pipe box is positioned correctly.

• Close grippers.

• Lubricate upper pipe threads.

• Move pipe to spindle. Verify that lower threads were lubricated as pipe moved to spindle.

• Raise pipe in box.

5. Connect pipe.

• Move carriage forward until saver sub nears male pipe thread.

• Slowly rotate spindle clockwise. Carriage will move forward as threads screw together.

• Slowly move carriage forward until pipe end touches end of transition sub.

• To screw pipes together and fully torque joint, slowly rotate drill pipe until spindle stops turning.

• Open wrench.

• Open grippers.

• Retract shuttles fully.

• Lower pipe lifters.

6. Close guides.

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JT1220 Mach 1 Operator’s Manual Conduct a Bore - 95

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. Turn drill bit to starting position. See “Prepare Entry Point” on page 71.

4. Slowly move carriage forward. Drill in downhole tools and 1/3 of first pipe before steering.

5. Monitor gauges.

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Conduct a Bore - 96 JT1220 Mach 1 Operator’s Manual

Enable Automated Pipeloader System

Add Pipe Remove Pipe

1. Make sure pipe box is properly positioned. See “Shift Pipe Box” on page 135.

2. Open front wrench, retract shuttles, and grip pipe for add pipe function to work.

3. Press top of add pipe/manual/remove pipe switch. Green control cycle light will come on.

4. Grippers will open, pipe will be lowered, and then green control cycle light will flash.

IMPORTANT: If you leave the seat during an add or remove pipe cycle, switch to manual control and finish pipe cycle. Then switch back to add pipe or remove pipe. If you leave the seat between add or remove pipe cycles, re-enabling system is not needed.

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 135.

1. Make sure pipe box is properly positioned. See “Shift Pipe Box” on page 135.

2. Open front wrench, retract shuttles, and grip pipe for remove pipe function to work.

3. Press bottom of add pipe/manual/remove pipe switch. Green control cycle light will come on.

4. Grippers will open, pipe will be lowered and lifted off shuttles, and then green control cycle light will flash.

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JT1220 Mach 1 Operator’s Manual Conduct a Bore - 97

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 135.

1. Press top of drilling unit throttle switch until engine is at full throttle.

2. Enable automated pipeloader system (automated pipeloader control only). See “Enable Automated Pipeloader System” on page 96.

3. Break joint at saver sub.

Manual Pipeloader Controls Automated Pipeloader Control

• Clamp pipe joint. See “Clamp Pipe” on page 92.

• Locate drill head.

• Engage front wrench until pipe is clamped and pressure develops.

• Slowly rotate spindle counterclockwise. Carriage will move back automatically as threads unscrew.

• After threads are fully unscrewed, stop rotation and move carriage to back of frame.

4. Load pipe.

Manual Pipeloader Controls Automated Pipeloader Control

• Make sure lift arms are completely lowered.

• Close grippers.

• Lube upper pipe threads.

• Move pipe to spindle and lube lower threads.

• Clamp pipe joint. See “Clamp Pipe” on page 92.

• Locate drill head.

• Engage front wrench until pipe is clamped and pressure develops.

• Slowly rotate spindle counterclockwise. Carriage will move back automatically as threads unscrew.

• After threads are fully unscrewed, stop rotation and move carriage to back of frame.

• While carriage is moving, green control cycle light will come on. Grippers will grip, pipe will be lubed, and then green control cycle light will flash.

• When carriage is moved to back of drill frame, press resume switch. Green control cycle light will come on.

• Pipe will be moved to spindle, front threads will be lubed, pipe in box will be lifted, and then green control cycle light will flash.

• Raise pipe in box.

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Conduct a Bore - 98 JT1220 Mach 1 Operator’s Manual

Add Pipe

5. Connect pipe to saver sub.

IMPORTANT: Always rotate clockwise unless breaking pipe joint. Rotating counterclockwise will unscrew joints.

• Move carriage forward until saver sub meets pipe.

• Slowly rotate spindle clockwise. Carriage will move forward automatically as threads screw together.

6. Connect new pipe.

Manual Pipeloader Controls Automated Pipeloader Control

• Slowly move carriage forward until pipe ends touch.

• To screw pipes together and fully torque joint, slowly rotate pipe until spindle stops turning and full pressure is developed.

• Open wrench.

• Open grippers.

• Retract shuttles fully.

• Lower pipe lifters.

7. Press and hold quick fill fluid pump switch until pipe fills and fluid pressure begins to rise.

8. Rotate spindle.

9. Slowly move carriage forward. Adjust rotation speed control according to bit size and soil conditions.

10. Engage and set cruise control as desired. See “Cruise Control” on page 140.

11. Monitor gauges.

12. Locate drill head with tracker at least every half-length of pipe.

• Slowly move carriage forward and rotate spindle until pipe screws together.

• To screw pipes together and fully torque joint, slowly rotate pipe until spindle stops turning and full pressure is developed.

• Open wrench.

• Press resume. Green control cycle light will come on.

• Grippers will open, shuttles will retract, pipe lifters will lower, and then green control cycle light will flash.

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JT1220 Mach 1 Operator’s Manual Conduct a Bore - 99

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. Corrections are made by tracking the drill head, comparing current position to bore plan, and steering drill head as needed.

Basic Rules

• Steering ability depends on soil condition; bit, drill head, and nozzle used; roll of drill head; and distance pushed without outer rot ation.

• All corrections should be made as gradually as possible. See “Recommended Bend Limits” on page 67.

• Over correcting will cause “snaking.” This can damage pipe and will make drilling and pullback more difficult. Begin to straighten out of each correction as early as possible.

• Do not push an entire piece of drill pipe into ground without rotation. This can exceed bend radius and cause pipe failure.

Procedure

1. Locate drill head. Take readings available with your beacon and locating equipment such as:

• depth

•pitch

• left/right information

• temperature

• beacon roll

2. Compare position to bore plan. Determine direction drilling should go.

3. Position drill head.

4. Push in drill pipe as needed to change direction.

5. Rotate in remaining length of drill pipe.

CMW

Ditch Witch JT1220 Mach 1 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Overview

Serial Number Location

Intended Use

Unit Components

Operator Orientation

About This Manual

Bulleted Lists

Numbered Lists

“Continued” Indicators

Foreword

Contents

Safety

Guidelines

Safety Alert Classifications

Safety Alerts

Emergency Procedures

Electric Strike Description

If an Electric Line is Damaged

If a Gas Line is Damaged

If a Fiber Optic Cable is Damaged

If Machine Catches on Fire

Controls

Set-Up Console

Tethered Ground Drive Controller

Left Control Console

Pipeloading Controls

Drilling/Operation Controls

Gauge Cluster

Unit Status Indicators

Pipeloading Status Indicators

Gauges

Right Control Console

Anchoring System Console

Seat/Armrest

Battery

ESID

Ditch Witch Electronics 750/752 Display

Indicators

Controls

Operation Overview

Planning

Setting Up at Jobsite

Drilling

Backreaming

Backreaming Tips

Leaving Jobsite

Storing Equipment

Prep are

Gather Information

Review Job Plan

Notify One-Call Services

Examine Pullback Material

Arrange for Traffic Control

Plan for Emergency Services

Inspect Site

Identify Hazards

Select Start and End Points

Classify Jobsite

Inspect Jobsite

Select a Classification

Apply Precautions

Plan Bore Path

Recommended Bend Limits

Entry Pitch

Minimum Setback

Minimum Depth

Bore Path Calculator

Prepare Jobsite

Mark Bore Path

Prepare Entry Point

Check Supplies and Prepare Equipment

Check Supplies

Prepare Equipment

Assemble Accessories

Drive

Start Unit