Ditch Witch JT1220 Mach 1 Operator's Manual
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
CMW
Overview - 2 JT1220 Mach 1 Operator’s Manual
Serial Number Location
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
CMW
JT1220 Mach 1 Operator’s Manual Overview - 3
Intended Use
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
9
j10om001h.eps
1. Operator’s station
2. Spindle
1
2
3
4
6
78
6. Pipeloader
7. Tracks
6
5
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
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.
CMW
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.
CMW
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
Copyright 2003, 2004, 2005, 2006
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.
CMW
JT1220 Mach 1 Operator’s Manual Contents - 7
Contents
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
1
5
9
19
55
59
75
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
77
87
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
CMW
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
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
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
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
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
CMW
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
CMW
Controls - 20 JT1220 Mach 1 Operator’s Manual
Set-Up Console
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.
c00ic147h.eps
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.
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
Tethered Ground Drive Controller
1
5
2
4
3
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
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 /
c00ic113h.eps
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
c00ic152h.eps
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.
CMW
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