Ditch Witch JT20 User Manual

JT20

Operator’s

Manual

CMW®

Issue 1.0

053-2633

JT20 Operator’s Manual

Overview - 1

Overview

Chapter Contents

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

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

Equipment Modification . . . . . . . . . . . . . . . . . . . . . . 3

Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Operator Orientation. . . . . . . . . . . . . . . . . . . . . . . . . 5

About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 5

•	Bulleted Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5
•	Numbered Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5
•	“Continued” Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5

CMW®

Overview - 2

JT20 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

engine serial number

trailer serial number

CMW®

JT20 Operator’s Manual

Overview - 3

Intended Use

Intended Use

The JT20 is a self-contained horizontal directional drilling unit designed to install buried cable and pipe at distances to 400’ (122 m) depending on soil conditions.

The unit is designed for operation in temperatures typically experienced in earth moving and construction work environments. Provisions may be required to operate in extreme temperatures. Contact your Ditch

Witch® dealer. Use in any other way is considered contrary to the intended use.

The JT20 can be used with Ditch Witch drilling fluid units and Ditch Witch locating equipment. It should be operated, serviced, and repaired only by persons familiar with its particular characteristics and acquainted with the relevant safety procedures.

Equipment Modification

This equipment was designed and built in accordance with applicable standards and regulations. Modification of equipment could mean that it will no longer meet regulations and may not function properly or in accordance with the operating instructions. Modification of equipment should only be made by competent personnel possessing knowledge of applicable standards, regulations, equipment design functionality/requirements and any required specialized testing.

CMW®

Overview - 4

JT20 Operator’s Manual

Unit Components

Unit Components

	1			2
				3
	9
				4
	6		6	5
	8	7
j10om001h.eps
1.	Operator’s station	6.	Pipeloader
2.	Spindle	7.	Tracks
3.	Carriage	8.	Vise wrenches

4. Drill frame

9. Anchoring system

5. Stabilizer

CMW®

JT20 Operator’s Manual

Operator Orientation

Overview - 5

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®

Overview - 6

JT20 Operator’s Manual

About This Manual

CMW®

JT20 Operator’s Manual

Foreword - 7

Foreword

This manual is an important part of your equipment. It provides safety information and operation instructions to help you use and maintain your Ditch Witch® equipment.

Read this manual before using your equipment. Keep it with the equipment at all times for future reference. If you sell your equipment, be sure to give this manual to the new owner.

If you need a replacement copy, contact your Ditch Witch dealer. 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 published. For the latest information on Ditch Witch equipment, see your Ditch Witch dealer.

Thank you for buying and using Ditch Witch equipment.

CMW®

Foreword - 8	JT20 Operator’s Manual

JT20

Operator’s Manual

Issue number 1.0/OM-5/13

Part number 053-2633

Copyright 2013

by The Charles Machine Works, Inc.

, Ditch Witch, CMW, Jet Trac, Fluid Miser, and Power Pipe are registered trademarks of The Charles Machine Works, Inc.

This product is covered by one or more of the following patents:

U.S. B1 5490569; 5684466; 5713423; 5794719; 5880680; 5941322; 6085852; 6109371; 6179065; 6250403; 6250404; 6311790; 6411094; 6543551; 6550547; 6672409; 6739413; 6761231; 6808210; 6827158; 6848506; 6871712; 7011166; 7025152; 7413031; 7392858; 7018164; 7240742; 7600584; 8201644; RE37450; RE37975; RE38418; AU 689533; 706544; 718034; 755862; 2217899; DE 69417019; 69529634; 66942993; 60304320; 69728716; 602006008328. FR 674093; GB 2312006; EP674093; EP846841; JP 3458247; UK 0984132; 1466068; 817901; and other U.S. and foreign patents pending.

CMW®

JT20 Operator’s Manual

Contents - 9

Contents

Overview

1

machine serial number, information about the type of work this machine is designed to perform, basic machine components, and how to use this manual

Foreword

7

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

Safety	11
machine safety alerts and emergency procedures
Controls	25
machine controls, gauges, and indicators and how to use them
Operation Overview	21
an overview for completing a job with this machine: planning, setting up, installing
product, and restoring the jobsite; with cross references to detailed procedures
Prepare	59
procedures for inspecting and classifying the jobsite, planning the installation path,
and preparing the jobsite for work
Drive	75
procedures for startup, cold start, driving, and shutdown
Transport	79
procedures for lifting, hauling, and towing
Conduct a Bore	87
procedures for drilling and backreaming
Systems and Equipment	109
downhole tools and drill pipe, anchor, electric strike, tracker control, and fluid
systems
Complete the Job	151
procedures for restoring the jobsite and rinsing and storing equipment
Service	155
service intervals and instructions for this machine including lubrication, replacement
of wear items, and basic maintenance

CMW®

Contents - 10	JT20 Operator’s Manual
Specifications	185
machine specifications including weights, measurements, power ratings, and fluid
capacities
Support	189
the warranty policy for this machine, and procedures for obtaining warranty
consideration and training
Service Record	193
a record of major service performed on the machine

CMW®

JT20 Operator’s Manual

Safety - 11

Safety

Chapter Contents

Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Safety Alert Classifications . . . . . . . . . . . . . . . . . . 13

Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Emergency Procedures . . . . . . . . . . . . . . . . . . . . . 17

•	Electric Strike Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	17
• If an Electric Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		18
• If a Gas Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		19
• If a Fiber Optic Cable is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . .		20
•	If Machine Catches on Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	20

CMW®

Safety - 12

JT20 Operator’s Manual

Guidelines

Guidelines

Follow these guidelines before operating any jobsite equipment:

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

•Contact your local One-Call (811 in USA) or the One-Call referral number (888-258-0808 in USA and Canada) to have underground utilities located before digging. Also contact any utilities that do not participate in the One-Call service. Mark proposed path with white paint prior to contacting One-Call or utilities.

•Classify jobsite based on its hazards and use correct tools and machinery, 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 may be present.

•Contact your Ditch Witch dealer if you have any question about operation, maintenance, or equipment use.

CMW®

JT20 Operator’s Manual

Safety - 13

Safety Alert Classifications

Safety Alert Classifications

These classifications and the icons defined on the following pages work together to alert you to situations which could be harmful to you, jobsite bystanders or your equipment. When you see these words and icons in the book or on the machine, carefully read and follow all instructions. YOUR SAFETY IS AT STAKE.

Watch for the three safety alert levels: DANGER, WARNING and CAUTION. Learn what each level means.

indicates a hazardous situation that, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations.

indicates a hazardous situation that, if not avoided, could result in death or serious injury.

indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

Watch for two other words: NOTICE and IMPORTANT.

NOTICE indicates information considered important, but not hazard-related (e.g., messages relating to property damage).

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

CMW®

Safety - 14

JT20 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.

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 serious injury. Use proper procedures and equipment or stay away.

Moving parts could cut off hand or foot. Stay away.

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.

CMW®

JT20 Operator’s Manual

Safety Alerts

Safety - 15

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 and cause injury or death. Stay away.

Fire or explosion possible. Fumes could ignite and cause burns. No smoking, no flame, no spark.

Avoid static electricity when fueling. Ultra Low Sulfur Diesel (ULSD) poses a greater static ignition hazard than earlier diesel formulations. Avoid death or serious injury from fire or explosion. Consult with your fuel system supplier to ensure the delivery system is in compliance with fueling standards for proper grounding and bonding practices.

Moving traffic - hazardous situation. Death or serious injury could result. Avoid moving vehicles, wear high visibility clothing, post appropriate warning signs.

CMW®

Safety - 16

JT20 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 data sheets (MSDS).

Breathing crystalline silica dust may cause lung disease. Cutting, drilling, or working materials such as concrete, sand, or rock containing quartz may result in exposure to silica dust. Use dust control methods or appropriate breathing protection when exposed to silica dust.

CMW®

JT20 Operator’s Manual

Emergency Procedures

Emergency Procedures

Safety - 17

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

Before operating any equipment, review emergency procedures and check that all safety precautions have been taken.

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

Electric Strike Description

Electric shock. Contacting electric lines will cause death or serious injury. Know location of lines and stay away.

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. Many 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.

CMW®

Safety - 18

JT20 Operator’s Manual

Emergency Procedures

If an Electric Line is Damaged

If you suspect an electric line has been damaged and you are on drilling unit or bonded equipment, DO NOT MOVE. Remain on drilling machine 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 self test button.

•If alarm sounds again, stay where you are and wait 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 lights in strike indicator are on, assume strike is continuing and stay 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 equipment, DO NOT TOUCH ANY EQUIPMENT connected to drilling unit. Take the following actions. The order and degree of action will depend on the situation.

•Stay where you are unless you are wearing electric insulating boots. If you leave, do not return to area or allow anyone into area until given permission by electric company.

CMW®

JT20 Operator’s Manual

Safety - 19

Emergency Procedures

If a Gas Line is Damaged

Fire or explosion possible. Fumes could ignite and cause burns. No smoking, no flame, no spark.

Explosion possible. Serious injury or equipment damage could occur. Follow directions carefully.

If you suspect a gas line has been damaged, take the following actions. The order and degree of action will depend on the situation.

•Immediately shut off engine(s), if this can be done safely and quickly.

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

•Warn others that a gas line has been cut and that they should 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.

CMW®

Safety - 20

JT20 Operator’s Manual

Emergency Procedures

If a Fiber Optic Cable is Damaged

Do not look into cut ends of fiber optic or unidentified cable. Vision damage can occur.

If Machine Catches on Fire

Perform emergency shutdown procedure and then take the following actions. The order and degree of action will depend on the situation.

•Immediately move battery disconnect switch (if equipped and accessible) 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.

CMW®

JT20 Operator’s Manual

Operation Overview - 21

Operation Overview

Chapter Contents

Planning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Setting Up at Jobsite . . . . . . . . . . . . . . . . . . . . . . . 22

Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Backreaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Leaving Jobsite. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Storing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 24

CMW®

Operation Overview - 22

JT20 Operator’s Manual

Planning

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 80.

Setting Up at Jobsite

1.Prepare jobsite. See page 71.

2.Unload drilling unit from trailer. See page 83.

3.Assemble drill string. See page 93.

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

5.Assemble strike system. See page 113.

6.Anchor drilling unit. See page 111.

7.Connect fluid system. See page 89.

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

CMW®

JT20 Operator’s Manual

Drilling

Operation Overview - 23

Drilling

1.Start system. See page 90.

2.Engage tracker control if desired. See page 123.

3.Drill first pipe. See page 95.

4.Record bore path. See page 102.

5.Enable automated pipeloader system. See page 95.

6.Add pipe. See page 96.

7.Drill remaining pipes in pipe box.

•Correct direction. See page 98.

•Engage cruise control. See page 142.

•Shift pipe box. See page 137.

8.Add up to a single column of drill pipe to empty box (see page 137) to complete bore.

9.Surface drill head. See page 102.

CMW®

Operation Overview - 24

JT20 Operator’s Manual

Backreaming

Backreaming

1.Assemble backream string. See page 104.

2.Start drilling unit and adjust throttle.See page 76.

3.Set drilling fluid flow. Check that fluid flows through all nozzles. See page 119.

4.Remove pipe from bore. See page 105.

5.Remove up to a single column of drill pipe from full box (see page 128) to complete backream.

6.Remove pullback device. See page 107.

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 107.

2.Remove anchors. See page 111.

3.Rinse unit and downhole tools. See page 154.

4.Disassemble strike system and disconnect from fluid system. See page 154.

5.Stow tools. See page 154.

6.Load unit onto trailer. See page 80.

Storing Equipment

1.For cold weather storage, antifreeze drilling unit. See page 152.

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

CMW®

JT20 Operator’s Manual

Controls - 25

Controls

Chapter Contents

Set-Up Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Tethered Ground Drive Controller . . . . . . . . . . . . 29

Left Control Console . . . . . . . . . . . . . . . . . . . . . . . 31

•	Engine Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	31
•	Pipeloading controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	37
•	Drilling/Operation controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	41

Right Control Console . . . . . . . . . . . . . . . . . . . . . . 46

Anchoring System Console . . . . . . . . . . . . . . . . . 48

Seat/Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

ESID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

CMW®

Controls - 26

JT20 Operator’s Manual

Set-Up Console

Set-Up Console

9

j38om039w.eps

1.	Tracker control key				6.	Engine shutdown override switch
2.	Cold start wait indicator				7.	Right stabilizer control
3.	Ignition switch				8.	Frame tilt control
4.	Left track switch				9.	Left stabilizer control
5.	Right track switch
Item					Description		Notes
1.	Tracker control key				To allow tracker operator to		Remove key and keep in tracker
					stop thrust and rotation, move		operator’s possession.
					key to enable position (up).
					To override tracker control
					mode, move key to disable
					position (right).

CMW®

JT20 Operator’s Manual

Set-Up Console

Controls - 27

Item			Description	Notes
2. Cold start wait indicator			Lights when intake air pre-
			heater is operating.
			Wait until light goes off before
			starting engine.

3.	Ignition switch				To start engine, insert key and	Restart engine with ignition switch
					turn clockwise.	after it has been turned off with
					To stop engine, turn key	remote engine stop switch.
					counterclockwise.	If wrenches are engaged when
						engine is stopped with ignition switch,
						wrenches will release and then
						engage when unit is started.
4.	Left track switch				To move forward, press top.	Use track switches only if tethered
					To move backward, press	control is inoperable.
					bottom.

	c00ic147h.eps
5. Right track switch				To move forward, press top.	Use track switches only if tethered
				To move backward, press	control is inoperable.
				bottom.

	c00ic148h.eps
6. Engine shutdown		If engine shutdown indicator	This control allows a temporary
override switch		comes on, press to delay	override of engine shutdown.
		engine shutdown for 30	NOTICE: After 30 seconds, engine
		seconds.
			will again shut down unless fault
			condition has been cleared on
			diagnostic gauge. See “Electronic
			Controlled Engine Overview” on
			page 144.
	c00ic178h.eps

CMW®

Controls - 28

JT20 Operator’s Manual

Set-Up Console

Item					Description	Notes
7. Right stabilizer control					To raise, pull up.	Lower left and right stabilizers to the
						ground to stabilize unit and then
					To lower, push down.	adjust for side-to-side stability. After
						unit is level, adjust for entry angle.

8. Frame tilt control				To raise front end of drill
				frame, pull up.
				To lower front end of drill
				frame, push down.

9. Left stabilizer control							To raise, pull up.	Lower left and right stabilizers to the
								ground to stabilize unit and then
							To lower, push down.	adjust for side-to-side stability. After
								unit is level, adjust for entry angle.

CMW®

JT20 Operator’s Manual

Tethered Ground Drive Controller

Controls - 29

Tethered Ground Drive Controller

1

5

2

4

3

j10om016h.eps

1.

Speed/direction control

4.

Operator presence switch

2.

Power mode switch

5.

Throttle switch

3.

Remote engine stop

Item

Description

Notes

1.

Speed/direction control

To move forward, push.

Operator presence switch must be

pressed and operator seat must be

To move backward, pull.

empty for control to work.

To steer, move left or right.

c00ic145h.eps

CMW®