Ditch Witch JT922 Operators Manual

JT922
Tier 4i
Operator’s
Manual
CMW®
Issue 1.0
053- 1298
JT922 Operator’s Manual
Overview - 1
Overview
Chapter Contents
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . 2
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operator Orientation. . . . . . . . . . . . . . . . . . . . . . . . . 5
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 5
•
Bulleted Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
•
Numbered Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
•
“Continued” Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
CMW
JT922 Operator’s Manual
Overview - 2
Serial Number Location
Serial Number Location
Record serial numbers and date of purchase in spaces provided. Drilling unit serial number is located as
shown.
Item
date of manufacture
date of purchase
drilling unit serial number
trailer serial number
engine serial number
CMW
JT922 Operator’s Manual
Overview - 3
Intended Use
Intended Use
The JT922 Mach 1 is a self-contained horizontal directional drilling unit designed to install buried cable and
pipe at distances to 300’ (90 m) depending on soil conditions and is intended for operation in ambient
temperatures from 0° to 115°F (-18° to 46°C). Use in any other way is considered contrary to the intended
use.
The JT922 Mach 1 can be used with Ditch Witch drilling fluid units and Ditch Witch locating equipment. 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
JT922 Operator’s Manual
Overview - 4
Unit Components
Unit Components
1. Operator’s station
6. Drill frame
2. Spindle
7. Tracks
3. Carriage
8. Vise wrenches
4. Drill pipe box
9. Anchoring system
5. Stabilizer
CMW
JT922 Operator’s Manual
Overview - 5
Operator Orientation
Operator Orientation
IMPORTANT: Top view of unit is shown.
1. Front of unit
2. Right side of unit
3. Rear of unit
4. Left side of unit
About This Manual
This manual contains information for the proper use of this machine. See the beige Operation Overview
pages for basic operating procedures. Cross references such as “See page 50” will direct you to detailed
procedures.
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
JT922 Operator’s Manual
About This Manual
CMW
JT922 Operator’s Manual
Foreword - 7
Foreword
This manual is an important part of your equipment. It provides safety information and operation
instructions to help you use and maintain your Ditch Witch equipment.
Read this manual before using your equipment. Keep it with the equipment at all times for future reference.
If you sell your equipment, be sure to give this manual to the new owner.
If you need a replacement copy, contact your Ditch Witch dealer. 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
JT922 Operator’s Manual
Foreword - 8
JT922 Tier 4i
Operator’s Manual
Issue number 1.0/OM-09/08
Part number 053-1298
Copyright 2008
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 registered 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
JT922 Operator’s Manual
Contents - 9
Contents
Overview
1
machine serial number, information about the type of work this machine is designed
to perform, basic machine components, and how to use this manual
Foreword
7
part number, revision level, and publication date of this manual, and factory contact
information
Safety
11
machine safety alerts and emergency procedures
Controls
21
machine controls, gauges, and indicators and how to use them
Operation Overview
45
an overview for completing a job with this machine: planning, setting up, installing
product, and restoring the jobsite; with cross references to detailed procedures
Prepare
49
procedures for inspecting and classifying the jobsite, planning the installation path,
and preparing the jobsite for work
Drive
65
procedures for startup, cold start, driving, and shutdown
Transport
69
procedures for lifting, hauling, and towing
Conduct a Bore
79
procedures for drilling and backreaming
Systems and Equipment
95
downhole tools and drill pipe, anchor, electric strike, tracker control, and fluid
systems
Complete the Job
125
procedures for restoring the jobsite and rinsing and storing equipment
Service
131
service intervals and instructions for this machine including lubrication, replacement
of wear items, and basic maintenance
CMW
Contents - 10
JT922 Operator’s Manual
Specifications
153
machine specifications including weights, measurements, power ratings, and fluid
capacities
Support
157
the warranty policy for this machine, and procedures for obtaining warranty
consideration and training
Service Record
a record of major service performed on the machine
CMW
161
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
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.
•
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
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 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.
CMW
Safety - 14
Safety Alerts
Safety Alerts
Turning shaft will kill you or crush arm or leg. Stay away.
Electric shock. Contacting electric lines will cause death or serious injury.
Know location of lines and stay away.
Deadly gases. Lack of oxygen or presence of gas will cause sickness or
death. Provide ventilation.
Moving tools will kill or injure. Shut off drill string power when anyone can be
struck by moving or thrown tools. Never use pipe wrenches on drill string.
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.
CMW
Safety - 15
Safety Alerts
Explosion possible. Serious injury or equipment damage could occur.
Follow directions carefully.
Incorrect procedures could result in death, injury, or property damage.
Learn to use equipment correctly.
Improper control function could cause death or serious injury. If control does
not work as described in instructions, stop machine and have it serviced.
Looking into fiber optic cable could result in permanent vision damage. 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.
Moving traffic - hazardous situation. Death or serious injury could result.
Avoid moving vehicles, wear high visibility clothing, post appropriate warning signs.
CMW
Safety - 16
Safety Alerts
Hot pressurized cooling system fluid could cause serious burns. Allow to
cool before servicing.
Flying objects may cause injury. Wear hard hat and safety glasses.
Hot parts may cause burns. Do not touch until cool.
Exposure to high noise levels may cause hearing loss. Wear hearing
protection.
Fall possible. Slips or trips may result in injury. Keep area clean.
Battery acid may cause burns. Avoid contact.
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).
CMW
Safety - 17
Emergency Procedures
Emergency Procedures
Jobsite hazards could cause death or serious injury. Use
correct equipment and work methods. Use and maintain proper safety
equipment.
Before operating any equipment, review emergency procedures and check that all safety precautions have
been taken.
EMERGENCY SHUTDOWN - Turn ignition switch to stop position or push remote engine stop button (if
equipped).
Electric Strike Description
Electric shock. 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
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 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 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.
•
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
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
Emergency Procedures
If a Fiber Optic Cable is Damaged
Do not look into cut ends of fiber optic or unidentified cable. Vision damage can occur.
If Machine Catches on Fire
Perform emergency shutdown procedure and then take the following actions. The order and degree of
action will depend on the situation.
•
Immediately move battery disconnect switch (if equipped) to disconnect position.
•
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
JT922 Operator’s Manual
Controls - 21
Controls
Chapter Contents
Set-Up Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Left Control Console . . . . . . . . . . . . . . . . . . . . . . . 24
Gauge Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Right Control Console . . . . . . . . . . . . . . . . . . . . . . 30
Anchoring System Console . . . . . . . . . . . . . . . . . 31
Seat/Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
ESID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
750/752 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
•
Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
•
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
CMW
JT922 Operator’s Manual
Controls - 22
Set-Up Console
Set-Up Console
1. left track control
4. Tracker control key
2. Right track control
5. Engine throttle control
3. Stabilizer and frame tilt control
Item
Description
1. Left track control
To move forward, push.
To move backward, pull.
To stop, move to center.
c00ic147h.eps
CMW
Notes
JT922 Operator’s Manual
Controls - 23
Set-Up Console
Item
Description
2. Right track control
To move forward, push.
Notes
To move backward, pull.
To stop, move to center.
c00ic148h.eps
3. Stabilizer and frame tilt
control
To raise stabilizer and
increase frame tilt, push.
Note: Stabilizer control lowers the
front of the drill frame along with the
stabilizer.
To lower stabilizer and
decrease frame tilt, pull.
4. Tracker control key
To allow tracker operator to
stop thrust and rotation, move
key to enable position (up).
IMPORTANT: Remove key and keep
in tracker operator’s possession.
To override tracker control
mode, move key to disable
position (right).
5. Engine throttle control
To increase engine speed,
push up.
To decrease engine speed,
pull down.
CMW
JT922 Operator’s Manual
Controls - 24
Left Control Console
Left Control Console
Drilling/Operation Controls
1. Auxiliary outlet
4. Wrench control
2. Ignition switch
5. Fluid flow control
3. Engine throttle control
Item
Description
Notes
1. Auxiliary outlet
Provides power for other
equipment.
Power output is 12V, 5A.
CMW
JT922 Operator’s Manual
Controls - 25
Left Control Console
Item
Description
2. Ignition switch
To start engine, insert key and
turn clockwise.
Notes
To stop engine, turn key
counterclockwise.
3. Engine throttle control
To increase engine speed,
push up.
To decrease engine speed,
pull down.
4. Wrench control
To clamp front wrench and
shut off drilling fluid, move
toward pipe box.
To unclamp front wrench,
move away from pipebox.
To clamp and rotate rear
(rotating) wrench, move
toward engine compartment.
To unclamp rear (rotating)
wrench, move toward seat.
5. Fluid flow control
To increase flow, turn
counterclockwise.
To decrease flow, turn
clockwise.
To stop flow, turn all the way
clockwise.
CMW
Controls - 26
JT922 Operator’s Manual
Gauge Cluster
Gauge Cluster
1. Drilling fluid pressure gauge
6. Hydraulic fluid temperature indicator
2. Thrust pressure gauge
7. Hydraulic filter service indicator
3. Rotation pressure gauge
8. Hourmeter
4. High temperature indicator
9. Fuel gauge
5. Engine oil pressure indicator
10. Cold start wait indicator
CMW
JT922 Operator’s Manual
Controls - 27
Gauge Cluster
Item
Description
1. Drilling fluid pressure
gauge
Displays drilling fluid pressure
supplied by drilling fluid
pump.
Notes
c00ic157h.eps
2. Thrust pressure gauge
Displays hydraulic fluid
pressure to thrust motor
during thrust and pullback.
Estimates thrust and pullback
force on lines outside gauge.
3. Rotation pressure
gauge
Displays hydraulic fluid
pressure to rotation motor
when spindle is turned
clockwise.
Estimates rotational torque on
lines outside gauge.
4. high temperature
indicator
Indicates engine is
overheating.
IMPORTANT: Alarms will sound when
engine overheats.
Stop engine and service unit.
c00ic120h.eps
CMW
JT922 Operator’s Manual
Controls - 28
Gauge Cluster
Item
Description
Notes
5. Engine oil pressure
indicator
Indicates engine oil pressure
is too low.
IMPORTANT: Alarms will sound when
engine oil pressure is too low.
Stop engine and check oil level.
6. Hydraulic fluid
temperature indicator
Indicates hydraulic fluid is
overheating.
•
Check hydraulic fluid level.
•
Check cooler for debris. See
page 141.
7. Hydraulic filter service
indicator
Indicates hydraulic fluid filter
needs replacing.
Change filter when indicator lights
continuously and as indicated on
page 146.
8. Hourmeter
Displays engine operating
time.
Use engine operating times to
schedule service.
CMW
JT922 Operator’s Manual
Controls - 29
Gauge Cluster
Item
Description
Notes
9. Fuel gauge
Displays fuel level in tank.
NOTICE: Use low sulfur or ultra low
sulfur fuel only.
Refer to engine operator’s manual for
cold weather fuel recommendations.
Tank holds 19 gal (72 L).
10. Cold start wait indicator
Lights when intake air preheater is operating.
Wait until light goes off before
starting engine.
CMW
JT922 Operator’s Manual
Controls - 30
Right Control Console
Right Control Console
1. Carriage control
2. Pipe lubricator button (optional)
Item
Description
1. Carriage control
To move carriage forward,
push.
To move carriage backward,
pull.
To rotate spindle
counterclockwise (breakout),
move right.
To rotate spindle clockwise
(makeup), move left.
2. Pipe lubricator button
(optional)
CMW
To apply joint compound to
threads at wrenches, press
button.
Notes
JT922 Operator’s Manual
Controls - 31
Anchoring System Console
Anchoring System Console
1. Left rotation control
3. Right rotation control
2. Left thrust control
4. Right thrust control
Item
Description
Notes
1. Left rotation control
To drive anchor, push down.
IMPORTANT: Stand on platform when
operating anchor controls.
To remove anchor, pull up.
CMW
JT922 Operator’s Manual
Controls - 32
Anchoring System Console
Item
Description
Notes
2. Left thrust control
To move anchor down, push
down.
IMPORTANT: Stand on platform when
operating anchor controls.
To move anchor up, pull up.
3. Right rotation control
To drive anchor, push down.
IMPORTANT: Stand on platform when
operating anchor controls.
To remove anchor, pull up.
4. Right thrust control
To move anchor down, push
down.
To move anchor up, pull up.
CMW
IMPORTANT: Stand on platform when
operating anchor controls.
JT922 Operator’s Manual
Controls - 33
Seat/Armrest
Seat/Armrest
1. Seat tilt latch
2. Seat leveling wheel
Item
Description
1. Seat tilt latch
To tilt seat forward for
transport, push knob.
Notes
To lower seat for operation,
pull knob.
2. Seat leveling wheel
To level seat when the unit is
set up on a side slope, turn
wheel.
CMW
JT922 Operator’s Manual
Controls - 34
Battery
Battery
1. Battery disconnect switch
Item
Description
1. Battery disconnect
switch
To disable battery power,
move switch to the
disconnect position.
To enable battery power,
move switch to the connect
position.
CMW
Notes
JT922 Operator’s Manual
Controls - 35
ESID
ESID
2
3
1
4
5
6
7
8
j07om042h.eps
1. Alphanumeric display
5. Current problem indicator
2. Strike indicator
6. OK indicator
3. Alarm interrupt button
7. Electrical power supply indicator
4. Voltage problem indicator
8. Self test button
Item
Description
1. Alphanumeric display
Display amount of current
and voltage being detected
as a percentage of strike
condition.
Notes
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).
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.
Remember that system can
go from one or two lights to
an electric strike immediately.
CMW
JT922 Operator’s Manual
Controls - 36
ESID
Item
Description
3. Alarm interrupt button
To turn off strike alarm at
drilling unit, press.
4. Voltage problem
indicator
Blinking red light indicates a
voltage indicator problem.
See “Troubleshoot Strike System” on
page 101.
5. Current problem
indicator
Blinking red light indicates a
current indicator problem.
See “Troubleshoot Strike System” on
page 101.
6. OK indicator
Green light means system
self test detected no
problems.
Strike system is ready to
operate.
CMW
Notes
JT922 Operator’s Manual
Controls - 37
ESID
Item
Description
7. Electrical power supply
indicator
Green light means control
box has sufficient electrical
power for operation.
Notes
Strike system is ready to
operate if OK indicator is also
on.
8. Self test button
To start manual self test,
press.
Checks all systems and circuits.
To reset system after a strike
has been detected, press.
NOTICE: See “If an Electric Line is
Damaged” on page 18.
CMW
JT922 Operator’s Manual
Controls - 38
750/752 Display
750/752 Display
Indicators
1. Beacon temperature display
5. Depth estimate
2. Pitch/slope indicator and percentage indicator
6. Display battery status indicator
3. Roll indicator
7. Beacon battery status indicator
4. Target indentifier indicator
8. Beacon temperature indicator
IMPORTANT: Some items operate differently depending where data is being saved. Internal refers to
pipe data being saved to 750 Display memory. External refers to pipe data being sent to a properly
connected laptop computer running a version of Trac Management System software.
Item
Description
1. Beacon temperature
display
Shows beacon temperature
readings in degrees Farenheit
and degrees Centigrade.
CMW
Notes
JT922 Operator’s Manual
Controls - 39
750/752 Display
Item
Description
Notes
2. Pitch/slope indicator
and percentage
indicator
Indicates pitch beacon
percent of grade.
Internal: shows pipe label and stored
pitch.
External: shows desired pitch.
3. Roll indicator
Indicates beacon roll angle.
4. Target identifier
indicator
Indicates approximate
beacon location.
Only one set of arrows is active at a
time.
5. Depth estimate
Indicates beacon depth
estimate.
Internal: shows job number and
stored depth.
External: shows desired depth.
CMW
JT922 Operator’s Manual
Controls - 40
750/752 Display
Item
Description
Notes
6. Display battery status
indicator
Indicates display power from
drilling unit.
If all bars are not showing, check
display power connections.
7. Beacon battery status
indicator
Indicates beacon battery
status.
See beacon instruction sheet.
8. Beacon temperature
indicator
Indicates beacon
temperature.
See beacon instruction sheet.
CMW
JT922 Operator’s Manual
Controls - 41
750/752 Display
Controls
1. Delete button
4. Roll stop button
2. On/Off button
5. Recall button
3. Channel select button
6. Store button
IMPORTANT: Some items operate differently depending where data is being saved. Internal refers to
pipe data being saved to 750 Display memory. External refers to pipe data being sent to a properly
connected laptop computer running a version of Trac Management System software.
Item
Description
Notes
1. Delete button
To delete current pipe, press.
Previous pipe number will appear in
numeric display when data is deleted.
Second function:
To delete all jobs in internal
logging memory, press with
Recall button.
CMW
JT922 Operator’s Manual
Controls - 42
750/752 Display
Item
Description
2. On/Off button
To turn on, press.
Notes
To turn off, press again.
3. Channel select button
To display current channel,
press and release.
Unit defaults to last channel used
each time unit is turned on.
To switch channels, press
and hold.
IMPORTANT: Make sure display and
tracker are set to the same channel.
Second function:
To start a new job, press with
Recall button.
“Init” and job number will be
displayed.
4. Roll stop button
This feature is not yet
available.
5. Recall button
To see data about pipe, press
and release.
Internal: shows data about previous
pipe.
Second function:
External: shows data about next pipe.
To access second functions,
press with other buttons.
CMW
JT922 Operator’s Manual
Controls - 43
750/752 Display
Item
Description
Notes
6. Store button
To display serial number,
press and hold while pressing
on/off button.
Pipe number will appear in numeric
display when data is stored.
To store current pipe data,
press.
IMPORTANT: Pipe data cannot be
stored without a valid depth estimate.
Second function:
To download all jobs stored in
internal logging memory:
•
Press with Recall button
•
Connect display to PC
running Trac
Management System
software.
CMW
Controls - 44
JT922 Operator’s Manual
750/752 Display
CMW
JT922 Operator’s Manual
Operation Overview - 45
Operation Overview
Chapter Contents
Planning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Setting Up at Jobsite . . . . . . . . . . . . . . . . . . . . . . . 46
Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Backreaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Leaving Jobsite. . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Storing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 47
CMW
Operation Overview - 46
JT922 Operator’s Manual
Planning
Planning
1. Gather information about jobsite. See page 51.
2. Inspect jobsite. See page 52.
3. Classify jobsite. See page 54.
4. Plan bore path. See page 56.
5. Check supplies and prepare equipment. See page 63.
6. Load equipment. See page 73.
Setting Up at Jobsite
1. Prepare jobsite. See page 62.
2. Unload drilling unit from trailer. See page 76.
3. Position drilling unit and frame. See page 81.
4. Assemble strike system. See page 99.
5. Anchor drilling unit. See page 97.
6. Calibrate tracker with beacon that will be installed in beacon housing. See tracker operator’s manual.
Drilling
1. Start system. See page 81.
2. Prime drilling fluid pump. See page 81.
3. Engage tracker control if desired. See page 110.
4. Assemble drill string. See page 84.
5. Drill first pipe. See page 86.
6. Record bore path. See page 89.
7. Add pipe. See page 87.
8. Drill remaining pipes in pipe box.
•
Correct direction. See page 88.
9. Surface drill head. See page 90.
CMW
JT922 Operator’s Manual
Operation Overview - 47
Backreaming
Backreaming
1. Assemble backream string. See page 91.
2. Start drilling unit and adjust throttle.
3. Set drilling fluid flow. Check that fluid flows through all nozzles.
4. Remove pipe from bore. See page 92.
5. Remove pullback device. See page 93.
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 93.
2. Remove anchors. See page 98.
3. Rinse unit and downhole tools. See page 128.
4. Disassemble strike system and disconnect from fluid system. See page 129.
5. Stow tools. See page 129.
6. Load unit onto trailer. See page 73.
Storing Equipment
1. For cold weather storage, antifreeze drilling unit. See page 126.
2. For long-term storage, disconnect battery disconnect switch.
CMW
Operation Overview - 48
JT922 Operator’s Manual
Storing Equipment
CMW
Manual
Prepare - 49
Prepare
Chapter Contents
Gather Information . . . . . . . . . . . . . . . . . . . . . . . . . 51
•
Review Job Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
•
Notify One-Call Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
•
Examine Pullback Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
•
Arrange for Traffic Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
•
Plan for Emergency Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Inspect Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
•
Identify Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
•
Select Start and End Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Classify Jobsite. . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
•
Inspect Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
•
Select a Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
•
Apply Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Plan Bore Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
•
Recommended Bend Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
•
Entry Pitch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
•
Minimum Setback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
•
Minimum Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
•
Bore Path Calculator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
CMW
Prepare - 50
Prepare Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
•
Mark Bore Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
•
Prepare Entry Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Check Supplies and Prepare Equipment . . . . . . . 63
•
Check Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
•
Prepare Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
•
Assemble Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
CMW
Manual
Manual
Prepare - 51
Gather Information
Gather Information
A successful job begins before the bore. The first step in planning is reviewing information already
available about the job and jobsite.
Review Job Plan
Review blueprints or other plans and make sure you have taken bore enlargement during backreaming
and pullback into account. Check for information about existing or planned structures, elevations, or
proposed work that may be taking place at the same time.
Notify One-Call Services
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.
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 information. 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.
CMW
Manual
Prepare - 52
Inspect Site
Inspect Site
Inspect jobsite before transporting equipment. Check for the following:
•
overall grade or slope
•
changes in elevation such as hills or open trenches
•
obstacles such as buildings, railroad crossings, or streams
•
signs of utilities (See “Inspect Jobsite” on page 54.)
•
traffic
•
access
•
soil type and condition
•
water supply
•
sources of locator interference (rebar, railroad tracks, etc.)
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 54.
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.
CMW
Manual
Prepare - 53
Inspect Site
Select Start and End Points
Select one end to use as a starting point. Consider the following when selecting a starting point:
Slope
Fluid system should be parked on a level site. Consider how slope will affect drilling unit setup, bending
pipe, and fluid flow out of hole.
Traffic
Vehicle and pedestrian traffic must be a safe distance from drilling equipment. Allow at least 10’ (3 m)
buffer zone around equipment.
Space
Check that starting and ending points allow enough space for gradual pipe bending. See “Minimum
Setback” on page 60.
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.
CMW
Manual
Prepare - 54
Classify Jobsite
Classify Jobsite
Inspect Jobsite
•
Follow U.S. Department of Labor regulations on excavating and trenching (Part 1926, Subpart P) and
other similar regulations.
•
Contact your local One-Call (811 in USA) or the One-Call referral number (888-258-0808 in USA and
Canada) to have underground utilities located before digging. Also contact any utilities that do not
participate in the One-Call service.
•
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
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.
CMW
Manual
Prepare - 55
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
Cutting, drilling, or working materials such as concrete, sand, or rock containing quartz may result in
exposure to silica dust. Use water spray or other means to control dust. If workers are exposed to dust
they must wear appropriate breathing protection. Silica dust may cause lung disease and is known to the
State of California to cause cancer.
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.
CMW
Prepare - 56
Manual
Plan Bore Path
Plan Bore Path
Plan the bore path, from entry to end, before drilling begins. The Ditch Witch Trac Management System
Plus is available for planning your bore path. This special software can be run in the field using a laptop
computer equipped with Windows® 95 or higher operating system. See your Ditch Witch dealer for details.
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 path 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
•
minimum depth
IMPORTANT: See the following pages for more information about these measurements. If not using
Trac Management System Plus, see “Bore Path Calculator” on page 61 and use these measurements to
help plan your bore.
CMW
Manual
Prepare - 57
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 JT922 drill pipe, make sure pitch (A)
changes no more than 6% 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 38.
Bend Radius
JT922 drill pipes have a tested minimum bend radius
of 105’ (32 m). This means that a 90-degree 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.
CMW
Manual
Prepare - 58
Plan Bore Path
Pipe-By-Pipe Bend Limits
Pipe
(C)
Forward (B)
Deflection (A)
Pipe
(C)
Forward (B)
Deflection (A)
1
6 ft 0 in (1.8 m)
0 ft 2 in (0.1 m)
15
79 ft 5 in (24.3 m)
36 ft 3 in (11.1 m)
2
12 ft 0 in (3.7 m)
0 ft 8 in (0.2 m)
16
83 ft 2 in (25.4 m)
40 ft 11 in (12.5 m)
3
17 ft 11 in (5.5 m)
1 ft 6 in (0.5 m)
17
86 ft 8 in (26.2m)
45 ft 9 in (13.9 m)
4
23 ft 9 in (7.2 m)
2 ft 9 in (0.8 m)
18
89 ft 11 in (27.4m)
50 ft 10 in (15.5 m)
5
29 ft 7 in (9 m)
4 ft 3 in (1.3 m)
19
92 ft 11 in (28.3m)
56 ft 0 in (17 m)
6
35 ft 4 in (10.8 m)
6 ft 1 in (1.8 m)
20
95 ft 6 in (29.2m)
61 ft 5 in (18.7 m)
7
40 ft 11 in (12.5 m)
8 ft 3 in (2.5 m)
21
97 ft 10 in (29.9m)
66 ft 11 in (20.4 m)
8
46 ft 4 in (14.1 m)
10 ft 9 in (3.2 m)
22
99 ft 11 in (30.5m)
72 ft 7 in (22.2 m)
9
51 ft 8 in (15.7 m)
13 ft 7 in (4.2 m)
23
101 ft 7 in (31m)
78 ft 4 in (23.9 m)
10
56 ft 9 in (17.3 m)
16 ft 8 in (5.1 m)
24
102 ft 11 in (31.4m)
84 ft 2 in (25.7 m)
11
61 ft 9 in (18.8 m)
20 ft 1 in (6.2 m)
25
103 ft 11 in (31.7m)
90 ft 1 in (27.5 m)
12
66 ft 6 in (20.3 m)
23 ft 9 in (7.2 m)
26
104 ft 7 in (31.9m)
96 ft 1 in (29.4 m)
13
71 ft 0 in (21.6 m)
27 ft 8 in (8.4 m)
27
105 ft 0 in (32m)
102 ft 1 in (31.2 m)
14
75 ft 4 in (23 m)
31 ft 10 in (9.8 m)
27.5
105 ft 0 in (32m)
105 ft 0 in (32 m)
CMW
Manual
Prepare - 59
Plan Bore Path
Pipe 14 is illustrated.
CMW
Prepare - 60
Manual
Plan Bore Path
Entry Pitch
Entry pitch is the slope of the drill frame compared with the slope of the ground. Determine entry pitch one
of two ways:
1. With Pitch Beacon
•
Lay pitch beacon on the ground and read
pitch.
•
Lay pitch beacon on drill frame and read pitch.
•
Subtract ground pitch from drilling unit pitch.
2. With Measurements
•
Measure from the ground to front end of drill
frame (H1).
•
Measure from the ground to back end of frame
(H2).
•
Subtract (H1) from (H2). 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.
CMW
Manual
Prepare - 61
Plan Bore Path
Minimum Depth
Because you must bend pipe gradually, entry pitch and
bend limits determine how deep the pipe will be when
it becomes horizontal. This is called the minimum
depth.
•
To reduce minimum depth (D1), reduce entry
pitch. This also decreases setback.
•
To increase minimum depth (D2), increase
entry pitch. This also increases setback.
Bore Path Calculator
Entry pitch, setback, and minimum depth work together with bend limits to determine the bore path. 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)
2 ft 9 in (0.8 m)
-18%
24 ft 6 in (7.5 m)
1 ft 1 in (0.33 m)
3 ft 3 in (1.0 m)
-20%
26 ft 6 in (8.1 m)
1 ft 2 in (0.36 m)
3 ft 9 in (1.1 m)
-22%
28 ft 5 in (8.7 m)
1 ft 3 in (0.38 m)
4 ft 4 in (1.3 m)
-24%
30 ft 4 in (9.2 m)
1 ft 5 in (0.43 m)
4 ft 7 in (1.4 m)
-25%
31 ft 3 in (9.5 m)
1 ft 5 in (0.43 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, totalling 8’ [2.4 m]) in the ground before
steering.
CMW
Manual
Prepare - 62
Prepare Jobsite
Prepare Jobsite
Jobsite hazards could cause death or serious injury. Use
correct equipment and work methods. Use and maintain proper safety
equipment.
NOTICE:
•
If jobsite classification is in question or if the possibility of unmarked electric utilities exists, classify
jobsite as electric.
•
Cutting high voltage cable can cause electrocution. Expose lines by hand before digging.
•
All vegetation near operator’s station must be removed. 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.
CMW
Manual
Prepare - 63
Check Supplies and Prepare Equipment
Check Supplies and Prepare Equipment
Check Supplies
•
receiver/transmitter or tracker with spare batteries
•
beacons with new and spare batteries
•
two-way radios with new and spare batteries
•
quick wrench (see page 118)
•
transition sub
•
anchoring equipment and accessories
•
bits, screens, nozzles (see page 113)
•
adapters, pipe, beacon housings
•
marking flags or paint
•
water and additional hoses
•
fuel (Use low sulfur or ultra low sulfur fuel only.)
•
drilling fluid additives (see page 105)
•
spare fuses
•
keys
•
backreamers, swivels, pulling devices (see page 113)
•
wash down hose and spray gun
•
duct tape
•
spray lubricant
•
tool joint compound (see page 134)
•
electrically insulating boots and gloves
•
personal protective equipment, such as hard hat and safety glasses
•
notepad and pencil
CMW
Prepare - 64
Manual
Check Supplies and Prepare Equipment
Prepare Equipment
Fluid Levels
•
fuel (Use low sulfur or ultra low sulfur fuel only.)
•
hydraulic fluid
•
battery charge
•
engine oil
Condition and Function
•
filters (air, oil, hydraulic)
•
fluid pump
•
couplers
•
tires and tracks
•
pumps and motors
•
drilling fluid mixer
•
hoses and valves
•
water tanks
Assemble Accessories
Fire Extinguisher
If required, mount a fire extinguisher near the power unit but away from possible points of ignition. The fire
extinguisher should always be classified for both oil and electric fires. It should meet legal and regulatory
requirements.
CMW
JT922 Operator’s Manual
Drive - 65
Drive
Chapter Contents
Start Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Steer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Shut Down Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
CMW
Drive - 66
JT922 Operator’s Manual
Start Unit
Start Unit
1. Insert key.
2. Turn key clockwise. See page 25 for more information.
3. Run engine at low throttle for 5 minutes.
Steer Unit
To steer drilling unit, follow instructions for type of steering desired. See page 22 for more information.
To steer while moving forward, move one control slightly more than the other to turn in the desired
direction. Drilling unit will gradually turn to left or right.
To steer while moving backward, move one control slightly more than the other to turn in the desired
direction. Drilling unit will gradually turn to left or right.
For tight steering at low speed, one control to reverse and one control to forward to turn in the desired
direction. Tracks will counter-rotate and turn drilling unit in a tight circle.
Tips to Reduce Track Wear
Rubber tracks are best suited at soil-based job sites with minimal rock and debris. Sharp objects such as
gravel, steel shards, and broken concrete will damage rubber tracks and undercarriage components.
Excessive operation on concrete or asphalt will shorten track life. When storing your machine, keep tracks
away from rain and direct sunlight.
Wash tracks daily to remove foreign objects and abrasive soil from sprockets and idler rollers. Drive slowly
and make wide turns when possible. Regularly check undercarriage components (sprocket, rollers, idler)
for wear and damage. Maintain proper track tension. (See “Check Track Tension and Condition” on
page 151.)
To prevent premature wear, avoid the following:
•
Spinning tracks under heavy load.
•
Turning on sharp objects such as stones, stumps and debris.
•
Quick turns or “spin” turns on asphalt or concrete.
•
Driving over curbs, ledges, and sharp objects.
•
Driving with sidewall edges pressed against hard walls, curbs or other objects.
•
Driving on slopes.
•
Operating on corrosive materials such as salt or fertilizer. Wash immediately.
CMW
JT922 Operator’s Manual
Drive - 67
Shut Down Unit
Shut Down Unit
1. Stop track movement.
2. Lower drill frame and stabilizer to the ground.
IMPORTANT: If frame and stabilizer cannot be lowered, use cylinder locks or other suitable
material to block the tracks. Remove cylinder locks or chocks before driving unit.
3. Run engine at low throttle for 3 minutes to cool.
4. Turn key to STOP.
5. Remove key.
CMW
Drive - 68
JT922 Operator’s Manual
Shut Down Unit
CMW
JT922 Operator’s Manual
Transport - 69
Transport
Chapter Contents
Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
•
Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
•
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Haul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
•
Inspect Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
•
Hitch Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
•
Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
•
Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
•
Unload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
•
Unhitch Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Tow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
CMW
Transport - 70
JT922 Operator’s Manual
Lift
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.
CMW
JT922 Operator’s Manual
Transport - 71
Lift
Procedure
Use a crane capable of supporting the equipment's size and weight. See “Specifications” on page 153 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.
CMW
Transport - 72
JT922 Operator’s Manual
Haul
Haul
Inspect Trailer
NOTICE: Read operation manual included with trailer prior to using trailer.
•
Check hitch for wear and cracks. Lubricate if needed.
•
Check suspension 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.
CMW
JT922 Operator’s Manual
Transport - 73
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.
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 stabilizer and drill frame to trailer floor.
5. Stop engine when unit is safely positioned on trailer bed.
6. Attach tiedowns to drilling unit where indicated on page 74.
CMW
Transport - 74
JT922 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 after engine shutdown. Ensure that any downhole tool or pipe in tool joint
vises is attached to spindle or removed before transport.
CMW
JT922 Operator’s Manual
Transport - 75
Haul
Attach chains at front and rear tie-down points (shown). Make sure chains are tight before transporting
unit.
IMPORTANT: Drill frame must be lowered to trailer floor before attaching chains.
CMW
JT922 Operator’s Manual
Transport - 76
Haul
Unload
Crushing weight. If load falls or moves it could kill or crush you. Use
proper procedures and equipment or stay away.
NOTICE:
•
Load and unload trailer on level ground.
•
Ensure trailer wheels are blocked.
•
Attach trailer to vehicle before loading or unloading.
1. Lower ramps.
2. Remove tiedowns.
3. Start drilling unit engine.
4. Raise stabilizers.
5. Raise drill frame.
6. Slow engine to low throttle and slowly back unit down trailer or ramps.
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.
CMW
JT922 Operator’s Manual
Transport - 77
Tow
Tow
Under normal conditions, drilling unit should not be towed. If unit breaks down and towing is necessary:
•
Tow for short distances at less than 1 mph (1.6 kph).
•
Attach chains to indicated tow points facing towing vehicle.
•
Use maximum towing force of 1.5 times unit weight.
•
disengage power to tracks.
IMPORTANT: When hydraulics are disengaged, unit has no brakes.
To disengage track hydraulics:
1. Loosen locknut (B).
2. Turn screw (A) on each counterbalance valve
clockwise until it stops.
IMPORTANT: Be sure to count number of
turns.
3. Repeat on other track.
To engage track hydraulics:
1. Turn screw (A) on counterbalance exactly
same number of turns counterclockwise.
2. Tighten locknut (B).
3. Repeat on other track.
To attach chains to tow points, determine which points are facing towing vehicle.
Loop chains around crossmember (either front or
back) on drill frame.
CMW
Transport - 78
JT922 Operator’s Manual
Tow
CMW
JT922 Operator’s Manual
Conduct a Bore - 79
Conduct a Bore
Chapter Contents
Position Equipment . . . . . . . . . . . . . . . . . . . . . . . . 81
Connect Fluid System . . . . . . . . . . . . . . . . . . . . . . 81
Start System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Prime Drilling Fluid Pump . . . . . . . . . . . . . . . . . . . 81
Operate Carriage Control . . . . . . . . . . . . . . . . . . . 82
Clamp Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Assemble Drill String . . . . . . . . . . . . . . . . . . . . . . . 84
•
Prepare Beacon Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
•
Attach Transition Sub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
•
Connect Drill Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Drill First Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Add Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Correct Direction . . . . . . . . . . . . . . . . . . . . . . . . . . 88
•
Basic Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
•
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
•
Drill Head Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
CMW
Conduct a Bore - 80
JT922 Operator’s Manual
Record Bore Path . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Surface Drill Head . . . . . . . . . . . . . . . . . . . . . . . . . 90
Assemble Backream String . . . . . . . . . . . . . . . . . 91
Remove Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Remove Pullback Device . . . . . . . . . . . . . . . . . . . . 93
CMW
JT922 Operator’s Manual
Conduct a Bore - 81
Position Equipment
Position Equipment
1. Review bore plan and select drilling unit position and fluid unit position. See “Select Start and End
Points” on page 53.
2. Move equipment into selected positions.
Start System
1. Start drilling unit and remote fluid unit. Allow both engines to warm up.
IMPORTANT: Ensure that mixture of drilling fluid matches drilling conditions.
2. Enable tracker control mode if desired. See “Tracker Control” on page 110.
3. Set engine to full throttle.
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.
CMW
JT922 Operator’s Manual
Conduct a Bore - 82
Operate Carriage Control
Operate Carriage Control
The thrust/rotation control has eight positions which allow the four basic
functions to be combined. The chart below summarizes functions that occur
when control is put at a combined position. Operator must be in seat for
control to function.
CMW
Carriage Movement
Rotation Direction
forward
clockwise (makeup)
reverse
counterclockwise (breakout)
JT922 Operator’s Manual
Conduct a Bore - 83
Clamp Pipe
Clamp Pipe
Turning shaft can kill you or crush arm or leg. Stay away.
NOTICE: Clamping anywhere else on the pipe will weaken the pipe. Pipe can later break,
even when operating under normal loads.
Incorrect procedures could result in death, injury, or property damage.
Learn to use equipment correctly.
NOTICE: Wrenches can open after engine shutdown. Ensure that any downhole tool or pipe 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.
CMW
Conduct a Bore - 84
JT922 Operator’s Manual
Assemble Drill String
Assemble Drill String
Prepare Beacon Housing
1. Select nozzles and bit.
IMPORTANT: A variety of nozzles and bits
are available to suit your particular job
conditions. See “Downhole Tools” on
page 113 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 114.
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 (3) 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 page 118.
CMW
JT922 Operator’s Manual
Conduct a Bore - 85
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 83.
4. Lift pipe box latches.
NOTICE: If drilling unit is set up in a side-slope,
the rear pipe box latch should be left latched to
help ensure that upper rows of drill pipe do not
fall.
5. Load pipe (4).
•
Lubricate upper pipe threads.
•
Move pipe to spindle. Move pin end of pipe into saver sub and release pipe to rest rear wrench.
Lubricate lower threads.
6. 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.
7. Close guides.
CMW
JT922 Operator’s Manual
Conduct a Bore - 86
Drill First Pipe
Drill First Pipe
Turning shaft can kill you or crush arm or leg. Stay away.
NOTICE:
•
Keep everyone at least 10’ (3 m) away from turning drill string.
•
Push rod or pipe slowly. Forcing can bend string. Do not use bent rod or pipe.
Jobsite hazards could cause death or serious injury. Use
correct equipment and work methods. Use and maintain proper safety
equipment.
1. Turn on drilling fluid.
2. Visually check for drilling fluid flow.
3. Turn drill bit to starting position. See “Prepare Entry Point” on page 62.
4. Slowly move carriage forward. See “Prepare Entry Point” on page 62. Take care to steer to drill
straight in line with drilling unit. Drill in downhole tools and 1/3 of first pipe before steering.
5. Monitor gauges.
CMW
JT922 Operator’s Manual
Conduct a Bore - 87
Add Pipe
Add Pipe
1. Set engine throttle to full speed.
2. Clamp pipe joint. See “Clamp Pipe” on page 83.
3. Locate drill head.
4. Engage front wrench until pipe is clamped and pressure develops.
5. Slowly rotate spindle counterclockwise. Move carriage back as threads unscrew.
6. After threads are fully unscrewed, stop rotation and move carriage to back of frame, slowing down as
carriage approaches rear end.
7. Connect Pipe. See “Connect Drill Pipe” on page 85.
8. Ensure that pipe fills and fluid pressure begins to rise.
9. Rotate spindle.
10. Slowly move carriage forward. Adjust rotation speed control according to bit size and soil conditions.
11. Monitor gauges.
12. Locate drill head with tracker at least every half-length of pipe.
CMW
Conduct a Bore - 88
JT922 Operator’s Manual
Correct Direction
Correct Direction
Correcting direction is a skill operators gain with experience and knowledge of equipment and soil
conditions. These instructions cover only basic procedures. For information about specific equipment or
jobsites, contact your Ditch Witch dealer.
To track progress and make corrections, one crew member locates the drill head and sends instructions to
the operator. 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 rotation.
•
All corrections should be made as gradually as possible. See “Recommended Bend Limits” on
page 57.
•
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
JT922 Operator’s Manual
Conduct a Bore - 89
Record Bore Path
Drill Head Position
The drill head position is determined by reading
beacon roll. Roll is displayed as a clock face
position.
1. Read beacon roll.
2. Slowly rotate pipe until locator displays desired
beacon roll.
To change direction:
1. Rotate pipe to clock position you intend to travel.
2. Push pipe into ground.
To move forward without changing direction:
Rotate pipe into ground.
Record Bore Path
Locate drill head every half-length of pipe. As the job is completed, record the actual data for each drill
pipe. List pitch and depth of each joint and a brief description of the procedure. In addition, draw a simple
sketch of the site and record depth and rough location of pullback.
The Trac Management System Plus is also available for plotting and tracking your bore path. It utilizes the
750 Tracker, 750 Display, a tracking beacon, and special software. The display can store jobs in its
memory or the system can be run in the field using a laptop computer equipped with the Windows® 95 or
higher operating system. See your Ditch Witch dealer for details.
CMW
Conduct a Bore - 90
JT922 Operator’s Manual
Surface Drill Head
Surface Drill Head
Moving tools will kill or injure. Shut off drill string power when anyone can
be struck by moving or thrown tools. Never use pipe wrenches on drill string.
1. Guide drill head to target pit or up through surface. Make all bends gradual. See “Recommended
Bend Limits” on page 57.
2. Clean area around exit point.
3. If using tracker control mode, tracker operator turns off tracker to disable drilling unit thrust/pullback
and rotation hydraulics. Tracker operator waits for green light to enter pit and change tools.
If not using tracker control mode, tracker operator signals to drilling unit operator to stop engine before
changing downhole tools.
4. Turn fluid flow control to off position as soon as drill head emerges.
5. Clean drill head especially around threads.
6. Disconnect EZ-Connect joint or use quick wrench to remove drill head. Keep threads clean. See
“Quick Wrench” on page 118.
CMW
JT922 Operator’s Manual
Conduct a Bore - 91
Assemble Backream String
Assemble Backream String
Turning shaft will kill you or crush arm or leg. Stay away.
NOTICE: Keep everyone away from material being installed.
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.
NOTICE: Continue to use strike system during backreaming.
1. Select backreaming devices. See “Backreamers” on page 115.
2. Determine fluid rate requirements and install appropriate nozzles to provide sufficient flow. See
“Backream Fluid Requirements” on page 116 and “Nozzles” on page 113.
3. Attach backreamer to backream beacon housing if tracking backream.
4. Install beacon, following beacon instructions for:
•
battery replacement
•
beacon positioning
5. Install beacon housing lid. See “Beacon Housings” on page 114.
6. Follow beacon instructions to check beacon operation.
7. Follow tracker instructions to calibrate beacon.
8. Connect EZ-Connect joint or use quick wrench to attach backreamer/beacon housing assembly to
transition sub. See “Quick Wrench” on page 118.
9. Attach swivel and additional pullback devices or product to end of backreamer/beacon housing
assembly.
CMW
Conduct a Bore - 92
JT922 Operator’s Manual
Remove Pipe
Remove Pipe
NOTICE: If engine is shut off during backreaming, drill pipe clamped by wrenches but not connected to
saver sub can be pulled downhole as vise wrenches loosen.
1. Stop carriage when pipes are aligned in wrenches.
2. Clamp pipe in front wrench. See page 83.
3. Clamp and rotate rear wrench to break front joint. See “Wrench control” on page 25.
4. Disengage rear wrench.
5. Unscrew front joint.
•
Slowly rotate spindle counterclockwise to unscrew pipe. Move carriage back slowly until threads
unscrew.
•
Move carriage back until pipe is properly positioned in rear wrench.
6. Break rear joint.
•
Engage rear wrench.
•
Slowly rotate spindle counterclockwise until joint is loosened. Do not fully unscrew joint.
•
Disengage rear wrench.
•
Move carriage back, move seat toward pipe and grip pipe with both hands.
•
Pull pin end of pipe clear of saver sub, lift pipe and stow it in box.
7. Lube front threads.
8. Attach saver sub to next pipe.
•
Move carriage forward until saver sub touches pipe.
•
Rotate spindle to screw onto pipe. Slowly tighten joint to full machine torque.
9. Disengage front wrench to release pipe.
CMW
JT922 Operator’s Manual
Conduct a Bore - 93
Remove Pullback Device
Remove Pullback Device
The pullback device can be removed when the last pipe is on the frame. It can also be removed when a
target pit along the bore path has been reached. Remaining pipe is then pulled back and removed.
Moving tools will kill or injure. Shut off drill string power when anyone can
be struck by moving or thrown tools. Never use pipe wrenches on drill string.
1. Turn off drilling fluid.
2. Move engine throttle to low speed.
3. Turn drilling unit engine off.
4. Use tracker control to verify that unit is turned off.
5. Clean pullback device.
6. Use quick wrench to remove pullback device. See “Quick Wrench” on page 118.
CMW
Conduct a Bore - 94
JT922 Operator’s Manual
Remove Pullback Device
CMW
JT922 Operator’s Manual
Systems and Equipment - 95
Systems and Equipment
Chapter Contents
Anchor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
•
Drive Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
•
Remove Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Electric Strike System . . . . . . . . . . . . . . . . . . . . . . 99
•
FCC Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
•
Assemble Voltage Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
•
Test Strike System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
•
Troubleshoot Strike System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
•
Use Electric Strike Simulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Drilling Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
•
Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
•
Polymer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
•
Bentonite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
•
Mixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
•
Basic Fluid Recipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
•
Drilling Fluid Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
•
Funnel Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Tracker Control . . . . . . . . . . . . . . . . . . . . . . . . . . 110
•
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
•
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
CMW
Systems and Equipment - 96
JT922 Operator’s Manual
Downhole Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 113
•
Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
•
Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
•
Beacon Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
•
Backreamers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
•
Backream Fluid Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Quick Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Drill Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
•
Perform Regular Drill Pipe Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
•
Use Drill Pipe Correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
CMW
JT922 Operator’s Manual
Systems and Equipment - 97
Anchor System
Anchor System
Crushing weight. If load falls or moves, it could kill or crush
you. Use proper procedures and equipment or stay away.
NOTICE:
•
Drive anchors properly before drilling.
•
Stand on platform when operating anchor controls.
•
Wear high-top protective boots with legs of pants completely tucked inside.
•
Wear protective gloves.
•
If you are not driving two anchors to full depth, drive optional ground rod into soil away from drilling
unit and connect ground rod to drilling unit.
Turning shaft can kill you or crush arm or leg. Stay away.
NOTICE: Do not replace anchor collar bolt with one longer than original. Clothing could
catch on turning shaft.
CMW
Systems and Equipment - 98
JT922 Operator’s Manual
Anchor System
Drive Anchors
IMPORTANT: Carefully time anchor rotation
with anchor movement. Properly driven
anchors should thread into soil and should
not auger up soil.
1. Use anchor rotation and thrust controls to
drive anchor into ground.
2. Anchor is set when cap top plate (1) rests
firmly on centering tube (2).
3. Repeat process for other anchor.
Remove Anchors
1. Use anchor rotation and thrust controls to
slowly remove anchor shaft from ground.
2. Repeat process for other anchor.
CMW
JT922 Operator’s Manual
Systems and Equipment - 99
Electric Strike System
Electric Strike System
Any time you drill in an electric jobsite, electric strike system must be properly set up, tested, and used.
You must wear protective boots and gloves meeting the following standards:
•
Boots must have high tops and meet the electric hazard protection requirements of ANSI Z-41, 1991,
when tested at 14,000 volts. Tuck legs of pants completely inside boots.
•
Gloves must have 17,000 AC maximum use voltage, according to ASTM specification D120-87.
If working around higher voltage, use gloves and boots with appropriately higher ratings.
NOTICE: The strike system does not prevent electric strikes or detect strikes before they occur. If
alarms are activated, a strike has already occurred and equipment is electrified.
Read and follow “Electric Jobsite Precautions” on page 55. Review safety procedures before each job.
FCC Statement
The Electric Strike System has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the
FCC rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated
in a commercial environment. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used
in accordance with the instructions, can cause harmful interference to radio communications. Operation of this equipment in a
residential area could cause harmful interference which the user will be required to correct at his own expense.
Changes or modifications not expressly approved in writing by The Charles Machine Works, Inc. may void the user's authority to
operate this equipment.
CMW
Systems and Equipment - 100
JT922 Operator’s Manual
Electric Strike System
Assemble Voltage Detector
1. Drive voltage stake into ground at least 6’
(2 m) away from any part of system.
2. Clip voltage limiter to voltage stake.
Test Strike System
If system fails any part of this test, see “Troubleshoot Strike System” on page 101 on the following page.
Do not drill until test is completed successfully.
1. Turn on drilling unit.
2. ESID control module will perform internal tests which check everything but alarms and strobe.
3. If green OK indicator and electrical power supply indicator lights remain on, press self test button to
perform total test of strike system. During this test:
•
All lights should glow.
•
Alphanumeric readout should display numbers.
•
Alarms and strobes on all connected units should sound.
4. If this test is successful, OK indicator and electrical power supply indicator lights will remain on.
5. Use Electric Strike Simulator to test voltage and current sensors. See page 103.
CMW
JT922 Operator’s Manual
Systems and Equipment - 101
Electric Strike System
Troubleshoot Strike System
When strike system detects a problem, an error code will be displayed. Anytime this happens, press self
test button to retest. If error code is still displayed and does not appear in this chart, have control module
checked or replaced.
Other problem situations and their possible causes and solutions are listed in the chart below.
Problem
Possible cause
Possible solution
No lights or readings
showing after drilling unit
key has been on at least
one minute
Problems in startup
Push self test button. If problem goes
away, retest strike system
No power to strike system
control module
Check drilling unit electric system
Check that harness from drilling unit
to control module is connected
Check that cable from drilling unit
carries more than 10V
Screen is blank
Defective control module
Have control module checked or
replaced
Strike system is not getting
adequate power from drilling
unit
Check drilling unit electric system
Check that harness from drilling unit
to control module is connected
Check that harness from drilling unit
carries more than 10V
Defective control module
Have control module checked or
replaced
Information on screen is
visible during self test but
not after test is complete
LCD contrast is not set properly
Contact your Ditch Witch dealer to
adjust contrast
OK indicator is on, but
electrical power supply
indicator is off
Strike system is not getting
adequate power from drilling
unit
Check drilling unit electric system
Check that harness from drilling unit
to control module is connected
Check that harness from drilling unit
carries more than 10V
Electrical power supply
indicator is on, but OK
indicator is off
Defective control module
Have control module checked or
replaced
Problem detected during test
Check for error code and have control
module checked or replaced
Defective control module
Have control module checked or
replaced
CMW
JT922 Operator’s Manual
Systems and Equipment - 102
Electric Strike System
Problem
Possible cause
Possible solution
Strobe light on drilling unit
does not work during total
test
Improper connections with
control module
Check connections and wiring
harness
Defective strobe light
1. Disconnect strobe and connect to
external 12V power source.
2. If strobe does not work, replace it.
Alarm on drilling unit does
not work during total test
Defective control module
Have control module checked or
replaced
Improper connections with
control module
Check connections and wiring
harness
Defective alarm
1. Disconnect strobe and connect to
external 12V power source.
2. If strobe does not work, replace it.
Defective control module
Have control module checked or
replaced
Strobe light and alarm on
drilling unit do not work
during total test
Improper connections with
control module
Check connections and wiring
harness
Defective control module
Have control module checked or
replaced
EC2 code displays and
current problem indicator is
on
Improper connections with
control module
Check cable connections on control
module and current transformer
Defective current transformer
1. Disconnect current transformer.
2. Check for 20-40 ohms from pin 1
to pin 4, 20-40 ohms from pin 1 to
pin 2, and less than 1 ohm from
pin 2 to pin 4.
Defective current transformer
cable
1. Disconnect cable from
transformer and control module.
2. Check continuity of cable.
3. If continuity is zero or cable is
damaged, replace.
EV1 code displays and
voltage problem indicator is
on
CMW
Defective control module
Have control module checked or
replaced
Improper connection of voltage
limiter to ground stake
Check voltage limiter connection to
ground stake and verify that ground
stake is driven into the ground
Defective voltage limiter
Have voltage limiter checked or
replaced
Defective control module
Have control module checked or
replaced
JT922 Operator’s Manual
Systems and Equipment - 103
Electric Strike System
Problem
Possible cause
Possible solution
EV2 code displays and
voltage problem indicator is
on
Improper connections with
control module
Check cable connection on control
module
Defective voltage limiter
Have voltage limiter checked or
replaced
Defective control module
Have control module checked or
replaced
Use Electric Strike Simulator
Use the Electric Strike Simulator (p/n 259-506) to test voltage and current sensors on ESID. If readings are
less than indicated here, replace 9V battery in simulator and retest.
Current Test
To test for current at normal levels:
1. Thread one lead wire through current transformer.
2. Clip ends of lead wires together to make one loop.
3. Move simulator switch to "current" and press test button.
4. Watch screen and lights above display on strike system.
•
Three or four lights should turn on.
•
Current "A" should show 30-50% in display.
CMW
Systems and Equipment - 104
JT922 Operator’s Manual
Electric Strike System
To test for current at strike levels:
1. Put two or three loops through current transformer.
2. Follow steps above to test.
3. Display should show the following:
•
All lights should turn on.
•
Alarm and strobe should turn on.
With two loops,
•
Current "A" should be 80-110%.
•
Strike indication might go on and off.
With three loops,
•
Current should be 130-160%.
•
Strike indication should be continuous.
Voltage Test
1. Place voltage limiter on something insulated from ground and drilling unit (such as dry board or tire),
but near frame of drilling unit.
2. Clip one lead to frame.
3. Clip other lead to one voltage limiter mount.
4. Move simulator switch to "voltage" and press test button.
5. Watch screen and lights above display on strike system.
•
All lights should turn on.
•
Alarm and strobe should turn on.
•
Voltage "V" should show 90-110%.
It is normal for simulator voltage levels to drift below strike level. When this happens, light in triangle should
go off and alarm and strobe should stop working. If the level drifts above strike level again, light, alarm, and
strobe should be turned on again.
CMW
JT922 Operator’s Manual
Systems and Equipment - 105
Drilling Fluid
Drilling Fluid
For productive drilling and equipment protection, use these recommended Baroid® products, available
from your Ditch Witch dealer.
•
Soda ash
•
Quik-Gel™ dry powder bentonite (p/n 259-804)
•
E-Z Mud™ liquid polymer (p/n 259-805)
•
Liqui-Trol™ liquid polymer suspension (p/n 259-808)
•
Quik-Trol™ dry powder polymer (p/n 259-809)
•
Bore-Gel™ drilling fluid (p/n 259-807)
•
Con-Det™ water-soluble cleaning solution (p/n 259-810)
Guidelines
Match drilling fluid to soil type. This chart is meant as a guideline only. See your local Ditch Witch dealer for
soil conditions and drilling fluid recommendations for your area. Also see our interactive Drilling Fluid
Formulator at www.ditchwitch.com.
Soil type
Drilling fluid recommendation
smooth, flowing sand
bentonite or Bore-Gel + medium chain polymer
coarse sand or light soil
bentonite or Bore-Gel
heavy clay
long chain polymer + Con-Det
swelling clay
long chain polymer + Con-Det
rock
Bore-Gel
Polymer
This drilling fluid additive provides excellent lubrication and increases viscosity in average soils and heavy
clay. In swelling clay, polymer can reduce swelling that traps pipe in the bore.
There are two types of polymer:
•
long chain such as Baroid EZ-Mud
•
medium chain such as Baroid Quik-Trol
CMW
Systems and Equipment - 106
JT922 Operator’s Manual
Drilling Fluid
Bentonite
Bentonite is a dry powder. When properly mixed with water, it forms a thin cake on bore walls, lubricating
the bore, keeping it open, and holding fluid in the bore.
Some things to remember when mixing bentonite:
•
Use clean water free of salt, calcium, or excessive chlorine.
•
Use water with pH level between 9 and 10.
•
Use water with hardness of less than 120 ppm.
•
Do not use bentonite containing sand.
•
Mix bentonite thoroughly or it will settle in tank.
•
Do not mix bentonite to a funnel viscosity of over 50.
For information on measuring funnel viscosity, see “Funnel Viscosity” on page 109.
Mixtures
Bentonite does not mix well in water containing polymer. To use both, mix bentonite first, then add polymer.
When adding other products follow the order listed below.
NOTICE:
•
If chemicals are added in the wrong order, they will not mix properly and will form clumps.
•
If tank contains bentonite/polymer mix and more drilling fluid is needed, completely empty tank and
start with fresh water before mixing another batch.
General mixing order:
1. Soda ash
2. Bentonite
3. Polymer
4. Con-Det
Bore-Gel contains premixed bentonite, polymer, and soda ash. Use approximately 15 lb/100 gal (7 kg/380
L) in normal drilling conditions, up to 45 lb/100 gal (21 kg/380 L) in sand or gravel and up to 50 lb/100 gal
(23 kg/380 L) in rock.
CMW
JT922 Operator’s Manual
Systems and Equipment - 107
Drilling Fluid
Basic Fluid Recipes
Soil type
Mixture/100 gal (378 L) of water
Notes
fine sand
35 lb (16 kg) Bore-Gel
coarse sand
35 lb (16 kg) Bore-Gel
.5 lb (225 g) No-Sag
Add .5 lb (225 g) of Quik-Trol for
additional filtrate control
fine sand below water
table
40 lb (18 kg) Bore-Gel
.75 lb (340 g) Quik-Trol
Add .5 - 1 gal (2-4 L) of Dinomul in high
torque situations
coarse sand below
water table
40 lb (18 kg) Bore-Gel
.75 lb (340 g) Quik-Trol
.75 lb (340 g) No-Sag
Add .5 - 1 gal (2-4 L) of Dinomul in high
torque situations
gravel
50 lb (23 kg) Bore-Gel
.75 lb (340 g) Quik-Trol
.75 lb (340 g) No-Sag
Add .5 lb (225 g) of Barolift to reduce loss
of returns
cobble
50 lb (23 kg) Bore-Gel
.75 lb (340 g) Quik-Trol
.75 lb (340 g) No-Sag
Add .5 lb (225 g) of Barolift to reduce loss
of returns
sand, gravel, clay or
shale
35 - 40 lb (16-18 kg) Bore-Gel
.5 pt (235 mL) EZ-Mud
.5 gal (2 L) Con-Det
Vary mixture according to percentage of
sand and clay
clay
.5 lb (225 g) Poly Bore
.5 gal (2 L) Con-Det
Flow rate should be 3-5 parts fluid to 1
part soil. May use .25 - .5 gal (1-2 L) of
Penetrol instead of Con-Det
swelling/sticky clay
.75 - 1 lb (340-450 g) Poly Bore
.5 - 1 gal (2-4 L) Con-Det
Flow rate should be 3-5 parts fluid to 1
part soil. May use .25 - .5 gal (1-2 L) of
Penetrol instead of Con-Det
solid rock (shale)
40 lb (18 kg) Bore-Gel
Use .5 pt (235 mL) of No Sag for large
diameter or longer bores
solid rock (other than
shale)
40 - 50 lb (18-23 kg) Bore-Gel
Use .5 pt (235 mL) of EZ-Mud in reactive
shales
rock/clay mixture
40 - 50 lb (18-23 kg) Bore-Gel
.5 pt (235 mL) EZ-Mud
rock/sand mixture
40 - 50 lb (18-23 kg) Bore-Gel
Use .5 pt (235 mL) of No Sag for large
diameter or longer bores
fractured rock
50 lb (23 kg) Bore-Gel
.5 - 1lb (225-450 g) No-Sag
Use .5 lb (225 g) of Barolift to reduce fluid
loss to formation
CMW
Systems and Equipment - 108
JT922 Operator’s Manual
Drilling Fluid
Drilling Fluid Requirements
1. Determine drilling conditions and choose appropriate drilling fluid mix.
2. Estimate amount of supplies needed and check availability.
•
Drilling fluid
•
Water supply. If more water than can be carried with the unit will be needed, arrange to transport
additional water.
•
Bentonite and/or polymer
3. Check water quality.
•
Use meter or pH test strips to test pH of water. If pH is below 9.0, add 1 lb (454 g) soda ash per
tank. Test and repeat until pH is between 9 and 10.
•
Check water hardness using hardness test strips. Treat with soda ash if hardness exceeds 125
ppm.
CMW
JT922 Operator’s Manual
Systems and Equipment - 109
Drilling Fluid
Funnel Viscosity
Viscosity is the measure of internal resistance of a fluid to flow; the greater the resistance, the higher the
viscosity. Viscosity of drilling fluids must be controlled.
To determine viscosity, you will need a Marsh funnel (p/n 259-267) and a measuring cup, available from
your Ditch Witch dealer.
IMPORTANT: Make sure Marsh funnel is clean and free of obstruction and that you have a stopwatch
available for timing the viscosity.
1. Using wash hose and a clean container, take a
fresh sample of drilling fluid. The sample must
be at least 1.5 qt (1.4 L).
2. With finger over bottom of funnel, fill with fluid
from the container through the screen until
fluid reaches the bottom of the screen.
3. Move funnel over 1 qt (.95 L) container.
4. Remove finger from bottom of funnel and use
the stopwatch to count the number of seconds
it takes for 1 qt (.95 L) of fluid to pass through
the funnel. The number of seconds is the
viscosity.
5. Thoroughly rinse measuring cup and Marsh
funnel.
CMW
Systems and Equipment - 110
JT922 Operator’s Manual
Tracker Control
Tracker Control
Overview
Incorrect procedures could result in death, injury, or property damage.
Learn to use equipment correctly.
This mode allows the tracker operator to disable hydraulic power to drilling unit thrust and rotation.
NOTICE: This mode does not disable thrust and rotation immediately. Functions are disabled within 16
seconds.
Use tracker control any time you change downhole tools or during other times when the drill string is
exposed. Tracker control works by stopping communication between the tracker and the display. When
this happens, the green tracker control light on the drilling unit comes on and thrust and rotation are
disabled.
Operation
Enable Thrust and Rotation
1. Start drilling unit.
2. Turn off 750 Display.
3. Press and hold DOWNLOAD (1) while
turning on 750 Display until a four-digit
code (2) appears.
CMW
JT922 Operator’s Manual
Systems and Equipment - 111
Tracker Control
4. Turn on 750 Tracker and check four-digit
code.
If codes on tracker and display match, thrust
and rotation hydraulics on the drilling unit are
enabled.
If codes on tracker and display do not match,
adjust tracker code:
•
Press and hold fore/aft/left/right button
while making the following adjustments.
•
Use ON/OFF to advance first two digits
(1). Use DEPTH to lower first two digits.
•
Use up arrow to advance last two digits
(2). Use down arrow to lower last two
digits.
•
Press and hold each button to advance or lower value quickly.
•
To start sending code from the tracker to the display, press and hold fore/aft/left/right button and
press MODE. Thrust and rotation hydraulics on the drilling unit are now enabled.
Troubleshooting Tip: If thrust and rotation are
not enabled:
•
Check whether the green tracker
control light located on drilling unit
anchoring console is on. If it is,
communication has probably stopped
between tracker and display, or tracker
is set to incorrect code.
•
If communication cannot be restored,
install tracker control key (shown) in
drilling unit. Green tracker control light
located on anchoring console will go
off. Thrust and rotation will function.
5. Remove tracker control key (shown) from set-up console at rear of drilling unit. Keep in tracker
operator’s possession.
6. Drill and track bore.
CMW
Systems and Equipment - 112
JT922 Operator’s Manual
Tracker Control
Disable Thrust and Rotation
1. When drill head enters target pit or exits the
ground, turn off tracker.
After 8-16 seconds, green tracker control light
(shown), located on drilling unit anchoring
console, will come on. Hydraulic power to
thrust and rotation will be disabled.
2. Turn engine off.
IMPORTANT: Tracker operator cannot
disable thrust and rotation from tracker if
tracker control key (shown) is installed in
drilling unit and turned to the disable
position. See “Tracker control key” on
page 23 for more information.
NOTICE: If you are not using tracker control,
turn off drilling unit before changing
downhole tools.
3. Change downhole tools.
4. If you are tracking backreamer’s path,
turn on tracker and enable code transmission. After 8-16 seconds, green tracker control light on drilling
unit anchoring console will go off and thrust and rotation will function.
If you are not tracking backreamer’s path, install tracker control key (shown) on drilling unit. Green
tracker control light on drilling unit anchoring console will go off and thrust and rotation will function.
CMW
JT922 Operator’s Manual
Systems and Equipment - 113
Downhole Tools
Downhole Tools
Nozzles
Nozzles control fluid flow from the pipe to the bore. Select nozzles that will supply at least the amount of
fluid per minute needed for the flow and pressure you will be using. A nozzle that will supply more fluid per
minute is recommended. See your Ditch Witch dealer for nozzle recommendations.
Bits
Selection
These charts are meant as a guideline only. No one bit works well in all conditions. See your Ditch Witch
dealer for soil conditions and bit recommendations for your area. Also see our interactive Downhole Tool
Selector at www.ditchwitch.com.
•
1 = best
•
2 = good
•
3 = fair
•
4 = not recommended
Bit
Sandy
Soil
Soft Soil
Medium
Soil
Hard
Soil
Rocky
Soil
Soft
Rock
Hard
Rock
Sand bit
1
2
4
4
4
4
4
Durabit
2
2
1
1
4
4
4
Tuff bit
2
1
1
1
2
3
4
Steep Taper Tuff bit
4
3
2
1
1
2
4
Barracuda bit
2
1
1
2
3
4
4
Steep Taper bit
4
3
2
1
1
2
4
Hard Surface bit
2
1
2
3
4
4
4
Glacier bit
4
4
4
3
1
2
4
Rhino bit
4
4
3
3
1
1
3
Jetting assembly
4
4
3
2
1
2
3
Rockmaster
4
4
3
2
1
1
1
Talon Rock bit
4
3
2
1
1
1
4
CMW
Systems and Equipment - 114
JT922 Operator’s Manual
Downhole Tools
Soil
Description
sandy soil
sugar sand, blow sand, or other soils where sand is the predominant component
soft soil
sandy loam
medium soil
loams, loamy clays
hard soil
packed clays, gumbo, all compacted soils
rocky soil
chunk rock, glacial till, cobble, rip rap, gravel
soft rock
soft limestone, sandstone, shale, coral, caliche
hard rock
granite, schist, marble, hard limestone
Installation
Remove all paint from mating surfaces before attaching any bit to housing. Install screws (p/n 107-277)
and torque to 120 ft•lb (163 N•m).
Beacon Housings
Beacon Installation
To ensure beacon is installed correctly in housing, place battery end of beacon away from bit end of
housing.
CMW
JT922 Operator’s Manual
Systems and Equipment - 115
Downhole Tools
Backreamers
A backreamer enlarges the hole as pipe is pulled back through the bore. No one backreamer works well in
all conditions. These charts are meant as a guideline only. See your local Ditch Witch dealer for soil
conditions and backreamer recommendations for your area.
•
1 = best
•
2 = good
•
3 = fair
•
4 = not recommended
Backreamer
Sandy
Soil
Soft Soil
Medium
Soil
Hard
Soil
Rocky
Soil
Soft
Rock
Hard
Rock
Beavertail
3
1
1
1
3
4
4
Three Wing
4
3
3
2
1
1
4
Water Wing
4
3
2
1
2
2
4
Compact Fluted
1
1
2
2
2
3
4
Kodiak
4
3
3
2
1
2
4
Rhino Rock
4
4
4
4
3
2
1
Rockmaster
4
4
4
4
3
1
1
Compaction
Cone
1
2
3
4
4
4
4
HC Hard
Condition
4
3
2
1
1
4
4
ST Saw Tooth
2
2
1
2
2
3
4
MX Mixer
2
2
3
4
4
4
4
CT Cutter
3
2
1
2
3
4
4
EX Expander
1
2
3
4
4
4
4
Fluted Cone
1
1
2
2
2
3
4
IMPORTANT: For soil definitions, see the chart on the previous page.
CMW
JT922 Operator’s Manual
Systems and Equipment - 116
Downhole Tools
Backream Fluid Requirements
Backreaming is only successful when enough fluid reaches the bore. The amount of fluid needed depends
on size of bore and soil condition.
Follow these steps to find the minimum amount of fluid needed in perfect conditions.
IMPORTANT: Use more fluid than recommended or the backream might be dry and unsuccessful.
Instructions
Example
1. Find amount of fluid needed for your size of
backreamer. See the table on the next page.
U.S. A 6” backreamer requires at least 1.47
gal/ft.
Metric A 152-mm backreamer requires at least
18.24 L/m.
2. Multiply this number by distance per minute
you plan to backream. The answer is an
estimate of amount of fluid you will need for
each minute of backreaming.
U.S. 1.5 gal x 2 ft/min = 3 gal for each minute of
backreaming.
Metric 18 L x .5 m/min = 9 L for each minute of
backreaming
IMPORTANT: After you have determined how much fluid you will need, see your Ditch Witch dealer for
nozzle recommendations.
CMW
JT922 Operator’s Manual
Systems and Equipment - 117
Downhole Tools
Backream Fluid Requirements
Backreamer/product
diameter
Gal/ft
L/m
Backreamer/product
diameter
Gal/ft
L/m
.5 in
13 mm
0.01
0.13
13.5 in
343 mm
7.44
92.35
1 in
25 mm
0.04
0.51
14 in
356 mm
8.00
99.31
1.5 in
38 mm
0.09
1.14
14.5 in
368 mm
8.58
106.54
2 in
51 mm
0.16
2.03
15 in
381 mm
9.18
114.01
2.5 in
64 mm
0.25
3.17
15.5 in
394 mm
9.80
121.74
3 in
76 mm
0.37
4.56
16 in
406 mm
10.44
129.72
3.5 in
89 mm
0.5
6.21
16.5 in
419 mm
11.11
137.95
4 in
102 mm
0.65
8.11
17 in
432 mm
11.79
146.44
4.5 in
114 mm
0.83
10.26
17.5 in
445 mm
12.49
155.18
5 in
127 mm
1.02
12.67
18 in
457 mm
13.22
164.17
5.5 in
139 mm
1.23
15.33
18.5 in
470 mm
13.96
173.42
6 in
152 mm
1.47
18.24
19 in
483 mm
14.73
182.92
6.5 in
165 mm
1.72
21.41
19.5 in
495 mm
15.51
192.68
7 in
178 mm
2.00
24.83
20 in
508 mm
16.32
202.68
7.5 in
190 mm
2.29
28.50
20.5 in
521 mm
17.15
212.94
8 in
203 mm
2.61
32.43
21 in
533 mm
17.99
223.46
8.5 in
216 mm
2.95
36.61
21.5 in
546 mm
18.86
234.23
9 in
229 mm
3.30
41.04
22 in
559 mm
19.75
245.25
9.5 in
241 mm
3.68
45.73
22.5 in
572 mm
20.65
256.52
10 in
254 mm
4.08
50.67
23 in
584 mm
21.58
268.05
10.5 in
267 mm
4.50
55.86
23.5 in
597 mm
22.53
279.83
11 in
289 mm
4.94
61.31
24 in
610 mm
23.50
291.86
11.5 in
292 mm
5.40
67.01
24.5 in
622 mm
24.49
304.15
12 in
305 mm
5.88
72.97
25 in
635 mm
25.50
316.69
12.5 in
318 mm
6.37
79.17
25.5 in
648 mm
26.53
329.49
13 in
330 mm
6.90
85.63
26 in
660 mm
27.58
342.53
CMW
Systems and Equipment - 118
JT922 Operator’s Manual
Quick Wrench
Quick Wrench
To attach or remove downhole tools, use quick wrench to join or break the joint.
Moving tools will kill or injure. Shut off drill string power when anyone can
be struck by moving or thrown tools. Never use pipe wrenches on drill string.
IMPORTANT: Apply TJC to threads and hand-tighten joint before attaching quick wrench components to
tighten joint.
Attach quick wrench in either the join or break position.
Join
Break
•
Unbolt vise (1) and place jaws around pipe.
•
Bolt jaws of vise together.
•
Place jaw (2) around pipe.
•
Pin handles (3) to wrench jaws. Be sure handles are both up.
•
Attach pivot nuts (4) to wrench handles so that screw drive handle (5) is over joint.
CMW
JT922 Operator’s Manual
Systems and Equipment - 119
Quick Wrench
To Join
1. Scribe straight line across joint on both
sides of separating line (A).
2. Scribe second line (B) on moveable side of
joint in the opposite direction of tightening
action .25” (6 mm) away from first line.
3. Turn handle until second line (B) meets first
(A).
4. Turn handle opposite direction two turns to
relieve pressure.
5. Remove quick wrench components.
To Break
1. Turn handle until joint is broken.
2. Remove quick wrench components.
CMW
Systems and Equipment - 120
JT922 Operator’s Manual
Drill Pipe
Drill Pipe
Perform Regular Drill Pipe Care
Precondition New Pipe
Repeat this procedure three times for each piece of pipe before it is used the first time:
1. Hand-lubricate entire surface of threads and shoulders of both ends of pipe with copper base tool
joint compound. See page 134 for correct lubricant.
2. Join pipe and tighten joint.
3. Break joint.
NOTICE: Failure to follow this procedure could result in fused joints. Pipe will be damaged or destroyed.
Lubricate Joints Before Each Use
Lubricate threads and shoulders of male joints with copper base tool joint compound. This prevents rust
and reduces wear on shoulders and threads. See page 134 for correct lubricant.
Clean the Threads
Clean the threads as needed with high-pressure water and detergent.
NOTICE: Do not use gasoline or other petroleum-based solvents. This prevents tool joint compound
from sticking to the joints and will reduce thread life.
After cleaning, hand lubricate entire surface of threads and shoulders.
CMW
JT922 Operator’s Manual
Systems and Equipment - 121
Drill Pipe
Use Caps and Plugs
Install plug on saver sub before transporting.
Cap and plug male and female ends of drill
pipe during prolonged storage.
Replace Worn Saver Sub
Because each pipe comes in contact with the saver sub, check saver sub regularly for wear. Replace it
when it is worn, or it will damage your drill pipe. See page 151 for replacement procedure.
Precondition a new saver sub the same way you do new pipe. See “Precondition New Pipe” on page 120.
Rotate Pipe Order
Because the lead drill pipe is in the ground longer, it is subjected to higher shock loads and experiences
more wear. To help spread this wear evenly over all pipe, move the lead pipe from the previous job out of
the first position.
CMW
Systems and Equipment - 122
JT922 Operator’s Manual
Drill Pipe
Use Drill Pipe Correctly
Align the Joints
Always carefully align the male and female
ends of pipe before screwing them together.
Poor alignment can damage the threads and
destroy the usefulness of the joint.
IMPORTANT: The first pipe drilled must be
in a straight line with the unit. A misaligned
pipe can damage threads on each pipe that
is added.
Clamp Pipe Correctly
Clamp on pipe when joint is centered between
wrenches. Clamp only on the tool joint of the
drill pipe as shown. This portion of the drill pipe
is designed for clamping and is considerably
thicker and stronger than the rest of the pipe.
NOTICE: Clamping anywhere else on the
pipe will weaken the pipe. Pipe can later
break, even when operating under normal
loads.
See “Clamp Pipe” on page 83 for more
information.
CMW
JT922 Operator’s Manual
Systems and Equipment - 123
Drill Pipe
Make Up and Break Out Joints Correctly
•
Make up and break out joints slowly. Do not ram pipes together during makeup or force them
apart during breakout. Carefully time rotation with carriage travel speed, and always connect and
disconnect joints slowly and deliberately. This will help prevent thread crossing, galling, and
shoulder swelling.
•
Torque joints fully. Once the joint is connected and the shoulder faces are touching, torque them
to full machine torque. Improperly torqued joints will damage the shoulder faces and threads, and
will cause joints to leak or break while drilling or backreaming.
Do not Overwork the Pipe
Never exceed the bend radius for your pipe. See “Recommended Bend Limits” on page 57. Do not
oversteer.
NOTICE: Bending pipe more sharply than recommended will damage pipe and cause failure.
CMW
Systems and Equipment - 124
JT922 Operator’s Manual
Drill Pipe
CMW
JT922 Operator’s Manual
Complete the Job - 125
Complete the Job
Chapter Contents
Antifreeze Drilling Unit . . . . . . . . . . . . . . . . . . . . 126
•
Add Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
•
Reclaim Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Rinse Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 128
Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Stow Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
CMW
Complete the Job - 126
JT922 Operator’s Manual
Antifreeze Drilling Unit
Antifreeze Drilling Unit
Your drilling unit can be left overnight in freezing conditions by circulating a polypropylene-based antifreeze
(p/n 265-644) through fluid system before shutdown.
Add Antifreeze
1. Drain remaining water from the onboard tank.
2. Pour 3 gal (11 L) of approved antifreeze into
the onboard tank.
3. Move carriage to front of drill frame.
4. Position 3-gal (11-L) bucket under spindle.
5. Install plug at quick coupler for drilling fluid
pump (shown).
6. Open valve between antifreeze tank and head
of drilling fluid pump.
7. Turn drilling fluid valve clockwise to zero
position.
8. Start unit and set throttle to slow position.
9. Slowly turn drilling fluid valve counterclockwise until pump runs slowly.
10. Run drilling fluid pump until antifreeze comes out of spindle.
11. Turn drilling fluid valve clockwise to zero position.
12. Open valve below operator’s console
(shown).
13. Slowly turn drilling fluid potentiometer
clockwise until pump runs slowly.
14. Close valve below console when antifreeze
runs out of valve below console.
15. Turn drilling fluid potentiometer
counterclockwise to zero position.
CMW
JT922 Operator’s Manual
Complete the Job - 127
Antifreeze Drilling Unit
Reclaim Antifreeze
1. Start drilling unit and run at low throttle.
2. Move carriage to front of drill frame.
3. Position 3-gal (11-L) bucket under spindle.
4. Turn drilling fluid pump on low speed.
5. Turn drilling fluid pump off when drilling fluid comes out of spindle.
6. Pour antifreeze into onboard tank.
IMPORTANT: Antifreeze can be removed from antifreeze tank and disposed of properly or it can be
reused until it is too diluted with drilling fluid to protect against freezing.
CMW
JT922 Operator’s Manual
Complete the Job - 128
Rinse Equipment
Rinse Equipment
Using Optional Washwand
Connect the washwand at quick connect (1) at
rear of unit. Open valve (2) to start water flow.
Close valve to stop water flow.
Procedure
See “Prime Drilling Fluid Pump” on page 81.
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. For instructions, see “Prime Drilling Fluid Pump”
on page 81.
Pressurized fluid or air could pierce skin and cause injury
or death. Stay away.
Spray water onto equipment to remove dirt and mud. Some pressure might be needed to remove dried
mud from wrench area.
NOTICE: Do not spray water onto operator’s console. Electrical components could be damaged. Wipe
down instead.
CMW
JT922 Operator’s Manual
Complete the Job - 129
Disconnect
Disconnect
Disconnect and store the following hoses and cables (if used):
•
electric strike system voltage stake
•
fluid hose
Stow Tools
Make sure all quick wrenches, bits, pullback devices, and other tools are loaded and properly secured on
trailer.
CMW
Complete the Job - 130
JT922 Operator’s Manual
Stow Tools
CMW
JT922 Operator’s Manual
Service - 131
Service
Chapter Contents
Service Precautions . . . . . . . . . . . . . . . . . . . . . . . 132
Recommended Lubricants/Service Key . . . . . . . 134
10 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
250 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
500 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
750 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
2000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
As Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
CMW
JT922 Operator’s Manual
Service - 132
Service Precautions
Service Precautions
Incorrect procedures could result in death, injury, or property damage.
Learn to use equipment correctly.
NOTICES:
•
Unless otherwise instructed, all service should be performed with engine off.
•
Refer to engine manufacturer’s manual for engine maintenance instructions.
Welding Precaution
NOTICE: Welding can damage electronics.
•
Disconnect battery to prevent damage to battery. Do not turn off battery disconnect switch with
engine running, or alternator and other electronic devices may be damaged.
•
Connect welder ground clamp close to welding point and make sure no electronic components
or bearings are in the ground path.
Washing Precaution
NOTICE: Water can damage electronics.
•
CMW
When cleaning equipment, do not spray electrical components with water.
JT922 Operator’s Manual
Service - 133
Service Precautions
Working Under Drilling Unit
Crushing weight could cause death or serious injury. Use
proper procedures and equipment or stay away.
Before working under area of drilling unit
supported by a stabilizer, make sure drilling unit is
parked on hard surface.
1. Remove yellow cylinder lock from storage at
rear of pipe box and place over extended
cylinder rod (shown) with curved ends toward
stabilizer shoe.
2. Raise stabilizer to lower unit until load is
supported by cylinder lock.
Opening/Closing Front Hood
To open
1. Unlock hood at outside latches (1).
2. Press key lock buttons to release latches and
tip hood toward you.
3. Release inside latch (2).
4. Lift hood to remove.
To close
1. Align pins (3) with designated holes.
2. Secure inside latch (2).
3. Secure latches (1). Lock if necessary.
CMW
JT922 Operator’s Manual
Service - 134
Recommended Lubricants/Service Key
Recommended Lubricants/Service Key
Item
Description
DEO
Diesel engine oil meeting API service classification CF-4 or E1-96 and SAE viscosity
recommended by engine manufacturer (SAE 15W40)
SAE
SAE 30
MPG
Multipurpose grease meeting ASTM D217 and NLGI 5
EPG
Extreme pressure grease meeting ASTM D217 and NLGI 5
EPS
Extreme pressure spray lubricant
MPL
Multipurpose gear oil meeting API service classification GL-5 (SAE 80W90)
THF
Tractor hydraulic fluid, similar to Phillips 66 HG, Mobilfluid 423, Chevron Tractor
Hydraulic Fluid, Texaco TDH Oil, or equivalent
TJC
Tool joint compound: Ditch Witch standard (p/n 259-858) or
summer grade (p/n 256-031)
Check level of fluid or lubricant
Check condition
Filter
Change, replace, adjust, service or test
Proper lubrication and maintenance protects Ditch Witch equipment from damage and failure. Service
intervals listed are for minimum requirements. In extreme conditions, service machine more frequently.
Use only recommended lubricants. Fill to capacities listed in “Fluid Capacities” on page 155.
For more information on engine lubrication and maintenance, see your Cummins® engine manual.
NOTICE:
•
Use only genuine Ditch Witch parts, filters, approved lubricants, TJC, and approved coolants to
maintain warranty.
•
Use the “Service Record” on page 161 to record all required service to your machine.
CMW
JT922 Operator’s Manual
Service - 135
Recommended Lubricants/Service Key
Engine Oil Temperature Chart
Temperature range anticipated before next oil change
CMW
JT922 Operator’s Manual
Service - 136
10 Hour
10 Hour
Location
DRILLING
UNIT
Task
Notes
Check engine air filter service indicator
Check engine oil level
DEO
Check hydraulic hoses
Check hydraulic fluid level
THF
Check pipe lube applicator
Check pipe auto lubricator spray nozzle
Check pipe auto lubricator TJC level
Check drilling fluid filter
Drilling Unit
Check Engine Air Filter Service
Indicator
Check air filter service indicator every 10 hours.
Change filter element when red flag pops up at 20.
“Change Air Filter” on page 151. Reset air filter
service indicator after changing filter.
CMW
TJC
JT922 Operator’s Manual
Service - 137
10 Hour
Check Engine Oil Level
While engine oil is warm, check oil level at dipstick
(1) every 10 hours. Add DEO at fill (2) as necessary
to keep oil level at highest line on dipstick.
Check Hydraulic Hoses
Pressurized fluid or air could pierce skin and cause injury
or death. Stay away.
NOTICE: Escaping pressurized fluid can cause injury or pierce skin and
poison.
•
Before disconnecting a hydraulic line, turn engine off and operate all controls to relieve pressure.
Lower, block, or support any raised component with a hoist. Cover connection with heavy cloth and
loosen connector nut slightly to relieve residual pressure. Catch all fluid in a container.
•
Before using system, check that all connections are tight and all lines are undamaged.
•
Fluid leaks can be hard to detect. Use a piece of cardboard or wood, rather than hands, to search for
leaks.
•
Wear protective clothing, including gloves and eye protection.
•
If you are injured, seek immediate medical attention from a doctor familiar with this type of injury.
Check hydraulic hoses for leaks every 10 hours.
CMW
Service - 138
JT922 Operator’s Manual
10 Hour
Check Hydraulic Fluid Level
Check hydraulic fluid level every 10 hours. Maintain
fluid level at halfway point on sight glass (2) when
engine is off and fluid is cool. Refill with THF at
hydraulic fluid fill (1) as necessary.
IMPORTANT: If hydraulic system must be
opened for repair, install new filter (p/n 153-791)
for first 50 hours of operation. If this filter
becomes plugged in fewer than 20 hours,
replace with clean filter. After 50 hours of normal
operation, replace with clean filter (p/n 153-792).
Check Pipe Auto Lubricator Spray
Nozzle (Optional)
Check pipe auto lubricator spray nozzle every 10
hours. Ensure that nozzle is free of obstructions
and operates properly. Clean as needed.
NOTICE: Ditch Witch tool joint compound is
specially formulated to work with Ditch Witch
pipe lubrication system. Use of other tool joint
compounds will clog system. See
“Recommended Lubricants/Service Key” on
page 134 for more information.
To clean
1. Rotate handle to the upward, or cleanout, position (A).
2. Operate pump until obstruction is flushed.
3. Rotate handle to the downward, or spray, position (B).
4. Clean nozzle guard. If necessary, pull handle/nozzle insert out of housing to clean with fine wire or
solvent.
CMW
JT922 Operator’s Manual
Service - 139
10 Hour
Check Pipe Auto Lubricator TJC Level
(Optional)
Check pipe auto lubricator TJC level every 10
hours. Change pail as needed. See “Change Auto
Lubricator TJC Pail” on page 150 for procedure.
NOTICE: Ditch Witch tool joint compound is
specially formulated to work with Ditch Witch
pipe lubrication system. Use of other tool joint
compounds will clog system. See
“Recommended Lubricants/Service Key” on
page 134 for more information.
Clean Drilling Fluid Filter
Clean drilling fluid filter every 10 hours. Ensure that
strainer is free of debris.
CMW
JT922 Operator’s Manual
Service - 140
50 Hour
50 Hour
Location
Task
Notes
DRILLING
UNIT
Check fluid pump oil level
SAE 30
Change fluid pump oil level (initial)
SAE 30
Check oil cooler
Change hydraulic filter
Initial service
Check ground drive gearbox oil level
2 gearboxes, MPL
Check rotation gearbox oil level
MPL
Inspect thrust rollers
Lubricate rotation gearbox sliding output shaft
Check and adjust belt tension
Clean alternator cooler turbine
Drilling Unit
Check Fluid Pump Oil Level
Check fluid pump oil level at fill plug (1) every 50
hours. Maintain fluid level at fill plug. Add SAE 30W
oil at fill plug (1) as needed.
CMW
EPS
JT922 Operator’s Manual
Service - 141
50 Hour
Change Fluid Pump Oil (Initial Service)
Change fluid pump oil after first 50 hours and every
750 hours thereafter. Drain at plug (2) and fill with
SAE 30 at plug (1). Maintain fluid level at fill plug.
Check Oil Cooler
Check oil cooler for dirt, grass, and other foreign
matter every 50 hours. Check more often if
operating in dusty or grassy conditions. Clean as
needed.
To clean
•
Clean fins with compressed air or spray wash.
•
Spray through oil cooler toward hydraulic tank.
•
If grease and oil are present on oil cooler, spray
with solvent and allow to soak overnight.
IMPORTANT: Be careful not to damage
fins with high pressure air or water.
Change Hydraulic Filter (Initial Service)
Change hydraulic filter after first 50 hours. Replace
filter every 500 hours thereafter. Change filter more
often if indicated by filter indicator.
IMPORTANT: If hydraulic system must be
opened for repair, install new filter (p/n 153791) for first 50 hours of operation. If this filter
becomes plugged in fewer than 20 hours,
replace with new filter. After 50 hours of
normal operation, replace with new filter (p/n
153-792).
CMW
Service - 142
JT922 Operator’s Manual
50 Hour
Check Rotation Gearbox Oil Level
Check rotation gearbox oil level every 50 hours. Fill
through plug (1) with MPL as needed.
IMPORTANT: Drill frame must be level for
accurate reading.
Inspect Thrust Rollers
Inspect thrust rollers every 50 hours. Clean or
replace if they do not turn freely.
Lubricate Rotation Gearbox Sliding
Output Shaft
Lube rotation gearbox sliding output shaft with EPS
every 50 hours.
To lube:
•
Stop engine and turn battery disconnect switch
to the off position.
•
Clean exposed portion of sliding output shaft
with pressure washer to remove grime.
•
Blow dry with compressed air.
•
Apply EPS spray lube to all exposed shaft
surfaces while manually moving the shaft in and out.
•
Turn battery disconnect switch to the on position.
CMW
JT922 Operator’s Manual
Service - 143
50 Hour
Check and Adjust Engine Belt Tension
Check belt tension every 50 hours. Belt is properly
tensioned when it moves about 3/8” (10 mm) when
pushed at the long span (A).
To adjust belt, move tensioner pulley:
Note: Boltheads are hidden. Use an 8 mm hex
wrench, 17 mm open end wrench, and a 1/2”
prybar for this procedure.
1. Loosen socket bolt (2) and bolt (1).
2. Use a prybar in slots (3) to move pulley.
3. Tighten socket bolt (2) and bolt (1).
4. Check tension.
Clean Alternator Cooler Turbine
Clean the alternator cooler turbine every 50 hours.
Remove side panel and use compressed air to
blow dirt and debris from fins (shown).
CMW
JT922 Operator’s Manual
Service - 144
250 Hour
250 Hour
Location
Task
DRILLING
UNIT
Inspect air intake system
Drilling Unit
Inspect Air Intake System
Inspect intake piping for cracked hoses, loose
clamps, or punctures. Tighten or replace parts as
necessary.
CMW
Notes
JT922 Operator’s Manual
Service - 145
500 Hour
500 Hour
Location
Task
DRILLING
UNIT
Check fuel filter strainer
Notes
Change fuel filter
Change engine oil and filter
DEO
Change hydraulic fluid and filter
Normal conditions
Drilling Unit
Check Fuel Filter Strainer
Check fuel filter strainer every 10 hours.
Clean fuel filter strainer:
1. Close fuel shut-off valve.
2. Unscrew nut (1).
3. Remove fuel strainer cover (2).
4. Clean fuel strainer (2) with diesel fuel. Replace
if necessary.
5. Place seal (3) in position.
6. Mount fuel strainer cover (2). Tighten screw (1).
7. Check for leaks.
Change Fuel Filter
Change fuel filter every 500 hours.
CMW
Service - 146
JT922 Operator’s Manual
500 Hour
Change Engine Oil & Filter (Normal
Service)
Change engine oil and filter every 500 hours for
normal service. Drain oil (3), change filter (2), and
add 9 qt (8.5 L) of DEO at fill (1).
IMPORTANT: Use oil specified in temperature
chart found in “Recommended Lubricants/
Service Key” on page 134.
Change Hydraulic Fluid and Filter
Change hydraulic fluid and filter every 500 hours.
Drain hydraulic fluid (3), change filter (4), add THF
at hydraulic fluid fill (2) and check level at sight
glass (1).
IMPORTANT: If hydraulic system must be
opened for repair, install new filter (p/n 153-791)
for first 50 hours of operation. If this filter
becomes plugged in fewer than 20 hours,
replace with new filter. After 50 hours of normal
operation, replace with new filter (p/n 153-792).
CMW
JT922 Operator’s Manual
Service - 147
750 Hour
750 Hour
Location
Task
Notes
DRILLING
UNIT
Change fluid pump oil
SAE 30
Drilling Unit
Change Fluid Pump Oil
Change fluid pump oil every 750 hours. Drain at
plug (2) and fill with SAE 30W oil at plug (1).
Maintain fluid level at fill plug. Capacity for pump is
1 qt (0.9 L).
CMW
JT922 Operator’s Manual
Service - 148
1000 Hour
1000 Hour
Location
Task
Notes
DRILLING
UNIT
Change rotation gearbox oil
MPL
Drilling Unit
Change Rotation Gearbox Oil
Drain oil at gearbox oil drain (2) every 1000 hours.
Replace drain plug. Fill with MPL at fill plug (1).
Replace fill plug.
IMPORTANT: Drill frame must be level for
accurate reading.
CMW
JT922 Operator’s Manual
Service - 149
As Needed
As Needed
Location
Task
DRILLING
UNIT
Clean engine cooling system
Notes
Change pipe auto lubricator pail
TJC
Change hydraulic filter
Any time system is opened
Check front pipe guide inserts
Check track tension and condition
Change air filter
Check saver sub
Inspect muffler
Replace fuses
CMW
Service - 150
JT922 Operator’s Manual
As Needed
Drilling Unit
Change Auto Lubricator TJC Pail
Check pipe auto lubricator TJC level and change
pail as needed.
To change pail
1. Remove wingnuts and bolts attaching base ring
(4) to pail cover (1).
2. Rotate base ring slightly to clear hooks on
cover and remove pail from cover.
3. Remove follower plate (3) from empty pail and
install into new pail. Press firmly on follower
plate until TJC comes up in center opening.
4. Remove base ring from empty pail and install onto new pail.
5. Install pail into place over pump dip tube. Use hooks on cover to support base ring.
6. Install bolts and wingnuts.
7. Remove cap (2) from discharge tee on pump. Operate pump until discharged TJC is free of air
pockets. Replace cap.
NOTICE: Use only genuine Ditch Witch tool joint compound to maintain warranty. See “Recommended
Lubricants/Service Key” on page 134 for more information.
Change Hydraulic Filter (Anytime
System Opened)
Change hydraulic filter anytime system is opened
for repair. Change filter and refill with THF at
hydraulic oil fill.
IMPORTANT: If hydraulic system must be
opened for repair, install new filter (p/n 153-791)
for first 50 hours of operation. If this filter
becomes plugged in fewer than 20 hours,
replace with new filter. After 50 hours of normal
operation, replace with new filter (p/n 153-792).
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JT922 Operator’s Manual
Service - 151
As Needed
Check Track Tension and Condition
Check track tension and condition, and adjust or
replace as needed. See your Ditch Witch dealer for
replacement parts.
To adjust
1. Pump MPG into fitting (A) until the length of the
compressed spring, dimension (B), is 15.25”
(387.35 mm).
2. Drive straight forward one machine length and
check tension again.
Change Air Filter
To change:
1. Remove air filter cover (4) and remove primary
(3) and secondary (2) elements.
2. Wipe inside of housing (1) and wash cover.
3. Insert new elements.
4. Replace cover with dust evacuator valve at the
6 o’clock position.
5. Reset air filter service indicator.
Check Saver Sub
Check saver sub and replace as needed. See your
Ditch Witch dealer for replacement parts.
Note: Saver sub must mate up to every drill
pipe. Check sub for thread wear. If saver sub
threads are more worn than pipe threads, saver
sub is damaging the drill pipe.
To replace
1. Remove eight bolts (shown) that attach saver
sub to spindle. Do not remove indexing dowels
from spindle.
2. Remove and replace o-ring, if necessary.
3. Install in reverse order and tighten eight bolts in a cross pattern to 55 ft•lb (74.6 N•m). Apply Loctite®
242 to bolts before installation.
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Service - 152
JT922 Operator’s Manual
As Needed
Inspect Muffler
Inspect muffler for looseness as needed.
Replace Fuses
Change fuses as needed. Refer to decal inside
panels to identify fuses.
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JT922 Operator’s Manual
Specifications - 153
Specifications
Dimensions
U.S.
Metric
L, overall machine length (per SAE J2022)
146 in
3.7 m
W, overall machine width (per SAE J2022)
48 in
1.2 m
H, overall machine height (per SAE J2022)
74 in
1.9 m
Entry angle (per SAE J2022)
10-14°
10-14°
Angle of approach
18°
18°
Angle of departure
18°
18°
Operating mass, water tank full, 50 drill pipe (per SAE J2022)
7050 lb
3200 kg
Operating mass, water tank empty, 50 drill pipe
6700 lb
3040 kg
Power Pipe
U.S.
Metric
Length (per SAE J2022), nominal
72 in
1.8 m
Joint diameter (per SAE J2022)
2 in
51 mm
Tubing diameter (per SAE J2022)
1.6 in
40 mm
Minimum bend radius
105 ft
32 m
Weight (per SAE J2022), lined
29 lb
13 kg
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Specifications - 154
JT922 Operator’s Manual
Operational
U.S.
Metric
Maximum spindle speed (per SAE J2022)
186 rpm
186 rpm
Maximum spindle torque (per SAE J2022)
1100 ft•lb
1491 N•m
Thrust force (per SAE J2022)
9,000 lb
40 kN
Pullback force (per SAE J2022)
9,000 lb
40 kN
Thrust travel speed (per SAE J2022)
188 fpm
57 m/min
Pullback travel speed (per SAE J2022)
188 fpm
57 m/min
Minimum bore diameter
3 in
76 mm
Backream diameter (soil dependent)
variable
variable
forward (per SAE J2022)
2.3 mph
3.7 km/h
reverse (per SAE J2022)
2.3 mph
3.7 km/h
Ground bearing pressure (per SAE J1309)
5.7 psi
0.4 kg/cm2
Power
U.S.
Metric
Displacement
189 in3
3.1 L
Bore
3.7 in
94 mm
Stroke
4.4 in
112 mm
manufacturer’s net power rating (per SAE J1349)
53.5 hp
39.9 kW
rated speed
2300 rpm
2300 rpm
Ground travel speed
Engine: Deutz D2011L04i
Fuel: diesel (Use low sulfur or ultra low sulfur fuel only.)
Cooling medium: integrated oil
Injection: direct
Aspiration: natural
Cylinders: 4
Power
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JT922 Operator’s Manual
Specifications - 155
Drilling Fluid System (Onboard)
U.S.
Metric
Maximum drilling fluid flow (per SAE J2022)
9 gpm
34 L/min
Maximum drilling fluid pressure (per SAE J2022)
750 psi
52 bar
Fluid Capacities
U.S.
Metric
Fuel tank *
19 gal
72 L
Hydraulic reservoir
18 gal
68 L
Engine oil, including filter
11.6 qt
11 L
* Under normal operating conditions, a full tank of fuel will last 10 hours.
Battery
SAE reserve capacity rating 165 min, 12V, negative ground, SAE cold crank rating @ 0°F (-18°C), 875
amps.
Noise Levels
Exterior 104 dBA sound power per ISO 6363
Operator 88 dBA sound pressure per ISO 6394
Specifications are called out according to SAE recommended practices where indicated. Specifications are
general and subject to change without notice. If exact measurements are required, equipment should be
weighed and measured. Due to selected options, delivered equipment may not necessarily match that
shown.
CMW
Specifications - 156
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JT922 Operator’s Manual
JT922 Operator’s Manual
Support - 157
Procedure
Support
Procedure
Notify your dealer immediately of any malfunction or failure of Ditch Witch equipment.
Always give model, serial number, and approximate date of your equipment purchase. This information
should be recorded and placed on file by the owner at the time of purchase.
Return damaged parts to dealer for inspection and warranty consideration if in warranty time frame.
Order genuine Ditch Witch replacement or repair parts from your authorized Ditch Witch dealer. Use of
another manufacturer's parts may void warranty consideration.
Resources
Publications
Contact your Ditch Witch dealer for publications and videos covering safety, operation, service, and repair
of your equipment.
Ditch Witch Training
For information about on-site, individualized training, contact your Ditch Witch dealer.
CMW
JT922 Operator’s Manual
Warranty - 158
Warranty
Ditch Witch Equipment and Parts
Limited Warranty Policy
Subject to the limitations and exclusions herein, free replacement parts will be provided at any authorized Ditch Witch dealership for
any Ditch Witch equipment or parts manufactured by The Charles Machine Works, Inc. (CMW) that fail due to a defect in material or
workmanship within one (1) year of first commercial use (Exception: 2 years for all SK5 attachments). Free labor will be provided at
any authorized Ditch Witch dealership for installation of parts under this warranty during the first year following initial commercial use
of the serial-numbered Ditch Witch equipment on which it is installed.
Exclusions from Product Warranty
•
Wear-related failure of parts subject to ground contact including, but not limited to, digging teeth, digging chains, sprockets,
backhoe buckets, plow blades, drill pipe, drill bits, backreamers, and swivels.
•
All incidental or consequential damages.
•
All defects, damages, or injuries caused by misuse, abuse, improper installation, alteration, neglect, or uses other than those for
which products were intended.
•
All defects, damages, or injuries caused by improper training, operation, or servicing of products in a manner inconsistent with
manufacturer’s recommendations.
•
All engines and engine accessories (these are covered by original manufacturer’s warranty).
•
Tires, belts, and other parts which may be subject to another manufacturer’s warranty (such warranty will be available to
purchaser).
•
All implied warranties not expressly stated herein, including any warranty of fitness for a particular purpose and merchantability.
IF THE PRODUCTS ARE PURCHASED FOR COMMERCIAL PURPOSES AS DEFINED BY THE UNIFORM COMMERCIAL CODE,
THEN THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE FACE HEREOF AND THERE ARE NO IMPLIED
WARRANTIES OF ANY KIND WHICH EXTEND TO A COMMERCIAL BUYER. ALL OTHER PROVISIONS OF THIS LIMITED
WARRANTY APPLY INCLUDING THE DUTIES IMPOSED.
Ditch Witch products have been tested to deliver acceptable performance in most conditions. This does not imply they will deliver
acceptable performance in all conditions. Therefore, to assure suitability, products should be operated under anticipated working
conditions prior to purchase.
Defects will be determined by an inspection within thirty (30) days of the date of failure of the product or part by CMW or its authorized
dealer. CMW will provide the location of its inspection facilities or its nearest authorized dealer upon inquiry. CMW reserves the right
to supply remanufactured replacements parts under this warranty as it deems appropriate.
Extended warranties are available upon request from your local Ditch Witch dealer or CMW.
Some states do not allow exclusion or limitation of incidental or consequential damages, so above limitation of exclusion may not
apply. Further, some states do not allow exclusion of or limitation of how long an implied warranty lasts, so the above limitation may
not apply. This limited warranty gives product owner specific legal rights and the product owner may also have other rights which vary
from state to state.
For information regarding this limited warranty, contact CMW’s Product Support department, P.O. Box 66, Perry, OK 73077-0066, or
contact your local Ditch Witch dealer.
First version: 1/91; Latest version: 1/03
CMW
JT922 Operator’s Manual
Service Record - 161
Service Record
Service Performed
Date
Hours
CMW
Service Record - 162
Service Performed
CMW
JT922 Operator’s Manual
Date
Hours