Ditch Witch JT3020 Mach 1/ All Terrain Manual

Ditch Witch JT3020 Mach 1/ All Terrain Manual
JT3020 Mach 1/All Terrain
Operator’s
Manual
CMW®
Issue 1.0
053- 1152
JT3020 Mach 1/All Terrain 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
CMW
JT3020 Mach 1/All Terrain 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
engine serial number
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Overview - 3
Intended Use
Intended Use
The JT3020 Mach 1 is a self-contained horizontal directional drilling unit designed to install buried cable
and pipe to distances of 650’ (200 m) depending on soil conditions. Its All Terrain version is designed to
drill through rock, cobblestone, broken rock, gravel, and caliche.
The unit is designed for operation in temperatures typically experienced in earth moving and construction
work environments. Provisions may be required to operate in extreme temperatures. Contact your Ditch
Witch dealer. Use in any other way is considered contrary to the intended use.
The JT3020 Mach 1/All Terrain should be used with genuine Ditch Witch drilling fluid units and Ditch Witch
tracking equipment. It should be operated, serviced, and repaired only by persons familiar with its
particular characteristics and acquainted with the relevant safety procedures.
CMW
Overview - 4
JT3020 Mach 1/All Terrain Operator’s Manual
Unit Components
Unit Components
1. Operator’s station
6. Tracks
2. Spindle
7. Pipeloader
3. Carriage
8. Vise wrenches
4. Drill frame
9. Anchoring system
5. Stabilizer
CMW
JT3020 Mach 1/All Terrain 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.
CMW
Overview - 6
JT3020 Mach 1/All Terrain Operator’s Manual
About This Manual
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Foreword - 7
Foreword
This manual is an important part of your equipment. It provides safety information and operation
instructions to help you use and maintain your Ditch Witch equipment.
Read this manual before using your equipment. Keep it with the equipment at all times for future reference.
If you sell your equipment, be sure to give this manual to the new owner.
If you need a replacement copy, contact your Ditch Witch dealer. If you need assistance in locating a
dealer, visit our website at www.ditchwitch.com or write to the following address:
The Charles Machine Works, Inc.
Attn: Marketing Department
PO Box 66
Perry, OK 73077-0066
USA
The descriptions and specifications in this manual are subject to change without notice. The Charles
Machine Works, Inc. reserves the right to improve equipment. Some product improvements may have
taken place after this manual was published. For the latest information on Ditch Witch equipment, see your
Ditch Witch dealer.
Thank you for buying and using Ditch Witch equipment.
CMW
Foreword - 8
JT3020 Mach 1/All Terrain Operator’s Manual
JT3020 Mach 1/All Terrain
Operator’s Manual
Issue number 1.0/OM-7/07
Part number 053-1152
Copyright 2007
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; 5,544,712; 5,546,833; 5,682,956; 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; RE37,450; RE37,923; RE37,975; Germany 694 17 019; 695 29 634; France 683,845; 674,093;
Australia 684,595; 689,533; 718,034; 706,544; 755,862; UK 2,309,239; 2,312,006; EP683,845; EP674,093 ; other U.S. and foreign
patents pending.
CMW
JT3020 Mach 1/All Terrain 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
65
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
69
procedures for inspecting and classifying the jobsite, planning the installation path,
and preparing the jobsite for work
Drive
89
procedures for startup, cold start, driving, and shutdown
Transport
93
procedures for lifting, hauling, and towing
Conduct a Bore
101
procedures for drilling and backreaming
Systems and Equipment
129
downhole tools and drill pipe, anchor, electric strike, tracker control, and fluid
systems
Complete the Job
189
procedures for restoring the jobsite and rinsing and storing equipment
Service
195
service intervals and instructions for this machine including lubrication, replacement
of wear items, and basic maintenance
CMW
Contents - 10
JT3020 Mach 1/All Terrain Operator’s Manual
Specifications
235
machine specifications including weights, measurements, power ratings, and fluid
capacities
Support
239
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
243
JT3020 Mach 1/All Terrain Operator’s Manual
Safety - 11
Safety
Chapter Contents
Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Safety Alert Classifications . . . . . . . . . . . . . . . . . . 13
Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Emergency Procedures . . . . . . . . . . . . . . . . . . . . . 17
•
Electric Strike Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
•
If an Electric Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
•
If a Gas Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
•
If a Fiber Optic Cable is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
•
If Machine Catches on Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
CMW
Safety - 12
JT3020 Mach 1/All Terrain Operator’s Manual
Guidelines
Guidelines
Follow these guidelines before operating any jobsite equipment:
•
Complete proper training and read operator’s manual before using equipment.
•
Contact your local One-Call service by dialing 811 (USA only) to have underground utilities located. A
One-Call referral number, 888-258-0808, is also available for both the USA and Canada. You should
also call any utility companies which 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 is present.
•
Contact your Ditch Witch dealer if you have any question about operation, maintenance, or equipment
use.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Safety - 13
Safety Alert Classifications
Safety Alert Classifications
These classifications and the icons defined on the following pages work together to alert you to situations
which could be harmful to you, jobsite bystanders or your equipment. When you see these words and
icons in the book or on the machine, carefully read and follow all instructions. YOUR SAFETY IS AT
STAKE.
Watch for the three safety alert levels: DANGER, WARNING and CAUTION. Learn what each level
means.
indicates 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
JT3020 Mach 1/All Terrain Operator’s Manual
Safety - 14
Safety Alerts
Safety Alerts
Turning shaft will kill you or crush arm or leg. Stay away.
Electric shock. Contacting electric lines will cause death or serious injury.
Know location of lines and stay away.
Deadly gases. Lack of oxygen or presence of gas will cause sickness or
death. Provide ventilation.
Moving tools will kill or injure. Shut off drill string power when anyone can be
struck by moving or thrown tools. Never use pipe wrenches on drill string.
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
JT3020 Mach 1/All Terrain Operator’s Manual
Safety - 15
Safety Alerts
Explosion possible. Serious injury or equipment damage could occur.
Follow directions carefully.
Incorrect procedures could result in death, injury, or property damage.
Learn to use equipment correctly.
Improper control function could cause death or serious injury. If control does
not work as described in instructions, stop machine and have it serviced.
Looking into fiber optic cable could result in permanent vision damage. 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
JT3020 Mach 1/All Terrain Operator’s Manual
Safety - 16
Safety Alerts
Hot pressurized cooling system fluid could cause serious burns. Allow to
cool before servicing.
Flying objects may cause injury. Wear hard hat and safety glasses.
Hot parts may cause burns. Do not touch until cool.
Exposure to high noise levels may cause hearing loss. Wear hearing
protection.
Fall possible. Slips or trips may result in injury. Keep area clean.
Battery acid may cause burns. Avoid contact.
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
JT3020 Mach 1/All Terrain Operator’s Manual
Safety - 17
Emergency Procedures
Emergency Procedures
Jobsite hazards could cause death or serious injury. Use
correct equipment and work methods. Use and maintain proper safety
equipment.
Before operating any equipment, review emergency procedures and check that all safety precautions have
been taken.
EMERGENCY SHUTDOWN - Turn ignition switch to stop position or push remote engine stop button (if
equipped).
Electric Strike Description
Electric shock. 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. Almost one-third of work-related electrocutions result from
contact with less than 440 volts.
Most electric strikes are not noticeable, but indications of a strike include:
•
power outage
•
smoke
•
explosion
•
popping noises
•
arcing electricity
If any of these occur, or if strike alarm sounds or flashes, assume an electric strike has occurred.
CMW
Safety - 18
JT3020 Mach 1/All Terrain Operator’s Manual
Emergency Procedures
If an Electric Line is Damaged
If you suspect an electric line has been damaged and you are on drilling unit or bonded ground mats,
DO NOT MOVE. Remain on drilling machine or mats and take the following actions. The order and degree
of action will depend on the situation.
•
Warn people nearby that an electric strike has occurred.
•
Have someone contact electric company.
•
Reverse drilling direction and try to break contact. Do not touch drill pipe with hands or hand-held
tools.
•
Press electric strike system status button.
•
•
If alarm sounds again, stay where you are and 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
JT3020 Mach 1/All Terrain Operator’s Manual
Safety - 19
Emergency Procedures
If a Gas Line is Damaged
Fire or explosion possible. Fumes could ignite and cause burns. No
smoking, no flame, no spark.
Explosion possible. Serious injury or equipment damage could occur.
Follow directions carefully.
If you suspect a gas line has been damaged, take the following actions. The order and degree of action will
depend on the situation.
•
Immediately shut off engine(s), if this can be done safely and quickly.
•
Remove any ignition source(s), if this can be done safely and quickly.
•
Warn others that a gas line has been cut and that they should leave the area.
•
Leave jobsite as quickly as possible.
•
Immediately call your local emergency phone number and utility company.
•
If jobsite is along street, stop traffic from driving near jobsite.
•
Do not return to jobsite until given permission by emergency personnel and utility company.
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
Safety - 20
JT3020 Mach 1/All Terrain Operator’s Manual
Emergency Procedures
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Controls - 21
Controls
Chapter Contents
Set-Up Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Tethered Ground Drive Controller . . . . . . . . . . . . 26
Left Control Console . . . . . . . . . . . . . . . . . . . . . . . 28
•
Unit status indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
•
Pipeloading controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
•
Drilling/Operation controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Right Control Console . . . . . . . . . . . . . . . . . . . . . . 39
•
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
•
Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
•
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Information Center . . . . . . . . . . . . . . . . . . . . . . . . . 49
•
Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
•
Soft keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Anchoring System Console . . . . . . . . . . . . . . . . . . 53
Seat/Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Engine Compartment Controls . . . . . . . . . . . . . . . 57
750/752 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
•
Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
•
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
CMW
Controls - 22
JT3020 Mach 1/All Terrain Operator’s Manual
Set-Up Console
Set-Up Console
1. Tracker control key
6. Engine shutdown override switch
2. Cold start wait indicator
7. Right stabilizer control
3. Ignition switch
8. Left stabilizer control
4. Left track switch
9. Back frame tilt control
5. Right track switch
10. Front frame tilt control
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Controls - 23
Set-Up Console
Item
Description
Notes
1. 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).
2. Cold start wait indicator
Lights when intake air preheater is operating.
Wait until light goes off before
starting engine.
3. Ignition switch
To start engine, insert key and
turn clockwise.
IMPORTANT:
•
Restart engine with ignition switch
after it has been turned off with
tethered control remote engine
stop switch.
•
If wrenches are engaged when
engine is stopped with ignition
switch, wrenches will release and
then engage when unit is started.
To stop engine, turn key
counterclockwise.
4. Left track switch
To move forward, press top.
IMPORTANT: Use track switches only
if tethered control is inoperable.
To move backward, press
bottom.
c00ic147h.eps
CMW
Controls - 24
JT3020 Mach 1/All Terrain Operator’s Manual
Set-Up Console
Item
Description
Notes
5. Right track switch
To move forward, press top.
IMPORTANT: Use track switches only
if tethered control is inoperable.
To move backward, press
bottom.
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6. Engine shutdown
override switch
If engine shutdown indicator
comes on, turn ignition switch
to STOP and press to delay
engine shutdown for 30
seconds.
NOTICE: After 30 seconds, engine
will again shut down unless fault
condition has been cleared on
diagnostic gauge.
IMPORTANT: See “Electronic
Controlled Engine Overview” on
page 167 for more information on Tier
3 engines.
c00ic178h.eps
7. Left stabilizer control
This control allows a temporary
override of engine shutdown.
To raise, pull up.
To lower, push down.
IMPORTANT: Lower left and right
stabilizers to the ground together,
then adjust individually.
WARNING: Crushing weight could
cause death or serious injury. Use
proper procedures and equipment or
stay away.
8. Right stabilizer control
To raise, pull up.
To lower, push down.
IMPORTANT: Lower left and right
stabilizers to the ground to stabilize
unit and then adjust for side-to-side
stability.
WARNING: Crushing weight could
cause death or serious injury. Use
proper procedures and equipment or
stay away.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Controls - 25
Set-Up Console
Item
Description
Notes
9. Back frame tilt control
To raise, pull up.
IMPORTANT: To ensure a stable
platform for drilling, use front and
back tilt controls together to set frame
at desired pitch without raising tracks
off the ground.
To lower, push down.
10. Front frame tilt control
To raise, pull up.
To lower, push down.
IMPORTANT: To ensure a stable
platform for drilling, use front and
back tilt controls together to set frame
at desired pitch without raising tracks
off the ground.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Controls - 26
Tethered Ground Drive Controller
Tethered Ground Drive Controller
1
5
2
4
3
j10om016h.eps
1. Speed/direction control
4. Operator presence switch
2. Drive mode switch
5. Throttle switch
3. Remote engine stop
Item
Description
Notes
1. Speed/direction control
To move forward, push.
IMPORTANT:
To move backward, pull.
•
Operator presence switch must
be pressed and operator seat
must be empty for control to work.
•
See “Steer Unit” on page 90 for
more information.
To steer, move left or right
while moving forward or
backward.
c00ic145h.eps
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Controls - 27
Tethered Ground Drive Controller
Item
Description
2. Drive mode switch
To select normal driving mode
(high), push.
Notes
To select loading and
unloading mode (low), pull.
To disable controller, return to
center.
c00ic146h.eps
3. Remote engine stop
To stop engine, press red
button.
4. Operator presence
switch
To operate ground drive with
tethered controller, press.
IMPORTANT: To restart engine, turn
ignition switch off and then back on.
To disable controller, release.
5. Throttle switch
To increase engine speed,
push.
To decrease engine speed,
pull.
CMW
Controls - 28
JT3020 Mach 1/All Terrain Operator’s Manual
Left Control Console
Left Control Console
Unit Status Indicators
1. Cold start wait indicator
6. Engine oil pressure gauge
2. Engine shutdown indicator
7. Selection switch
3. Operator alert indicator
8. Tachometer/Diagnostic gauge
4. Operator presence indicator
9. Fuel gauge
5. Engine coolant temperature gauge
10. Voltmeter
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Controls - 29
Left Control Console
Item
Description
1. Cold start wait indicator
Lights when intake air preheater is operating.
Notes
Wait until light goes off before
starting engine.
2. Engine shutdown
indicator
Lights when a critical engine
fault occurs. Engine will shut
down 30 seconds after light
comes on.
A code will be stored in the ECU. See
“Diagnostic gauge” on page 30 for
more information.
IMPORTANT: See “Electronic
Controlled Engine Overview” on
page 167 for more information on
engine diagnostic system and
diagnostic codes.
To reset, turn ignition switch to STOP,
then to run.
3. Operator alert indicator
Lights when a non-critical
engine fault occurs.
A code will be stored in the ECU. See
“Diagnostic gauge” on page 30 for
more information.
IMPORTANT: See “Electronic
Controlled Engine Overview” on
page 167 for more information on
diagnostic system and diagnostic
codes.
4. Operator presence
indicator
Indicates operator is seated
in operator’s station.
Thrust and rotation will not operate
unless light is on.
CMW
Controls - 30
JT3020 Mach 1/All Terrain Operator’s Manual
Left Control Console
Item
Description
Notes
5. Engine coolant
temperature gauge
Displays engine coolant
temperature.
Normal coolant temperature is
160°-212° F (88°-100° C).
6. Engine oil pressure
gauge
Displays engine oil pressure.
Full load reading should be 60-80 psi
(2.4-4.5 bar).
7. Selection switch
To scroll through engine
statistics and diagnostic
codes on diagnostic gauge
display, push.
8. Tachometer and
diagnostic gauge
Tachometer
Displays engine speed.
IMPORTANT: For more information
about the engine diagnostic system
and codes see “Engine Diagnostic
Codes” on page 169.
Diagnostic gauge
Displays engine hours, trip
meter, engine statistics, and
engine diagnostic codes.
To view information, press the
selection switch.
9. Fuel gauge
Displays fuel level in tank.
Use only #2 diesel fuel.
Refer to engine operator’s manual for
cold weather fuel recommendations.
Tank holds 42 gal (159 L).
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Controls - 31
Left Control Console
Item
Description
Notes
10. Voltmeter
Displays system voltage.
Should show 13-14V with engine
running.
CMW
Controls - 32
JT3020 Mach 1/All Terrain Operator’s Manual
Left Control Console
Pipeloading Controls
1. Pipe lift switch
6. Pipe gripper switch
2. Rear wrench rotation switch
7. Pipe lubricator switch
3. Rear wrench clamp switch
8. Pipe position switch
4. Front wrench clamp switch
9. Add pipe/manual/remove pipe switch
5. Pipe shuttle switch
10. Set/Resume switch
Item
Description
1. Pipe lift switch
To raise, press top.
To lower, press.
To stop, release.
CMW
Notes
JT3020 Mach 1/All Terrain Operator’s Manual
Controls - 33
Left Control Console
Item
Description
2. Rear wrench rotation
switch
To rotate counterclockwise,
press top.
Notes
To rotate clockwise, press
bottom.
To stop rotation, release.
3. Rear wrench clamp
switch
To unclamp, press top.
To clamp, press bottom.
4. Front wrench clamp
switch
To unclamp, press top.
To clamp, press bottom.
5. Pipe shuttle switch
To move toward pipe box,
press top.
To move toward spindle,
press bottom.
To stop shuttles, release.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Controls - 34
Left Control Console
Item
Description
6. Pipe gripper switch
To close, press top.
Notes
To open, press bottom.
To stop grippers, release.
7. Pipe lubricator switch
To apply joint compound,
press top.
Applies joint compound to threads at
wrenches.
8. Pipe position switch
To shift pipe box away from
operator, press top.
IMPORTANT: See “Shift Pipe Box” on
page 160.
To shift pipe box toward
operator, press bottom.
To stop pipe box, release.
9. Add pipe/manual/
remove pipe switch
To select “add pipe”
automated pipeloader
function, press top.
See “Enable Automated Pipeloader
System” on page 113.
To use manual pipeloader
controls, move to center.
To select “remove pipe”
automated pipeloader
function, press bottom.
10. Set/Resume switch
RESUME
SET
c00ic113h.eps
CMW
/
/
To resume operation or
increase operation levels,
press top.
To set operating conditions or
reduce operation levels,
press bottom.
See “Cruise Control” on page 165.
See “Carve mode switch” on page 36
and 120.
JT3020 Mach 1/All Terrain Operator’s Manual
Controls - 35
Left Control Console
Drilling/Operation Controls
1. Fluid pump speed switch
6. Remote engine start switch
2. Carve mode switch
7. Inner spindle speed control (AT only)
3. Console/Work light switch
8. Inner spindle switch (AT only)
4. Engine throttle switch
9. Manual inner spindle control (AT only)
5. Fluid flow control
10. Outer spindle brake switch (AT only)
CMW
Controls - 36
JT3020 Mach 1/All Terrain Operator’s Manual
Left Control Console
Item
Description
Notes
1. Fluid pump speed
switch
For high speed, press top.
High speed delivers more flow at
lower pressure.
For low speed, press bottom.
Low speed delivers less flow at higher
pressure.
To activate carve mode, press
top.
Two-speed thrust is not allowed in
carve mode.
To deactivate carve mode,
press bottom.
Cruise Control is not available in
carve mode.
2. Carve mode switch
Carve mode is disabled while front
wrench is closed.
3. Console/Work light
switch
To turn on, press top.
To turn off, press bottom.
c00ic151h.eps
4. Engine throttle switch
To increase speed, press top.
To enable autothrottle mode,
leave switch in top position.
To disable autothrottle mode,
return switch to center after
desired speed is reached.
To decrease speed, press
bottom.
CMW
Autothrottle mode slows the engine to
low throttle after 15 seconds of
inactivity involving thrust, rotation,
drilling fluid flow, or pipeloader
functions. To return to high speed,
activate thrust, rotation, drilling fluid,
or an add/remove pipe cycle.
JT3020 Mach 1/All Terrain Operator’s Manual
Controls - 37
Left Control Console
Item
Description
Notes
5. Fluid flow control
To increase flow, turn
clockwise.
Note: Drilling fluid pump must be
switched on. See “Right Control
Console” on page 39.
To decrease flow, turn
counterclockwise.
To stop flow, turn all the way
counterclockwise.
6. Remote engine start
switch
To start engine from
operator’s station, push
button.
IMPORTANT: This button works only
when key in set-up console is on,
operator is in seat, and battery
disconnect switch is closed.
Release when engine starts.
c00ic152h.eps
7. Inner spindle speed
control
To increase inner rotation
speed, turn clockwise.
To decrease inner rotation
speed, turn counterclockwise.
8. Inner spindle switch
Note: Inner spindle switch must be on
and AT/JT switch in AT position. See
“Engine Compartment Controls” on
page 57.
To turn on, press top.
IMPORTANT:
To turn off, move to center.
•
To restart inner rotation after
operator has left seat, turn inner
rotation off and then on.
•
Normal dither works in manual
control mode unless the manual
inner spindle control is moved
from its normal position.
To manually control inner
rotation speed and direction,
press bottom. Then use
manual inner spindle control
as needed.
CMW
Controls - 38
JT3020 Mach 1/All Terrain Operator’s Manual
Left Control Console
Item
Description
Notes
9. Manual inner spindle
control
To rotate clockwise, move to
top.
IMPORTANT:
•
Inner spindle switch must be in
manual position for this control to
work.
•
Range of speed is reduced to
allow easier manual control.
•
Up/down paddle is spring
centered. Moving it above center
rotates inner rod clockwise.
Moving it further rotates the rod
faster. Moving it below center
does the same for counter
clockwise rotation.
To rotate counterclockwise,
move to bottom.
To stop inner rotation,
release.
10. Outer spindle brake
switch
To engage, press top.
To disengage, press bottom.
Prevents outer spindle from rotating
when inner spindle or mud motor are
in use.
Brake is temporarily released when
front wrench is closed to allow pipe
change.
c00ic255h.eps
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Controls - 39
Right Control Console
Right Control Console
Controls
1. Carriage control
4. Drilling fluid pump switch
2. Drilling fluid quick fill switch
5. Dual speed carriage control (enhanced
function control)
3. Remote engine stop switch
CMW
Controls - 40
JT3020 Mach 1/All Terrain Operator’s Manual
Right Control Console
Item
Description
Notes
1. Carriage control
To move carriage forward,
push.
IMPORTANT: See “Operate Carriage
Control” on page 105 for more
information.
To move carriage backward,
pull.
To rotate spindle
counterclockwise (breakout),
move right.
To rotate spindle clockwise
(makeup), move left.
2. Drilling fluid quick fill
switch
To override fluid control
setting for full pump flow,
press and hold.
IMPORTANT: Also overrides
temporary fluid shutdown when front
wrench is closed.
To return fluid flow to flow
control setting, release.
3. Remote engine stop
switch
4. Drilling fluid pump
switch
To stop engine, press.
IMPORTANT:
To restart engine, press
remote engine start switch
(page 35).
•
If this switch is used to stop
drilling unit, be sure to turn
ignition switch off if machine will
be left unattended for long
periods of time. Battery discharge
can occur.
•
If wrenches are engaged when
remote stop is pressed, wrenches
will remain engaged but could
gradually open.
To turn on, press once.
To turn off, press once.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Controls - 41
Right Control Console
Item
Description
Notes
5. Dual speed carriage
control (enhanced
function control)
To engage an enhanced
function, push and hold.
Enhanced Operations
1. Two-speed thrust
To return to normal operation,
release.
2. Fine adjustment for cruise and
carve mode
3. Automated add pipe for pipes in
delivery chute
4. Counter clockwise carve at full
rotation
5. Jammed collar separation (AT
only)
6. Failed makeup system override
7. Single pipe loader reset
CMW
Controls - 42
JT3020 Mach 1/All Terrain Operator’s Manual
Right Control Console
Indicators
1. Main controller diagnostic light (red)
7. Carriage home status indicator
2. Pipeloader diagnostic light (red)
8. Rear stop status indicator
3. Hydraulic fluid temperature indicator
9. Pipe lift status indicator
4. Hydraulic filter service indicator
10. Front pipe box status indicator
5. Front wrench status indicator
11. Rear pipe box status indicator
6. Shuttle home status indicator
12. Fluid pump status indicator
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Controls - 43
Right Control Console
Item
Description
Notes
1. Main controller
diagnostic light (red)
If system is OK, light should
be off.
See “Interpret Diagnostic Codes” on
page 167.
If system is not getting power,
light should be on.
If a non-essential diagnostic
code is recorded, light should
flash on and off for 10
seconds.
If an essential diagnostic
code is recorded, light should
repeatedly flash on for three
seconds and off for half a
second.
2. Pipeloader diagnostic
light (red)
If system is OK, light should
be off.
See “Interpret Diagnostic Codes” on
page 167.
If system is not getting power,
light should be on.
If a non-essential diagnostic
code is recorded, light should
flash on and off for 10
seconds.
If an essential diagnostic
code is recorded, light should
repeatedly flash on for three
seconds and off for half a
second.
3. Hydraulic fluid
temperature indicator
Indicates hydraulic fluid is
overheating.
•
Check hydraulic fluid level.
•
Check cooler for debris. See
page 210.
CMW
Controls - 44
JT3020 Mach 1/All Terrain Operator’s Manual
Right Control Console
Item
Description
Notes
4. Hydraulic filter service
indicator
Indicates hydraulic fluid filter
needs replacing.
Change filter when indicator lights
continuously and as indicated on
page 216.
5. Front wrench status
indicator
If front wrench is closed, light
should be on.
If front wrench is open, light
should be off.
6. Shuttle home status
indicator
If shuttle is retracted, light
should be on.
If shuttle is not completely
retracted, light should be off.
7. Carriage home status
indicator
If carriage is in the home
zone at either end of drill
frame, light should be on.
If carriage is not in the home
zone at either end of drill
frame, light should be off.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Controls - 45
Right Control Console
Item
Description
8. Pipe lift status indicator
If pipe lifter is lifted fully and
lift pressure switch is
engaged, light should be on.
Notes
If pipe lift pressure switch is
not engaged, light should be
off.
9. Rear stop status
indicator
If carriage is at very back of
drill frame, light should be on.
IMPORTANT: The stop sensor is
used to determine when to stop
carriage when backing up.
If carriage is away from very
back of drill frame, light
should be off.
10. Front pipe box status
indicator
If active pipe column contains
pipe, light should be on.
IMPORTANT:
•
Check pipe box status lights to
see when active column of pipe
box is empty. See “Shift Pipe Box”
on page 160.
•
One light on and one light off
indicates a jammed pipe. See
“Correct Misaligned or Jammed
Pipe” on page 161.
If active pipe column does not
contain pipe, light should be
off.
11. Rear pipe box status
indicator
If active pipe column contains
pipe, light should be on.
IMPORTANT:
•
Check pipe box status lights to
see when active column of pipe
box is empty. See “Shift Pipe Box”
on page 160.
•
One light on and one light off
indicates a jammed pipe. See
“Correct Misaligned or Jammed
Pipe” on page 161.
If active pipe column does not
contain pipe, light should be
off.
CMW
Controls - 46
JT3020 Mach 1/All Terrain Operator’s Manual
Right Control Console
Item
Description
Notes
12. Fluid pump status
indicator
If fluid pump is on, light
should be on.
NOTICE: Do not run fluid pump
without fluid.
If fluid pump is off, light
should be off.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Controls - 47
Right Control Console
Gauges
1. Rotation torque gauge
3. Drilling fluid pressure gauge
2. Thrust/pullback force gauge
4. Inner rotation torque gauge (AT only)
Item
Description
1. Rotation torque gauge
Displays rotational torque of
outer rotation drive.
Notes
CMW
Controls - 48
JT3020 Mach 1/All Terrain Operator’s Manual
Right Control Console
Item
Description
2. Thrust/pullback force
gauge
Displays thrust/pullback force
of thrust drive.
3. Drilling fluid pressure
gauge
Displays drilling fluid system
pressure.
4. Inner rotation torque
gauge (AT only)
Displays rotational torque of
inner rotation drive.
CMW
Notes
NOTICE: Monitor this gauge and
drilling fluid flowmeter carefully to see
if values are rising and falling at the
same time. If they are not, nozzle
might be plugged or fluid supply
depleted.
JT3020 Mach 1/All Terrain Operator’s Manual
Controls - 49
Information Center
Information Center
Displays
1. Float position display
6. Operational message display
2. ESID display
7. Pipeloader message display
3. Drilling fluid flow display
8. Diagnostic message display
4. Outer rotation speed display
9. Active display indicator
5. Inner rotation speed display
10. Diagnostic indicator
Item
Description
Notes
1. Float position display
Displays the position of the
carriage float.
When making and breaking joint, float
should generally be in middle of
range.
CMW
Controls - 50
JT3020 Mach 1/All Terrain Operator’s Manual
Information Center
Item
Description
Notes
2. ESID display
Displays the ESID
information.
IMPORTANT: If a strike is detected,
the bottom portion of the display
automatically switches to the ESID
information display.
3. Drilling fluid flow
display
Displays the estimated GPM
or LPM of drilling fluid being
pumped.
4. Outer rotation speed
display
Displays the measured RPM
of outer rotation pipe.
5. Inner rotation speed
display
Displays the measured RPM
of inner rotation pipe (AT
only).
6. Operational message
display
Displays operational status of
cruise control, carve mode,
drill fluid, tracker control, and
diagnostic test mode.
7. Pipeloader message
display
Displays messages related to
add or remove pipe cycles.
8. Diagnostic message
display
Displays messages related to
diagnostic information of
machine.
9. Active display indicator
Indicates that information
center display is actively
updating.
IMPORTANT: If nothing is changing
on the display except this indicator,
communications may have stopped.
10. Diagnostic indicator
Indicates errors in Main dc,
ESID dc and ICrt dc
Device shown is the source of the
diagnostic code shown.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Controls - 51
Information Center
Soft Keys
Keys F1-F6 can be assigned different functions based on which display is selected. Pressing any of the
assigned keys may reassign any key as needed for the new display.
The soft keys are described below as they are assigned (shown) in the diagram, but can have many other
configurations that are not shown here.
1. Clear button
4. Pipe counter button
2. Module button
5. Hours information button
3. Buz off/ buz on button
6. Extra function button (not assigned)
Item
Description
Notes
1. Clear button
Press button to clear a
diagnostic code or return to
the previous screen.
IMPORTANT: Removes diagnostic
code from the display but does not
clear the code.
2. Module button
Used for further diagnostics
on machine.
Provides access to individual
components in the system.
CMW
Controls - 52
JT3020 Mach 1/All Terrain Operator’s Manual
Information Center
Item
Description
Notes
3. Buzz off/buzz on button
Toggles indicator (intermittent
buzzer) off or on for reminder
when key is on but engine is
not running.
IMPORTANT: If the key is left on,
battery will discharge.
4. Pipe counter button
Displays pipe count in lower
part of display to allow
operator to count pipe while
drilling and backreaming.
Pipe counter only works when running
automated add pipe or remove pipe
cycles. If changing pipe manually,
counter will not increment or
decrement. Can display both positive
and negative counts.
Push to reset to zero at any
time.
5. Hours information
button
Displays hour counters for
machine, including: total
hours, inner rotation hours,
cruise hours and drill fluid
hours. Button also records
total pipe used, pipe added
with automation and pipe
removed with automation.
6. Extra function button
Available to perform
additional tasks when
needed.
CMW
Hours are displayed in tenths of an
hour. 050 is equivalent to 5.0 hours.
JT3020 Mach 1/All Terrain Operator’s Manual
Controls - 53
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, pull.
IMPORTANT: Stand on platform when
operating anchor controls.
To remove anchor, push.
CMW
Controls - 54
JT3020 Mach 1/All Terrain Operator’s Manual
Anchoring System Console
Item
Description
Notes
2. Left thrust control
To move anchor down, pull.
IMPORTANT: Stand on platform when
operating anchor controls.
To move anchor up, push.
3. Right rotation control
To drive anchor, pull.
IMPORTANT: Stand on platform when
operating anchor controls.
To remove anchor, push.
4. Right thrust control
To move anchor down, pull.
To move anchor up, push.
CMW
IMPORTANT: Stand on platform when
operating anchor controls.
JT3020 Mach 1/All Terrain Operator’s Manual
Controls - 55
Seat/Armrest
Seat/Armrest
1. Seat recline control
2. Seat slide control
Item
Description
1. Seat recline control
To recline or raise seatback,
lift.
Notes
To lock seatback in position,
release.
CMW
Controls - 56
JT3020 Mach 1/All Terrain Operator’s Manual
Seat/Armrest
Item
Description
2. Seat slide control
To slide forward or backward,
move left.
To lock seat in position, move
right.
CMW
Notes
JT3020 Mach 1/All Terrain Operator’s Manual
Controls - 57
Engine Compartment Controls
Engine Compartment Controls
1. Throttle switch
3. High/auto fan speed switch
2. AT/JT drilling mode switch (AT only)
4. Battery disconnect switch
Item
Description
Notes
1. Throttle switch
To increase engine speed,
press top.
Use this switch only if throttle switch
on console does not work.
To decrease engine speed,
press bottom.
c00ic243h.eps
To further increase or
decrease speed, press
additional times (or hold until
desired speed is reached).
CMW
Controls - 58
JT3020 Mach 1/All Terrain Operator’s Manual
Engine Compartment Controls
Item
Description
Notes
2. AT/JT drilling mode
switch (AT only)
To select AT mode, press top.
Use AT mode when using AT pipe
with inner rod and rock drilling bits.
To select AT Dirt mode, move
to middle.
To select JT mode, press
bottom.
Use AT Dirt mode when using AT pipe
with inner rod and adapter to use dirt
tool head.
Use JT drilling mode when using JT
pipe without inner rod.
3. High/auto fan speed
switch
For high speed, press top.
For automatic speed, press
bottom.
4. Battery disconnect
switch
To connect, move clockwise.
To disconnect, move
counterclockwise.
CMW
IMPORTANT: If switch is on high
speed, fan will run at full speed all the
time. If switch is on auto speed, fan
speed will vary.
JT3020 Mach 1/All Terrain Operator’s Manual
Controls - 59
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 750/752 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
Indicates beacon temperature
in degrees Centigrade or
degrees Farenheit.
Notes
CMW
Controls - 60
JT3020 Mach 1/All Terrain Operator’s Manual
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
JT3020 Mach 1/All Terrain Operator’s Manual
Controls - 61
750/752 Display
Item
Description
Notes
6. Display battery status
indicator
Indicates display power from
drilling unit.
If all five 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
Controls - 62
JT3020 Mach 1/All Terrain Operator’s Manual
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 750/752 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
JT3020 Mach 1/All Terrain Operator’s Manual
Controls - 63
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
JT3020 Mach 1/All Terrain Operator’s Manual
Controls - 64
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:
CMW
•
Press with Recall button
•
Connect display to PC
running Trac
Management System
software.
JT3020 Mach 1/All Terrain Operator’s Manual
Operation Overview - 65
Operation Overview
Chapter Contents
Planning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Setting Up at Jobsite . . . . . . . . . . . . . . . . . . . . . . . 66
Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Backreaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Leaving Jobsite. . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Storing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 68
CMW
Operation Overview - 66
JT3020 Mach 1/All Terrain Operator’s Manual
Planning
Planning
1. Gather information about jobsite. See page 71.
2. Inspect jobsite. See page 72.
3. Classify jobsite. See page 74.
4. Plan bore path. See page 76.
5. Check supplies and prepare equipment. See page 87.
6. Load equipment. See page 96.
Setting Up at Jobsite
1. Prepare jobsite. See page 86.
2. Mix drilling fluid.
3. Unload drilling unit from trailer. See page 99.
4. Assemble drill string. See page 107.
5. Position drilling unit and drill frame. See page 103.
6. Assemble strike system. See page 133.
7. Anchor drilling unit. See page 131.
8. Connect fluid system. See page 103.
9. Calibrate tracker with beacon that will be installed in beacon housing. See tracker operator’s manual.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Operation Overview - 67
Drilling
Drilling
1. Start system. See page 103.
2. Engage tracker control if desired. See page 144.
3. Drill first pipe. See page 112.
4. Record bore path. See page 120.
5. Enable automated pipeloader system. See page 113.
6. Add pipe. See page 114.
7. Drill remaining pipes in pipe box.
•
Correct direction. See page 118.
•
Engage cruise control. See page 165.
•
Shift pipe box. See page 159.
8. Add additional drill pipe to empty box (see page 162) to complete bore.
9. Surface drill head. See page 121.
•
Remove drill head.
•
Grease downhole tool (AT mode).
CMW
Operation Overview - 68
JT3020 Mach 1/All Terrain Operator’s Manual
Backreaming
Backreaming
1. Assemble backream string. See page 122.
2. Start drilling unit and adjust throttle.
3. Set drilling fluid flow. Check that fluid flows through all nozzles. See page 139.
4. Remove extra drill pipe from pipe box (see page 154) to complete backream.
5. Remove remaining pipe to complete backream. See page 124.
6. Remove pullback device. See page 127.
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 127.
2. Remove anchors. See page 133.
3. Rinse unit and downhole tools. See page 192.
4. Disassemble strike system and disconnect from fluid system. See page 193.
5. Stow tools. See page 193.
6. Load unit onto trailer. See page 96.
Storing Equipment
1. For cold weather storage, antifreeze drilling unit. See page 190.
2. For long-term storage, disconnect battery disconnect switch.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Prepare - 69
Prepare
Chapter Contents
Gather Information . . . . . . . . . . . . . . . . . . . . . . . . . 71
•
Review Job Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
•
Notify One-Call Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
•
Examine Pullback Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
•
Arrange for Traffic Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
•
Plan for Emergency Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Inspect Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
•
Identify Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
•
Select Start and End Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Classify Jobsite. . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
•
Inspect Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
•
Select a Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
•
Apply Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Plan Bore Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
•
Recommended Bend Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
•
Entry Pitch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
•
Minimum Setback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
•
Minimum Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
•
Bore Path Calculator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
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Prepare Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
•
Mark Bore Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
•
Prepare Entry Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Check Supplies and Prepare Equipment . . . . . . . 87
•
Check Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
•
Prepare Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
•
Assemble Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
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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.
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JT3020 Mach 1/All Terrain Operator’s Manual
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 74.)
•
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.
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.
Identify Hazards
Identify safety hazards and classify jobsite. See “Classify Jobsite” on page 74.
Jobsite hazards could cause death or serious injury. Use
correct equipment and work methods. Use and maintain proper safety
equipment.
NOTICE:
•
Wear personal protective equipment including hard hat, safety eye wear, and hearing protection.
•
Do not wear jewelry or loose clothing.
•
Notify One-Call and companies which do not subscribe to One-Call.
•
Comply with all utility notification regulations before digging or drilling.
•
Verify location of previously marked underground hazards.
•
Mark jobsite clearly and keep spectators away.
Remember, jobsite is classified by hazards in place -- not by line being installed.
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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 82.
Check that there is enough space to work and to set up electric strike system.
Comfort
Consider shade, wind, fumes, and other site features.
Drill downhill when possible so fluid will flow away from drilling unit.
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JT3020 Mach 1/All Terrain Operator’s Manual
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.
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Classify Jobsite
Apply Precautions
Once classified, precautions appropriate for jobsite must be taken.
Electric Jobsite Precautions
In addition to using a directional drilling system with an electric strike system, use one or both of these
methods.
•
Expose line by careful hand digging or soft excavation. Use beacon to track bore path.
•
Have service shut down while work is in progress. Have electric company test lines before returning
them to service.
Natural Gas Jobsite Precautions
In addition to using a directional drilling system and positioning equipment upwind from gas lines, use one
or both of these methods.
•
Expose lines by careful hand digging or soft excavation. Use beacon to track bore path.
•
Have gas shut off while work is in progress. Have gas company test lines before returning them to
service.
Crystalline Silica (Quartz) Dust Precautions
Follow OSHA or other guidelines for exposure to crystalline silica when trenching, sawing or drilling
through material that might produce dust containing crystalline silica (quartz).
Other Jobsite Precautions
You may need to use different methods to safely avoid other underground hazards. Talk with those
knowledgeable about hazards present at each site to determine which precautions should be taken or if
job should be attempted.
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JT3020 Mach 1/All Terrain Operator’s 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 83 and use these measurements to
help plan your bore.
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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.
Make sure pitch (A) changes no more than the
following percentages over the full length of each pipe.
JT pipe
5.6%
AT pipe
5.4%
AT cobble pipe
4.5%
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 750/752 Display on the operator’s console. See page 59.
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JT3020 Mach 1/All Terrain Operator’s Manual
Plan Bore Path
Bend Radius
JT3020 drill pipes have a tested minimum bend radius
of 175’ (53 m). This means that a 90-degree bend in
the bore path:
•
has a radius (A) of 175’ (53 m)
•
requires approximately 275’ (84 m) of drill pipe
(B).
NOTICE: Bending drill pipe more sharply than
recommended will damage the pipe and cause
failure over time.
•
If bend radius is reduced, drill pipe life is
reduced.
•
If bend radius is increased, drill pipe life is
increased.
IMPORTANT: Use the charts on the next page to keep bends within safe limits.
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Plan Bore Path
Pipe-By-Pipe Bend Limits
JT pipe
Pipe
(C)
Forward (B)
Deflection (A)
Pipe
(C)
Forward (B)
Deflection (A)
1
9’ 10” (3.0 m)
0’ 3.3” (.08 m)
15
130’ 8.8” (39.9 m)
58’ 8” (17.9 m)
2
19’ 7.7” (6.0 m)
1’ 1.3” (.34 m)
16
137’ .8” (41.8 m)
66’ 2.4” (20.2 m)
3
29’ 4.7” (9.0 m)
2’ 5.8” (.76 m)
17
142’ 11.6” (43.6 m)
74’ 1” (22.6 m)
4
39’ .5” (11.9 m)
4’ 4.9” (1.3 m)
18
148’ 5” (45.2 m)
82’ 3.3” (25.1 m)
5
48’ 6.8” (14.8 m)
6’ 10.5” (2.1 m)
19
153’ 4.7” (46.8 m)
90’ 9.2” (27.7 m)
6
57’ 11.3” (17.7 m)
9’ 10.4” (3.0 m)
20
157’ 10.6” (48.1 m)
99’ 6.3” (30.3 m)
7
67’ 1.6” (20.5 m)
13’ 4.7” (4.1 m)
21
161’ 10.6” (49.3 m)
108’ 6.2” (33.1 m)
8
76’ 1.3” (23.2 m)
17’ 5” (5.3 m)
22
165’ 4.3” (50.4 m)
117’ 8.7” (35.9 m)
9
84’ 10.2” (25.9 m)
21’ 11.3” (6.7 m)
23
168’ 3.8” (51.3 m)
127’ 1.3” (38.7 m)
10
93’ 3.8” (28.4 m)
26’ 11.5” (8.2 m)
24
170’ 8.9” (52 m)
136’ 7.7” (41.6 m)
11
101’ 5.9” (30.9 m)
32’ 5.2” (9.9 m)
25
172’ 7.6” (52.6 m)
146’ 3.6” (44.6 m)
12
109’ 4.1” (33.3 m)
38’ 4.4” (11.7 m)
26
173’ 11.7” (53.0 m)
156’ .6” (47.6 m)
13
116’ 10.2” (35.6 m) 44’ 8.8” (13.6 m)
27
174’ 9.1” (53.3 m)
165’ 10.3” (50.6 m)
14
123’ 11.9” (37.8 m) 51’ 6.1” (15.7 m)
28
175’ (53.3 m)
175’ (53.3 m)
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Plan Bore Path
AT Pipe
Pipe
(C)
Forward (B)
Deflection (A)
Pipe
(C)
Forward (B)
Deflection (A)
1
9’ 4.7” (2.9 m)
0’ 3.0” (0.1 m)
16
132’ 6.7” (40.4 m)
60’ 9” (18.5 m)
2
18’ 9.2” (5.7 m)
1’ 1.1” (.3 m)
17
138’ 6” (42.2 m)
68’ .4” (20.7 m)
3
28’ 0.9” (8.6 m)
2’ 3.2” (.7 m)
18
144’ .5” (43.9 m)
75’ 7.4” (23 m)
4
37.7’ 3.7” (11.4 m)
4’ .3” (1.9 m)
19
149’ 2.1” (45.5 m)
83’ 6” (25.4 m)
5
46’ 5.2” (14.2 m)
6’ 3.3” (19 m)
20
153’ 10.4” (46.9 m)
91’ 7.6” (27.9 m)
6
55’ 5.1” (16.9 m)
9’ .1” (2.7 m)
21
158’ 1.5” (48.2 m)
100’ .2” (30.5 m)
7
64’ 3.1” (19.6 m)
12’ 2.7” (3.7 m)
22
161’ 11” (49.4 m)
108’ 7.4” (33.1 m)
8
72’ 10.9” (22.2 m)
15’ 10.9” (4.8 m)
23
165’ 3” (50.4 m)
117’ 4.9” (35.8 m)
9
81’ 4.1” (24.8 m)
20’ .6” (6.1 m)
24
168’ 1.3” (51.2 m)
126’ 4.3” (38.5 m)
10
89’ 6.5” (27.3 m)
24’ 7.7” (7.5 m)
25
170’ 5.7” (52 m)
135’ 5.5” (41.3 m)
11
97’ 5.9” (29.7 m)
29’ 8” (9 m)
26
172’ 4.2” (52.5 m)
144’ 8” (44.1 m)
12
105’ 1.8” (32.0 m)
35’ 1.3” (10.7 m)
27
173’ 8.8” (53 m)
153’ 11.5” (46.9 m)
13
112’ 6.1” (34.3 m)
40’ 11.5” (12.5 m)
28
174’ 7.3” (53.2 m)
163’ 3.8” (49.8 m)
14
119’ 6.5” (36.4 m)
47’ 2.3” (14.4 m)
29
175’’ (53.3 m)
175’ (53.3 m)
15
126’ 2.8” (38.5 m)
53’ 9.5” (16.4 m)
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Plan Bore Path
AT cobble pipe
Pipe
(C)
Forward (B)
Deflection (A)
Pipe
(C)
Forward (B)
Deflection (A)
1
9’ 4.8” (2.9 m)
0’ 2.5” (0.1 m)
19
157’ 10” (48.1 m)
71’ 5.7” (21.8 m)
2
18’ 9.3” (5.7 m)
0’ 10.1” (.3 m)
20
163’ 10.5” (49.9 m)
78’ 8.2” (24 m)
3
28’ 1.4” (8.6 m)
1’ 10.7” (.6 m)
21
169’ 7” (51.7 m)
86’ 1.7” (26.3 m)
4
37’ 4.8” (11.4 m)
3’ 4.3” (1 m)
22
174’ 11.5” (53.3 m)
93’ 10.3” (28.6 m)
5
46’ 7.3” (14.2 m)
5’ 2.9” (1.6 m)
23
179’ 11.8” (54.9 m)
101’ 9.6” (31 m)
6
55’ 8.7” (17 m)
7’ 6.3” (2.3 m)
24
184’ 7.7” (56.3 m)
109’ 11.6” (33.5 m)
7
64’ 8.7” (19.7 m)
10’ 2.7” (3.1 m)
25
188’ 11.2” (57.6 m)
118’ 3.9” (36.1 m)
8
73’ 7.2” (22.4 m)
13’ 3.9” (4.1 m)
26
192’ 10.2” (58.8 m)
126’ 10.5” (38.7 m)
9
82’ 4” (25.1 m)
16’ 9.7” (5.1 m)
27
196’ 4.5” (59.9 m)
135’ 7” (41.3 m)
10
90’ 10.7” (27.7 m)
20’ 8.3” (6.3 m)
28
199’ 6.1” (60.8 m)
144’ 5.4” (44 m)
11
99’ 3.3” (30.3 m)
24’ 11.4” (7.6 m)
29
202’ 2.9” (61.6 m)
153’ 5.3” (46.8 m)
12
107’ 5.4” (32.8 m)
29’ 6.9” (9 m)
30
204’ 6.8” (62.4 m)
162’ 6.6” (49.5 m)
13
115’ 5” (35.2 m)
34’ 6.7” (10.5 m)
31
206’ 5.8” (62.9 m)
171’ 9” (52.3 m)
14
123’ 1.8’ (37.5 m)
39’ 10.8” (12.2 m)
32
207’ 11.9” (53.3 m)
181’ .3” (55.2 m)
15
130’ 7.7” (39.8 m)
45’ 7” (13.9 m)
33
209’ 1” (63.4 m)
190’ 4.3” (55.2 m)
16
137’ 10.4” (42 m)
51’ 7.1” (15.7 m)
34
209’ 9” (63.9 m)
199’ 8.8” (60.9 m)
17
144’ 9.8” (44.1 m)
57’ 11.1” (17.7 m)
35
210’ (64 m)
210’ (64 m)
18
151’ 5.7” (46.2 m)
64’ 6.7” (19.7 m)
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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 minimum setback
longer and deeper.
Minimum Setback
Setback is the distance from the entry point to where
pipe becomes horizontal (B1).
NOTICE: If setback is too small (B2), you will
exceed bend limits and damage the pipe.
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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.
JT pipe
Minimum depth (D)
Entry pitch (A)
Setback (B)
Depth to begin steering (S)
4 ft 5 in (1.3 m)
-18%
11 ft 8 in (3.6 m)
1 ft 8 in (0.51 m)
5 ft 3 in (1.6 m)
-20%
11 ft 11 in (3.6 m)
1 ft 10 in (0.56 m)
6 ft 1 in (1.9 m)
-22%
12 ft 2 in (3.7 m)
2 ft 0 in (0.61 m)
7 ft (2.1 m)
-24%
12 ft 5 in (3.8 m)
2 ft 2 in (0.66 m)
7 ft 11 in (2.4 m)
-26%
12 ft 7 in (3.8 m)
2 ft 4 in (0.71 m)
9 ft (2.7 m)
-28%
12 ft 10 in (3.9 m)
2 ft 6 in (0.76 m)
10 ft (3 m)
-30%
13 ft (4 m)
2 ft 8 in (0.81 m)
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Plan Bore Path
IMPORTANT: Numbers in table based on 175’ (53 m) minimum bend radius, beacon housing, EZConnect, connector, transition sub, and 1/3 of first drill pipe (L, totaling 8’ 8” [2.6 m]) in the ground before
steering.
AT pipe
Minimum depth (D)
Entry pitch (A)
Setback (B)
Depth to begin steering (S)
3 ft 11 in (1.2 m)
-18%
9 ft 4 in (2.7 m)
1 ft 1 in (0.33 m)
4 ft 8 in (1.4 m)
-20%
9 ft 7 in (2.9 m)
1 ft 3 in (0.38 m)
5 ft 5 in (1.7 m)
-22%
9 ft 11 in (3.0 m)
1 ft 4 in (0.41 m)
6 ft 4 in (1.9 m)
-24%
10 ft 3 in (3.1 m)
1 ft 6 in (0.46 m)
7 ft 3 in (2.2 m)
-26%
10 ft 6 in (3.2 m)
1 ft 7 in (0.48 m)
8 ft 2 in (2.5 m)
-28%
10 ft 9 in (3.3 m)
1 ft 8 in (0.51 m)
9 ft 2 in (2.8 m)
-30%
11 ft 1 in (3.6 m)
1 ft 10 in (0.56 m)
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Plan Bore Path
AT Cobble pipe
Minimum depth (D)
Entry pitch (A)
Setback (B)
Depth to begin steering (S)
9 ft 4 in (2.8 m)
-18%
11 ft 8 in (3.6 m)
1 ft 1 in (0.33 m)
9 ft 7 in (2.9 m)
-20%
11 ft 11 in (3.6 m)
1 ft 3 in (0.38 m)
9 ft 11 in (3 m)
-22%
12 ft 2 in (3.7 m)
1 ft 4 in (0.41 m)
10 ft 3 in (3.1 m)
-24%
12 ft 5 in (3.8 m)
1 ft 6 in (0.46 m)
10 ft 6 in (3.2 m)
-26%
12 ft 7 in (3.8 m)
1 ft 7 in (0.48 m)
10 ft 9 in (2.3 m)
-28%
12 ft 10 in (3.9 m)
1 ft 8 in (0.51 m)
11 ft 1 in (3.4 m)
-30%
13 ft (4 m)
1 ft 10 in (0.56 m)
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Prepare - 86
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. “Align the Joints” on page 155.
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. Steer down as required at start. Drill
head will tend to move in easiest direction (toward
surface) when rotated near the surface.
To prevent bending or straining pipe, position drilling
unit for straight entry.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Prepare - 87
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 152)
•
transition sub
•
anchoring equipment and accessories
•
bits, screens, nozzles (see page 147)
•
adapters, pipe, beacon housings
•
marking flags or paint
•
water and additional hoses
•
fuel
•
drilling fluid additives (see page 139)
•
spare fuses
•
keys
•
backreamers, swivels, pulling devices (see page 147)
•
wash down hose and spray gun
•
duct tape
•
spray lubricant
•
tool joint compound (see page 199)
•
electrically insulating boots and gloves
•
personal protective equipment, such as hard hat and safety glasses
•
notepad and pencil
CMW
Prepare - 88
JT3020 Mach 1/All Terrain Operator’s Manual
Check Supplies and Prepare Equipment
Prepare Equipment
Fluid Levels
•
fuel
•
hydraulic fluid
•
engine coolant
•
battery charge
•
engine oil
Condition and Function
•
filters (air, oil, hydraulic)
•
fluid pump
•
couplers
•
tires and tracks
•
pumps and motors
•
drilling fluid mixer
•
hoses and valves
•
water tanks
Assemble Accessories
Fire Extinguisher
If required, mount a fire extinguisher near the power unit but away from possible points of ignition. The fire
extinguisher should always be classified for both oil and electric fires. It should meet legal and regulatory
requirements.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Drive - 89
Drive
Chapter Contents
Start Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Steer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Shut Down Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
CMW
Drive - 90
JT3020 Mach 1/All Terrain Operator’s Manual
Start Unit
Start Unit
1. Insert key.
2. Turn key clockwise. See page 23 for more information.
3. Run engine at low throttle for 5 minutes.
Steer Unit
To steer drilling unit while using tethered ground drive controller, follow instructions
for type of steering desired.
To steer while moving forward, push forward and move to left or right. Drilling unit
will turn to left or right.
To steer while moving backward, pull back and move to left or right. Drilling unit
will turn to left or right.
c00ic145h.eps
For tight steering in low speed, move control to left or right limit, then forward or backward as needed.
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 202.)
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 track edges pressed against hard walls, curbs or other objects.
•
Driving on slopes.
•
Operating on corrosive materials such as salt or fertilizer. Wash immediately.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Drive - 91
Shut Down Unit
Shut Down Unit
1. Stop track movement.
2. Lower drill frame and stabilizers to the ground.
IMPORTANT: If frame and stabilizers cannot be lowered, use cylinder locks or other suitable
material to block the tracks. Remove cylinder locks or chocks before driving unit.
3. Run engine at low throttle for 3 minutes to cool.
4. Turn ignition switch to STOP.
5. Remove key.
CMW
Drive - 92
JT3020 Mach 1/All Terrain Operator’s Manual
Shut Down Unit
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Transport - 93
Transport
Chapter Contents
Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
•
Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
•
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
•
Pipe box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
•
Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
•
Unload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Tow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
CMW
Transport - 94
JT3020 Mach 1/All Terrain 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
JT3020 Mach 1/All Terrain Operator’s Manual
Transport - 95
Lift
Procedure
Use a crane capable of supporting the equipment's size and weight. See “Specifications” on page 235 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.
Pipe Box
Prepare Pipe Box
See “Remove/Install Pipe Box” on page 158.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Transport - 96
Load
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. Using tethered ground drive controller, pull power mode switch into low position. See page 28.
3. Move drilling unit to rear of trailer and align with ramps.
4. Slowly drive unit onto trailer.
5. Lower stabilizers to trailer floor.
6. Lower drill frame to trailer floor.
7. Stop engine when unit is safely positioned on trailer bed for proper tongue weight.
8. Attach tiedowns to drilling unit where indicated on page 97.
9. Ensure that all covers are properly secured.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Transport - 97
Load
Tie Down
Points
Tiedown points are identified by tiedown decals. Securing to trailer at other
points can damage machinery.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Transport - 98
Load
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.
•
Use Grade 7-3/8” (18.7 cm) transport chain to secure drilling unit.
Loop a Grade 7-3/8” (18.7 cm) transport chain around each tie down point. See chart below for correct
distances between tiedown ends. Make sure tiedowns are tight before transporting.
Note: If hauling unit without pipe box, remove remaining pipe in drill frame chute.
CMW
Distance
U.S.
Metric
A
12-45”
31-114 cm
B
0-45”
0-114 cm
C
less than 55”
less than 140 cm
JT3020 Mach 1/All Terrain Operator’s Manual
Transport - 99
Tow
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. Using tethered ground drive controller, pull power mode switch into low position. See page 27.
5. Raise stabilizers.
6. Raise drill frame.
7. Slowly back unit down trailer or ramps.
Tow
Under normal conditions, drilling unit should not be towed. If towing is necessary:
•
tow for short distances at less than 1 mph (1.6 km/h),
•
attach chains to indicated tow points facing towing vehicle (shown),
•
use maximum towing force of 1.5 times unit weight,
•
disengage track planetaries.
If front tow points are facing towing vehicle, loop chain (1) through tow point and pull straight forward. If
back tow points are facing towing vehicle, loop chain (2) through each tow point and bring them together to
a central pull point.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Transport - 100
Tow
To disengage track planetaries, reverse small cover plate in center of planetary on each track drive.
IMPORTANT: When planetaries are disengaged, unit has no brakes.
A. Normal operation
CMW
B. Towing
JT3020 Mach 1/All Terrain Operator’s Manual
Conduct a Bore - 101
Conduct a Bore
Chapter Contents
Position Equipment . . . . . . . . . . . . . . . . . . . . . . . 103
Connect Fluid System . . . . . . . . . . . . . . . . . . . . . 103
Start System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Prime Drilling Fluid Pump . . . . . . . . . . . . . . . . . . 104
Operate Carriage Control . . . . . . . . . . . . . . . . . . 105
Clamp Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Assemble Drill String . . . . . . . . . . . . . . . . . . . . . . 107
•
Prepare Beacon Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
•
Attach Transition Sub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
•
Attach Beacon Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
•
Connect Drill Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Drill First Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Enable Automated Pipeloader System . . . . . . . 113
Add Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Correct Direction . . . . . . . . . . . . . . . . . . . . . . . . . 118
•
Basic Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
•
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
•
Drill Head Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
CMW
Conduct a Bore - 102
JT3020 Mach 1/All Terrain Operator’s Manual
Use Carve Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Record Bore Path . . . . . . . . . . . . . . . . . . . . . . . . . 120
Surface Drill Head . . . . . . . . . . . . . . . . . . . . . . . . 121
Assemble Backream String . . . . . . . . . . . . . . . . 122
Remove Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Remove Pullback Device . . . . . . . . . . . . . . . . . . . 127
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Conduct a Bore - 103
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 73.
2. Move equipment into selected positions.
Connect Fluid System
1. Connect fluid hose from mixing system to drilling fluid
pump. A 2.0” (50.8 mm) or larger, non-collapsible
hose is required.
2. Install y-strainer between mixing unit and drilling fluid
pump. Position strainer so that drilling fluid flows in
the direction of the arrow. In most cases, positioning
strainer at outlet of mixing unit gives best results.
IMPORTANT: Clean y-strainer regularly. See
page 208.
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. See “Drilling Fluid”
on page 139.
2. Enable tracker control mode if desired. See “Tracker Control” on page 144.
3. Press top of drilling unit throttle switch. Engine will increase to full throttle. If you do not want to use
autothrottle mode, return switch to center position.
CMW
Conduct a Bore - 104
JT3020 Mach 1/All Terrain Operator’s Manual
Prime Drilling Fluid Pump
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
JT3020 Mach 1/All Terrain Operator’s Manual
Conduct a Bore - 105
Operate Carriage Control
Operate Carriage Control
Drilling
During normal drilling operation, the thrust/rotation control handles both
operations and allows any combination of the two based on the position of
the controller:
•
Push joystick toward 1A for forward thrust with clockwise rotation.
NOTICE: Counterclockwise rotation can unthread pipe in the ground.
•
Push joystick toward 2A for forward thrust with counterclockwise rotation.
•
Pull joystick toward 2B for reverse thrust, with counterclockwise rotation.
•
Pull joystick toward 1B reverse thrust, with clockwise rotation.
Assisted Make-up
During pipe change operations when front wrench is closed and carriage is
on front or rear home, the thrust/rotation control only handles the speed and
direction of rotation. The machine controller handles thrust and matches the
speed and direction of rotation to smoothly thread or unthread pipe sections.
Push joystick toward 1A or 1B for clockwise rotation (machine controlled
forward thrust).
Push joystick toward 2A or 2B for counterclockwise rotation (machine controlled reverse thrust).
If the thrust/rotation control is moved straight forward or backward so there is no rotation, only thrust is
controlled.
CMW
Conduct a Bore - 106
JT3020 Mach 1/All Terrain Operator’s Manual
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 between wrenches
(1 and 2). Always clamp on the larger diameter
areas on either side of the tool joint face.
IMPORTANT: Clamping pipes on top of
female end threads can damage threads. Only
clamp female pipe ends behind the threads.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Conduct a Bore - 107
Assemble Drill String
Assemble Drill String
AT Mode (With All Terrain Pipe)
1. Rockmaster tool
1
2. bit
2
3. JT3020 All Terrain
3
j15om031h.eps
AT Mode (With Cobble Pipe)
1. Cobblemaster tool
1
2. bit
2
3. JT3020 All Terrain lead pipe, cobble.
3
j15om031h.eps
CMW
Conduct a Bore - 108
JT3020 Mach 1/All Terrain Operator’s Manual
Assemble Drill String
Prepare Rockmaster Tool
1. Select bit. Ensure that bit has suitable number of nozzles for jobsite conditions. See page 147.
2. Install bit onto Rockmaster tool using the wrench set and scribe line technique. See page 152 for
correct procedures.
3. Ensure that Rockmaster tool is properly lubricated (from last usage). If using Rockmaster tool for the
first time, lubricate the tool:
•
Remove plug from tool.
•
Install zerk.
•
Rotate the tool by hand while pumping tool with MPG (see “Recommended Lubricants/Service
Key” on page 199) until grease comes out at the seal.
4. Install beacon, following beacon instructions for:
•
battery replacement
•
beacon positioning
5. Install beacon housing lid. See page 148.
6. Follow beacon instructions to check beacon operation.
7. Follow tracker instructions to calibrate beacon.
Attach Lead Pipe
1. Start drilling unit engine.
2. Apply TJC (tool joint compound) to shoulders and threads, and thread lead pipe onto saver sub.
3. Clamp rear wrench.
4. Use machine power to connect lead pipe to saver sub. Tighten to full machine torque.
Attach Downhole Tool
See “Quick Wrench” on page 152.
Machine Torque
1. Remove blocks from pipe guides.
2. Pull tool into lower wrench.
3. Close wrench.
4. Use machine torque to tighten joint fully.
Quick Wrenches
1. Lube joints with TJC (tool joint compound).
2. Attach quick wrenches to the joint in the join position and tighten joint. See page 152 for procedure.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Conduct a Bore - 109
Assemble Drill String
AT Dirt Mode (All Terrain Pipe)
1. bit
2. beacon housing
3. adapter
4. collar
5. transition sub
6. inner spindle spacer
7. JT3020 AT drill pipe
JT Mode
1. bit
2. beacon housing
3. adapter
4. collar
5. transition sub
6. JT3020 Mach 1 drill pipe
CMW
Conduct a Bore - 110
JT3020 Mach 1/All Terrain Operator’s Manual
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 page 147 for more information, or contact your Ditch Witch dealer.
2. Insert nozzle into beacon housing.
3. Attach bit to beacon housing.
4. Install beacon, following beacon instructions for:
•
battery replacement
•
beacon positioning.
5. Install beacon housing lid.
6. Follow beacon instructions to check beacon operation.
7. Follow tracker instructions to calibrate beacon.
Attach Transition Sub
1. Remove blocks from pipe guides.
2. Pull transition sub into front wrench.
3. Close wrench.
4. Lube joints.
5. Use machine torque to tighten joint fully.
Attach Beacon Housing
Use machine torque to attach beacon housing.
1. Pull beacon housing into front wrench.
2. Close wrench.
3. Use machine torque to tighten joint fully.
Connect Drill Pipe
1. Start drilling unit engine.
2. Align drill pipe in front wrench.
3. Clamp tool joint in front wrench. See “Clamp Pipe” on page 106.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Conduct a Bore - 111
Assemble Drill String
4. Disconnect from pipe:
•
Rotate spindle counterclockwise until threads on pipe segments are disengaged from each other.
Carriage will move backward as pipe rotates counterclockwise.
•
Stop rotation and move carriage backward until it stops on the rear stop switch.
5. Load pipe:
•
Make sure pipe box is positioned correctly.
•
Open grippers or make sure they are open.
•
Grippers open as pipe is lowered.
•
Close grippers around pipe.
•
Lubricate pipe threads at front wrench.
•
Move pipe to spindle.
•
Raise pipe lifters.
6. Connect pipe:
•
Move carriage forward until spindle meets back end of pipe joint. Rotate spindle clockwise until pipe
begins to spin. Relax grippers slightly.
•
Move carriage forward until pipe joints meet at front wrench.
•
Rotate spindle clockwise. Carriage will move forward as pipe threads tighten.
•
Rotate clockwise until spindle stops turning, and joint is fully tightened.
•
Open grippers.
•
Retract shuttles fully.
•
Open front wrench.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Conduct a Bore - 112
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.
AT Mode
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 86.
4. Rotate inner spindle clockwise.
5. Slowly move carriage forward. Drill first pipe as straight as possible.
6. Monitor gauges.
•
If inner rotation torque approaches 800 ft•lb (1080 N•m), slow carriage travel.
•
If inner rotation stalls, stop carriage thrust. If inner rotation does not resume, pull pipe back.
AT Dirt/JT Mode
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 86.
4. Slowly move carriage forward. Drill first pipe as straight as possible.
5. Monitor gauges.
6.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Conduct a Bore - 113
Swab the Hole
Swab the Hole
IMPORTANT: Swab hole after each pipe is drilled to remove cuttings and keep the hole clear (AT
Mode). Some conditions may require more frequent swabbing.
1. Move carriage forward until carriage touches rear
wrench.
2. Move carriage to rear of drill frame with drilling
fluid and inner rotation on.
3. Move carriage forward until pipe joint is properly
located between wrenches for joint breakout.
Enable Automated Pipeloader System
Add Pipe
Remove Pipe
1. Ensure pipe box is properly positioned. See
“Shift Pipe Box” on page 160.
1. Ensure pipe box is properly positioned. See
“Shift Pipe Box” on page 160.
2. Open front wrench.
2. Open front wrench.
3. Retract shuttles.
3. Retract shuttles.
4. Adjust engine to full throttle for add pipe
function to work.
4. Adjust engine to full throttle for remove pipe
function to work.
5. Press top of add pipe/manual/remove pipe
switch. If any steps are skipped, the
Information Center will inform the operator
which steps to take to continue operation.
5. Press bottom of add pipe/manual/remove pipe
switch. If any steps are skipped, the
Information Center will inform the operator
which steps to take to continue operation.
6. Grippers will open, pipe will be lifted, pipe box
checked (pipe available), then lowered into
shuttles. If no pipe is detected, the operator is
instructed to move the pipe box before
continuing.
6. Grippers will open, pipe will be lowered and
lifted out of shuttles.
7. Ensure pipe box column is not full. If pipe box
column is full, shift pipe box to the next empty
column.
IMPORTANT: If operator leaves the seat during an add or remove pipe cycle when the information
center says “Adding (or removing) pipe”, the pipe cycle will pause and the information center will say
PIPE paused in <pipe state>. When returning to the seat, the display changes to three cycling
messages that say “PIPE LOADER paused”, “to continue...”, “press RESUME switch.” This happens
because the automation was moving something when you left the seat and it waits for you to tell it to
finish moving. If you leave the seat while the display says the pipe cycle is “ready” or “waiting”, reenabling the system is not needed.
CMW
Conduct a Bore - 114
JT3020 Mach 1/All Terrain Operator’s Manual
Add Pipe
Add Pipe
AT Mode
1. Press top of drilling unit throttle switch. Engine will increase to full throttle.
2. Enable automated pipeloader system if desired. See “Enable Automated Pipeloader System” on
page 113.
3. Break joint at saver sub.
Manual Pipeloader Controls
Automated Pipeloader Control
•
Turn inner rotation off and position pipe
between wrenches. See “Clamp Pipe” on
page 106.
•
Turn inner rotation off and position pipe
between wrenches. See “Clamp Pipe” on
page 106.
•
If spindle brake is set, disengage it, rotate
outer pipe to 3 o’clock, and close front
wrench.
•
If spindle brake is set, disengage it, rotate
outer pipe to 3 o’clock, and close front
wrench.
•
Locate drill head.
•
Locate drill head.
•
Rotate spindle counterclockwise.
•
Rotate spindle counterclockwise.
•
Carriage moves back slowly as threads
separate.
•
Carriage moves back slowly as threads
separate.
•
After threads are fully separated, stop
rotation and move carriage to back of
frame until rear stop indicator is lit in right
console.
•
After threads are fully separated, stop
rotation and move carriage to back of
frame until rear stop indicator is lit in right
console.
•
While carriage is moving, grippers will grip,
pipe is lubed, and information center
displays corresponding messages.
4. Load pipe.
Manual Pipeloader Controls
Automated Pipeloader Control
•
Ensure that lift arms are completely
lowered.
•
•
Close grippers.
•
Move pipe in shuttles to spindle and lube
threads at wrench.
With carriage on rear stop switch at back
of drill frame (light is on in right console),
press RESUME. Display changes to
“Adding Pipe”. Pipe is moved to spindle,
pipe in box will is lifted.
•
Display reads “ADD PIPE waiting”.
•
Raise pipe in box.
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Conduct a Bore - 115
Add Pipe
5. Connect pipe to saver sub.
Manual Pipeloader Controls
Automated Pipeloader Control
•
Move carriage forward until saver sub
meets pipe.
•
Move carriage forward until saver sub
meets pipe.
•
Rotate spindle clockwise until saver sub
threads onto pipe.
•
Rotate spindle clockwise until saver sub
threads onto pipe.
•
Relax grippers.
•
Press RESUME. Grippers will relax.
6. Connect new pipe.
Manual Pipeloader Controls
Automated Pipeloader Control
•
Slowly move carriage forward to allow
inner rod to match up and rotate spindle
clockwise until pipe threads together.
•
Slowly move carriage forward to allow
inner rod to match up and rotate spindle
clockwise until pipe threads together.
•
To fully tighten joint, slowly rotate pipe until
spindle stops turning.
•
•
Open wrench and turn on inner rotation
switch if needed.
Press RESUME. Display changes to
“Adding Pipe”. Grippers will open, shuttles
will retract, pipe lifters will lower. Display
will read “ADD PIPE waiting”.
•
Open grippers fully.
•
To fully tighten joint, slowly rotate pipe until
spindle stops turning.
•
Retract shuttles.
•
•
Lower pipe lifters.
Open wrench and turn on inner rotation
switch if needed. If wrench will not open,
look at information center.
7. Press and hold quick fill fluid pump switch until pipe fills and fluid pressure begins to rise.
8. Adjust fluid flow control to set flow to appropriate level.
9. Turn inner rotation off.
10. Set clock position for steering or rotate spindle.
11. Turn inner rotation on.
12. Slowly move carriage forward. Adjust rotation speed control according to bit size and soil conditions.
13. Engage and set cruise control as desired. See “Cruise Control” on page 154.
14. Monitor gauges.
•
If inner rotation torque reaches 800 ft•lb (1080 N•m), slow carriage travel.
•
If inner rotation stalls, stop carriage travel. If inner rotation does not resume, pull pipe back.
15. Locate drill head with tracker at least every half-length of pipe.
IMPORTANT: To improve accuracy of depth estimate, turn inner rotation off, disengage spindle
brake, and rotate outer pipe to 3 o’clock.
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JT3020 Mach 1/All Terrain Operator’s Manual
Add Pipe
16. Engage spindle brake if desired, and drill rest of pipe.
IMPORTANT: If steering, rotate to desired clock position, engage spindle brake and drill.
JT Mode
1. Press top of drilling unit throttle switch. Engine will increase at full throttle.
2. Enable automated pipeloader system if desired. See “Enable Automated Pipeloader System” on
page 113.
3. Break joint at saver sub.
Manual Pipeloader Controls
Automated Pipeloader Control
•
Position pipe in wrenches.See “Clamp
Pipe” on page 106.
•
•
Locate drill head.
With pipe loader enabled, see “Enable
Automated Pipeloader System” on
page 113. Position pipe in wrenches. See
“Clamp Pipe” on page 106.
•
Rotate pipe to 12 o’clock position.
•
Locate drill head.
•
Close front wrench.
•
Rotate pipe to 12 o’clock position.
•
Rotate spindle counterclockwise.
•
Close front wrench.
•
Carriage moves back slowly as threads
separate.
•
Rotate spindle counterclockwise.
•
After threads are fully separated, stop
rotation and move carriage to back of
frame until rear stop indicator is lit in right
console.
•
Carriage moves back slowly, as threads
separate.
•
After threads are fully separated, stop
rotation and move carriage to back of
frame until rear stop indicator is lit in right
console.
•
While carriage is moving, grippers will grip,
pipe is lubed, and information center
displays corresponding messages.
4. Load pipe.
Manual Pipeloader Controls
Automated Pipeloader Control
•
Ensure that lift arms are completely
lowered.
•
•
Close grippers.
With carriage on rear stop switch at back
of drill frame (light is on in right console),
press RESUME. Display changes to
“Adding Pipe”.
•
Move pipe in shuttles to spindle and lube
front threads at wrench.
•
•
Raise pipe in box.
Pipe is moved to spindle, pipe in box will
be lifted. Display reads “ADD PIPE
waiting”.
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Conduct a Bore - 117
Add Pipe
5. Connect pipe to saver sub.
Manual Pipeloader Controls
Automated Pipeloader Control
•
Move carriage forward until saver sub
meets pipe.
•
Move carriage forward until saver sub
meets pipe.
•
Rotate spindle clockwise until saver sub
threads onto pipe.
•
Rotate spindle clockwise until saver sub
threads onto pipe.
•
Relax grippers.
•
Press RESUME. Grippers will relax.
6. Connect new pipe.
Manual Pipeloader Controls
Automated Pipeloader Control
•
Slowly move carriage forward until new
pipe meets pipe in wrench.
•
Slowly move carriage forward until new
pipe meets pipe in wrench.
•
Rotate spindle clockwise until pipe threads
together.
•
Rotate spindle clockwise until pipes thread
together.
•
To fully tighten joint, slowly rotate pipes
until spindle stops turning.
•
•
Open wrench.
Press RESUME. Display reads “Adding
Pipe”, grippers open, shuttles retract, pipe
lifters lower. Display reads “ADD PIPE
waiting”.
•
Open grippers fully.
•
•
Retract shuttles.
To fully tighten joint, slowly rotate pipe until
spindle stops turning.
•
Lower pipe lifters.
•
Open wrench. If wrench will not open, look
at information center. It will say that pipe
row is empty and pipe box needs to be
moved. After pipe box has been moved to
the new row, the front wrench can be
opened.
7. Press and hold quick fill fluid pump switch until pipe fills and fluid pressure begins to rise.
8. Adjust fluid flow control to set flow to appropriate level.
9. Rotate spindle.
10. Slowly move carriage forward. Adjust rotation speed control according to bit size and soil conditions.
11. Engage and set cruise control as desired. See “Cruise Control” on page 165.
12. Monitor gauges.
13. Locate drill head with tracker at least every half-length of pipe.
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JT3020 Mach 1/All Terrain 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
General
•
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 77.
•
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.
JT Mode
•
Do not push an entire piece of drill pipe into ground without rotation. This can exceed bend radius and
cause pipe failure.
AT Mode
•
Steering in rock is slower than steering in other soil conditions. Be patient.
•
Inner shaft is rotating at all times when AT mode is selected and inner rotation switch is on.
•
Stop outer rotation and engage spindle brake when making directional changes.
•
Depth estimate and pitch accuracy improve if drill head is at 3 o’clock when reading is taken.
•
Pull back 6” (152 mm) of pipe before checking pitch.
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Conduct a Bore - 119
Correct Direction
Procedure
1. Locate drill head. Take readings available with your beacon and locating equipment such as:
•
depth
IMPORTANT: In AT mode, depth
estimate improves if drill head is at
12 o’clock position (A) rather than
horizontal (B).
•
pitch
•
left/right information
•
temperature
•
beacon roll
A
B
j15om033h.eps
2. Compare position to bore plan. Determine direction drilling should go.
3. Position drill head.
4. Drill in pipe.
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:
JT mode
AT mode
1. Rotate pipe to clock position you intend to
travel.
1. Rotate outer pipe to clock position you intend
to travel.
2. Push pipe into ground.
2. Engage spindle brake.
3. Engage inner rotation and push pipe into
ground.
To move forward without changing direction:
JT mode
AT mode
1. Rotate pipe.
1. Rotate outer pipe.
2. Push pipe into ground.
2. Engage inner rotation and push pipe into
ground.
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JT3020 Mach 1/All Terrain Operator’s Manual
Use Carve Mode
Use Carve Mode
The Carve Mode feature assists changing direction when thrust stalls while pushing in difficult soil
conditions. Carve mode allows the operator to rotate the bit and slowly thrust to grind away the soil.
Note:
•
2-speed thrust is not allowed in carve mode.
•
Cruise Control is not available in carve mode.
•
Carve mode is disabled while front wrench is closed.
1. Press top of carve mode switch to activate. The information center display on right console will show
“Carve Mode”.
2. Forward thrust is limited to a moderate speed.
3. Use the joystick as normal except that moving the joystick beyond the carve mode limit does not result
in increased speed.
4. If the ground is too hard to simply push through when steering, move the joystick fully forward and rock
the joystick left and right to obtain some cutting action at the tool head.
NOTICE: Counterclockwise rotation can unthread pipe in the ground.
5. The thrust limit can be changed by pressing the “set-decrease” switch to slow it down or the “resumeincrease” switch to speed it up. During normal adjustment, faster limits result in larger adjustment
steps. To obtain a fine adjustment of this limit, press and hold the enhanced function button while
making the adjustment. Each step will be the smallest possible change regardless of the actual limit
setting.
6. Press bottom of Carve Mode switch to deactivate.
7. If returning to carve mode without turning the key off, the previously set thrust limit will be used.
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
Ditch Witch 750/752 Tracker, 750/752 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.
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Conduct a Bore - 121
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 77.
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/or 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 152.
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JT3020 Mach 1/All Terrain Operator’s Manual
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 149.
2. Determine fluid rate requirements and install appropriate nozzles to provide sufficient flow. See
“Backream Fluid Requirements” on page 150 and “Nozzles” on page 147.
3. Attach backreamer to beacon housing if tracking backream.
4. Install beacon, following beacon instructions for:
•
battery replacement
•
beacon positioning
5. Install beacon housing lid. See page 148.
6. Follow beacon instructions to check beacon operation.
7. Follow tracker instructions to calibrate beacon.
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Assemble Backream String
8. If in AT mode, install inner spindle spacer
onto end of lead pipe.
9. Use quick wrenches to attach transition sub to drill pipe string. See “Quick Wrench” on page 152.
10. Use quick wrenches to attach backreamer/beacon housing assembly to transition sub. See “Quick
Wrench” on page 152.
11. Attach additional pullback devices or product to end of backreamer/beacon housing assembly.
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JT3020 Mach 1/All Terrain Operator’s Manual
Remove Pipe
Remove Pipe
1. Enable automated pipeloader system if desired. See “Enable Automated Pipeloader System” on
page 113.
2. Position pipe joint between wrenches.
3. Clamp pipes with both wrenches (1,2).
Always clamp on the large diameter areas
of either side of the tool joint face.
4. Break front joint.
Manual Pipeloader Controls
Automated Pipeloader Control
•
Turn rear wrench counterclockwise to
break joint.
•
Turn rear wrench counterclockwise to
break joint.
•
Open rear wrench and rotate wrench
clockwise to original position.
•
Open rear wrench and rotate wrench
clockwise to original position.
5. Grip pipe.
Manual Pipeloader Controls
Automated Pipeloader Control
•
Lift pipe out of shuttles. Grippers will open
as pipe is lifted.
•
•
Extend shuttles to spindle position.
Press RESUME. Display reads “Removing
Pipe” and shuttles extend, grippers grip
fully then relax open, and pipe lifters lower.
•
Close grippers. Relax grippers to allow
pipe to rotate.
•
Display reads “REM PIPE Waiting”
•
Lower lifters.
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Conduct a Bore - 125
Remove Pipe
6. Break front joint.
Manual Pipeloader Controls
Automated Pipeloader Control
•
Rotate spindle counterclockwise to
separate pipe.
•
Rotate spindle counterclockwise to
separate pipe.
•
Continue to rotate until joint is fully
separated.
•
Continue to rotate until joint is fully
separated.
7. Break rear joint.
Manual Pipeloader Controls
Automated Pipeloader Control
•
Close rear wrench.
•
Close rear wrench.
•
Rotate spindle counterclockwise until joint
is loosened at saver sub. Do not fully
unthread joint.
•
Rotate spindle counterclockwise until joint
is loosened at saver sub. Do not fully
unthread joint.
•
Open rear wrench.
•
Open rear wrench.
•
Move carriage back until front end of pipe
is between the two markers on the pipe
guide (A).
•
Move carriage back until front end of pipe
is between the two markers on the pipe
guide (A).
•
Close grippers.
•
Press RESUME. Grippers close.
•
Rotate spindle counterclockwise until
saver sub is separated from pipe.
•
Rotate spindle counterclockwise until
saver sub is separated from pipe.
•
Move carriage to back of frame until rear
stop indicator is lit in right console.
•
Move carriage to back of frame until rear
stop indicator is lit in right console.
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JT3020 Mach 1/All Terrain Operator’s Manual
Remove Pipe
8. Load pipe into pipe box.
Manual Pipeloader Controls
Automated Pipeloader Control
•
Retract shuttles to delivery chute.
•
•
Release grippers and raise lift arms to
place pipe in box.
•
Lube front threads.
Press RESUME. Display reads
“Removing Pipe”, shuttles will retract to
delivery chute, threads are lubed, grippers
release pipe, and pipe lifters raise to place
pipe in box.
•
Display reads “REM PIPE Waiting”.
9. Attach saver sub to next pipe.
Manual Pipeloader Controls
Automated Pipeloader Control
•
Move carriage forward until saver sub
touches pipe.
•
Move carriage forward until saver sub
touches pipe.
•
Rotate spindle to thread saver sub onto
pipe. Carriage moves forward slowly as
pipe threads together. Slowly tighten joint
to full machine torque.
•
Rotate spindle to thread saver sub onto
pipe. Carriage moves forward slowly as
pipe threads together. Slowly tighten joint
to full machine torque.
10. Open front wrench to release pipe.
11. Check pipe box flags to see if row is full. If so, move pipe box to next empty row.
NOTICE: Damage can occur when lifting with too many pipes in a column. Be aware of the number of
pipes in the column and check indicator flags as column is filled.
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Conduct a Bore - 127
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. Press bottom of drilling unit throttle switch until engine is at low throttle.
2. Turn off drilling fluid.
3. Clean pullback device.
4. Turn drilling unit engine off.
5. Disconnect pullback material.
6. Use quick wrenches to remove pullback device. See “Quick Wrench” on page 152.
CMW
Conduct a Bore - 128
JT3020 Mach 1/All Terrain Operator’s Manual
Remove Pullback Device
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 129
Systems and Equipment
Chapter Contents
Anchor System . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
•
Drive Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
•
Remove Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Electric Strike System . . . . . . . . . . . . . . . . . . . . . 133
•
FCC Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
•
Assemble Voltage Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
•
Test Strike System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
•
Troubleshoot Strike System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
•
Use Electric Strike Simulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Drilling Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
•
Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
•
Polymer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
•
Bentonite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
•
Mixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
•
Basic Fluid Recipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
•
Drilling Fluid Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
•
Funnel Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Tracker Control . . . . . . . . . . . . . . . . . . . . . . . . . . 144
•
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
•
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
CMW
Systems and Equipment - 130
JT3020 Mach 1/All Terrain Operator’s Manual
Downhole Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 147
•
Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
•
Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
•
Beacon Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
•
Backreamers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
•
Backream Fluid Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
Quick Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Drill Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
•
Perform Regular Drill Pipe Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
•
Use Drill Pipe Correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Pipeloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
•
Shift Pipe Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
•
Correct Dropped Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
•
Correct Misaligned or Jammed Pipe . . . . . . . . . . . . . . . . . . . . . . . . . .161
•
Rotate Drill Pipe Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
•
Add/Remove Single Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
•
Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
•
Adjust Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
•
Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
•
Disengage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
•
Resume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
Interpret Diagnostic Codes . . . . . . . . . . . . . . . . . 167
•
Electronic Controlled Engine Overview. . . . . . . . . . . . . . . . . . . . . . . . .167
•
Code Severity Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
•
Machine Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 131
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.
Select Anchor
Two anchor types are available. Choose the correct anchor type based on jobsite conditions.
Anchor type
Situation used
rock bit
hard/soft rock, asphalt, concrete, cobble
auger bit
soft soil to hard soil, soft rock
IMPORTANT: Do not attempt to operate anchor controls while drill fluid is on. Drill fluid operation may
divert power from anchor system so that anchor controls perform poorly.
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JT3020 Mach 1/All Terrain Operator’s Manual
Anchor System
Drive Anchors (Rock)
1. Raise anchor shaft to top of anchor frame.
NOTICE: Centering cap MUST be
positioned in centering tube to prevent
damage to anchor.
2. Use high speed rotation and low thrust
speed to drive anchor into ground.
3. Carefully position cap (1) into centering
tube (2) as anchor is being driven into the
ground.
4. Anchor is set when auger shaft flange (3)
rests firmly on cap (1) and centering tube
(2).
5. Repeat process for other anchor.
6. Leave anchors attached to anchor
drivers.
Drive Anchors (Soil)
IMPORTANT: Carefully time anchor rotation with anchor movement. Properly driven anchors should not
auger up soil.
1. Raise anchor shaft to top of anchor frame.
2. Use rotation and thrust controls to drive anchor into ground.
NOTICE:
•
Rotate augers slowly and thrust hard to thread auger into the ground.
•
Centering cap MUST be positioned in centering tube to prevent damage to anchor.
3. Carefully position cap (1) into centering tube (2) as anchor is being driven into the ground.
4. Anchor is set when auger shaft flange (3) rests firmly on cap (1) and centering tube (2).
5. Repeat process for other anchor.
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JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 133
Electric Strike System
Remove Anchors
1. Use anchor rotation and thrust controls to slowly remove anchor shaft from ground.
2. Repeat process for other anchor.
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 75. 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.
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JT3020 Mach 1/All Terrain 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 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. On Information Center, press F2 (Module), then F4 (ESID), and then F2 (Test) to perform total test of
strike system. During this test:
•
ESID bar graph in upper right corner of Information Center display should turn on (black).
•
Alphanumeric readout (ESID, Volts and Amps) should display numbers.
•
Alarms and strobes on all connected units should sound.
•
If this test is successful, no diagnostic codes will be displayed or recorded under Codes (F4) in
ESID.
4. Use Electric Strike Simulator to test voltage and current sensors. See page 137.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 135
Electric Strike System
Troubleshoot Strike System
When strike system detects a problem, a diagnostic code will be displayed. Anytime this happens, go to
the ESID menu and select test function to retest. If a diagnostic 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
V and A flashing on
Information Center ESID
display
Problems in startup
Go to ESID menu and select test
function. If problem goes away, retest
strike system
No power to strike system
control module
Check drilling unit electrical system
Check that harness from drilling unit
to control module is connected
Check that cable from drilling unit
carries more than 10V
dc513 Test Wire shows on
Information Center
Defective control module
Have control module checked or
replaced
Defective CAN bus connection
Ensure CAN cable from drilling unit to
ESID control module is connected
Test wire not connected
Check that test wire is connected to
ESID control module
Check that test wire is connected to
Information Center
Have ESID control module checked
or replaced
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 alarm and connect to
external 12V power source.
2. If alarm 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
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Systems and Equipment - 136
JT3020 Mach 1/All Terrain Operator’s Manual
Electric Strike System
Problem
Possible cause
Possible solution
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
dc518 POST AC I code
displays and A is flashing
on Information Center ESID
display
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.
dc517 POST AC V code
displays and V is flashing
on Information Center ESID
display
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
JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 137
Electric Strike System
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. Select Module, ESID menu on Information Center.
4. Move simulator switch to "current" and press test button.
5. Watch display on Information Center.
•
ESID bar graph should show 1/2 scale on display.
•
ESID % and Current "AMPS" should show 30-50% in display.
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:
•
ESID bar graph should show full bar.
•
Alarm and strobe should turn on.
•
ESID and STK LED should flash.
With two loops,
•
Current "Amps" should be 80-110%.
•
Strike indication might go on and off.
With three loops,
•
Current should be 130-160%.
•
Strike indication should be continuous.
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JT3020 Mach 1/All Terrain Operator’s Manual
Electric Strike System
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.
•
ESID bar graph should show full bar.
•
Alarm and strobe should turn on.
•
ESID and STK LED should flash.
•
ESID% and Voltage "Volts" should show 90-110%.
It is normal for simulator voltage levels to drift below strike level. When this happens, ESID bar should
show less than full and alarm and strobe should stop working. If the level drifts above strike level again,
light, ESID bar, and strobe should be turned on again.
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JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 139
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 - 140
JT3020 Mach 1/All Terrain 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 143.
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.
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JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 141
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
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JT3020 Mach 1/All Terrain 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
JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 143
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 - 144
JT3020 Mach 1/All Terrain 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 750/752 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. Thrust and rotation are disabled when green light on drilling unit is flashing.
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
2
1. Start drilling unit.
2. Turn off 750/752 Display.
3. Press and hold DOWNLOAD (1) while turning on
750/752 Display until a four-digit code (2) appears.
CH
SEL
j07om023c.eps
CMW
ON
OFF
JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 145
Tracker Control
4. Turn on 750/752 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.
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.
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 and rotate clockwise. Green tracker
control light located on anchoring console
will go off. Thrust and rotation will function.
NOTICE: 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.
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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.
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.
2. Change downhole tools.
3. If 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 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
JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 147
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
3
4
4
4
4
Tornado bit
2
2
2
1
1
3
4
Tuff bit
3
2
1
1
3
1
4
Steep Taper Tuff bit
2
2
1
1
2
1
4
Barracuda bit
2
1
1
2
3
4
4
Steep Taper bit
2
2
1
2
2
3
4
Hard Surface bit
3
1
2
3
4
4
4
Glacier bit
4
4
4
3
1
2
4
Rhino bit
4
4
3
3
1
1
3
Rockmaster
4
4
3
2
1
1
1
Talon bit
3
3
2
1
1
2
4
CMW
Systems and Equipment - 148
JT3020 Mach 1/All Terrain 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 tighten bolts to 120 ft•lb (163 N•m).
Beacon Housings
Lid Installation
5
3
5
1
5
6
4
5
2
5
1. Clean all threads, bolt holes and mating surfaces.
2. Follow tightening sequence (shown).
3. Use removable thread locker (Loctite® 242 or
equivalent), if desired.
4. Tighten bolts to 60-70 ft•lb (81-95 N•m).
5. Repeat tightening sequence.
CMW
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Systems and Equipment - 149
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. Also see our interactive Downhole Tool
Selector at www.ditchwitch.com.
•
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
Rockmaster
4
4
4
4
3
1
1
IMPORTANT: For soil definitions, see the chart on the previous page.
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JT3020 Mach 1/All Terrain Operator’s Manual
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/min.
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
JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 151
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 - 152
JT3020 Mach 1/All Terrain 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.
IMPORTANT: Use standard jaws (A) for drill pipe and most downhole tools. Use jaws (B) for adapters,
subs, or other tools that have flats. Use bit block (C) for the Rockmaster tool.
Note: Most tools with flats can be joined or broken with vice (standard jaw) as well as flats.
Join
Break
•
Unbolt vise (1) and place jaws around pipe.
•
Bolt jaws of vise together.
•
Place jaw (2) around pipe, transition sub, or downhole tool.
•
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
JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 153
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 3/8” (9.5
mm) away from first line.
A
B
3. Turn handle until second line (B) meets first (A).
A
B
4. Turn handle opposite direction two turns to relieve
pressure.
A
5. Remove quick wrench components.
A
j07om071h.eps
To Break
NOTICE: Ensure that engine is not on or tracker control has disabled the unit before breaking joints.
1. Turn handle until joint is broken.
2. Turn handle opposite direction two turns to relieve pressure.
3. Remove quick wrench components.
CMW
Systems and Equipment - 154
JT3020 Mach 1/All Terrain 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 199 for recommended lubricant.
2. Join pipe and tighten joint.
3. Break joint.
4. Move pipe back to box.
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 199 for recommended 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.
Replace Worn Saver Sub
Because each pipe comes in contact with the saver sub, check saver sub regularly for wear. Compare
condition of saver sub threads to condition of your drill pipe threads. Replace saver sub any time when its
thread condition is not better than thread condition of your drill pipe. Failing to replace saver sub will result
in damaged drill pipe. See page 233 for replacement procedure.
Precondition a new saver sub the same way you do new pipe. See “Precondition New Pipe” on page 154.
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
JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 155
Drill Pipe
Use Drill Pipe Correctly
Align the Joints
Always carefully align the male and female
ends of pipe before threading them
together. Poor alignment can damage the
threads and destroy the usefulness of the
joint.
NOTICE: If joints get out of alignment
during a bore, use frame tilt or rear
stabilizers to adjust the unit.
Clamp Pipe Correctly
Clamp on pipe when joint is 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 106 for more
information.
CMW
Systems and Equipment - 156
JT3020 Mach 1/All Terrain Operator’s Manual
Drill Pipe
Make Up and Break Out Joints Correctly
Assisted Makeup protects threads by automatically matching carriage movement speed to rotation during
makeup and breakout.
•
To connect pipes together and fully tighten joint, slowly rotate pipe until spindle stops turning and
full pressure is developed. Improperly tightened joints will damage the shoulder faces and threads,
and will cause joints to leak or break while drilling or backreaming.
•
To disconnect pipes, slowly rotate spindle counterclockwise. Carriage will move back automatically
as threads fully separate.
IMPORTANT: If assisted makeup is not functioning, unit will not thrust or rotate while carriage is on front
or rear home with front wrench closed. Press and hold enhanced function control switch (see “Right
Control Console” on page 39) to operate thrust and rotation and follow these instructions.
Make up and break out joints slowly. Do not ram pipes together during makeup or force them apart
during breakout. Carefully match carriage travel speed to rotation speed, and always connect and
disconnect joints slowly and deliberately. This will help prevent thread crossing, galling, and shoulder
swelling.
Makeup
•
Carefully move carriage forward until
spindle (or pipe) contacts threads of pipe in
the wrench and begins to collapse spring on
the side of the carriage (shown). Do not
fully collapse the spring. Stop thrusting and
rotate clockwise until spring is fully relaxed.
Carefully move thrust forward as you spin
the threads together, keeping the spring as
relaxed as possible.
•
Tighten joints fully. Once the joint is
connected and the shoulder faces are
touching, tighten to full machine torque.
Improperly tightened joints will damage the
shoulder faces and threads, and will cause
joints to leak or break while drilling or
backreaming.
Breakout
Carefully move the carriage backward until the spring on the side of the carriage is almost fully collapsed.
Do not fully collapse the spring. Stop thrusting and rotate counterclockwise until spring is fully relaxed.
Carefully move thrust backward and spin the threads apart, keeping the spring as relaxed as possible until
the pipe joint is fully separated.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 157
Drill Pipe
Do not Overwork the Pipe
Never exceed the bend radius for your pipe. See “Recommended Bend Limits” on page 77. Do not
oversteer.
NOTICE: Bending pipe more sharply than recommended will damage pipe and cause failure.
CMW
Systems and Equipment - 158
JT3020 Mach 1/All Terrain Operator’s Manual
Pipeloader
Pipeloader
Remove/Install Pipe Box
Crushing weight. If load falls or moves it could kill or crush you. Use
proper procedures and equipment or stay away.
NOTICE:
•
Lift only one box of pipe at a time.
•
Always walk around unit and check for obstructions before moving load.
•
Do not take your eyes off moving load. Always look in the direction load is moving.
•
Never swing a load over people.
•
Never remove pins from ends of pipe box until you have attached lifting device. Box may fall if pipe
lift switch is pressed without end pins in place.
•
Use crane capable of supporting the equipment's size and weight. See page 235 or measure and
weigh equipment before lifting.
Prepare
1. Press pipe lift switch to fully raise first row of
pipe.
2. Remove pins (1) and support bars (2) from
drill frame storage pockets.
3. Insert each support bar (2) into opening (4)
and allow it to sit on chute (3) and retain with
pin (1) through tab (5).
4. Press pipe lower switch to lower pipes in
chute.
5. Remove support rods (1) from pipe box
storage (2).
6. Insert support rods into pipe supports (3) and
retain with pins (4).
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 159
Pipeloader
Remove Pipe Box
1. Install lift block (5) and adjust to match drill frame angle.
2. Remove threaded caps (6) from back pins.
3. Remove front (7) pin.
4. Move pipe box off of drill frame.
Install Pipe Box
1. Move pipe box over pipeloader and lower into position. Stand on step of main frame to guide pipe box
if necessary.
2. Install threaded caps on back pins.
3. Install front pin.
4. Remove lift block and pin.
NOTICE: Pipe box should only be installed onto pipeloader when pipe box shuttle is in first row position.
CMW
Systems and Equipment - 160
JT3020 Mach 1/All Terrain Operator’s Manual
Pipeloader
Shift Pipe Box
IMPORTANT: Lift arms must be fully raised for pipe box to move.
Drilling
1. Shift pipe box when both pipe box status lights
are off (column is empty). If automated
pipeloader is being used, the Information
Center will inform you that it is time to move
the pipe box.
2. Release pipe box switch when box hits mechanical stops, then move back to align mechanical pointer
in center of appropriate dot on decal (shown) for new column.
Backreaming
1. Shift pipe box when active column is full. Indicator flag will lift partially when there is room for one more
pipe.
NOTICE: Damage can occur when lifting with too many pipes in a column. Be aware of the number of
pipes in the column and check indicator flags as column is filled.
2. Release pipe box switch when mechanical pointer is in center of appropriate dot on decal (shown) for
new column.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 161
Pipeloader
Correct Dropped Pipe
To return a dropped pipe to the drill string, turn off engine and manually retrieve pipe. Return it to the pipe
box by loading it as a single piece of pipe. See “Add Single Pipe” on page 163.
Correct Misaligned or Jammed Pipe
One pipe box status light on and one light off indicates a misaligned or jammed pipe. Turn off engine and
inspect pipe in active column.
•
If one end of a drill pipe is jammed and will not drop correctly from pipe box, inspect pipe box position.
If pipe box appears to be improperly aligned with discharge chute, return to operator’s station and
move pipe box slightly until mechanical pointer is in center of appropriate dot on decal (see page 160)
for active column.
•
If drill pipe is bent, remove it from pipe box and discard.
NOTICE: If neither of the causes and solutions outlined above correct the misaligned or jammed pipe,
contact your Ditch Witch dealer for assistance.
Rotate Drill Pipe Order
Rotating the lead pipe is a manual process. Rotate drill pipes in the drill string weekly.
Guidelines
•
Rotate only as many columns as used on the longest bore of the week. For example, if the longest
bore was 320’ (98 m), then only rotate the four columns used.
•
Plan to rotate the pipes during the longest bore of the week.
Procedure
1. Before beginning pullback, temporarily remove next pipe from the box. See “Add/Remove Single
Pipe” on page 162. Close both auxiliary pipe loaders.
2. Follow regular pullback procedure to load remaining pipe into pipe box.
3. When all pipes (except lead pipe on AT units) have been returned to pipe box, open both auxiliary pipe
loaders, see “Add/Remove Single Pipe” on page 162, place the pipe that was temporarily removed in
step 1 into the remaining position in the delivery chute.
4. Turn off engine.
5. Close both auxiliary pipe loaders.
CMW
Systems and Equipment - 162
JT3020 Mach 1/All Terrain Operator’s Manual
Pipeloader
Add/Remove Single Pipe
Load a drill pipe into an empty column of pipe box to finish bore without changing pipe boxes.
Electric shock. Contacting electric lines will cause death or serious injury.
Know location of lines and stay away.
•
Do not attempt to load and unload pipe while drilling or backreaming. Load or unload all of the pipes
that will be needed before resuming drilling or backreaming. Unprotected worker can be injured by
electric strike.
Incorrect procedures could result in death, injury, or property damage.
Learn to use equipment correctly.
NOTICE:
•
Open or close both auxiliary pipe loaders. Moving shuttles with one auxiliary pipe loader open and
one closed will damage equipment and cause possible injury.
•
Carriage must be all the way back on the rear stop switch to load and unload pipe.
•
Use caution when loading single pipes on side slopes.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 163
Pipeloader
Add Single Pipe
1. Ensure pipe box is positioned properly. See “Shift Pipe Box” on page 160.
NOTICE: If loading more than one column full of pipe, start by filling an inside column, then shift box
inward and load pipe in the next empty column.
2. Move shuttles out half way (45°).
Crushing weight. If load falls or moves it could kill or crush you. Use
proper procedures and equipment or stay away.
3. Remove pipe guide (1) (shown in storage
position) from drill frame and insert in slot
on drill frame.
4. Ensure backup bracket (4) on drill frame
allows pipe guide to align with front face
(5) on drill frame, adjust if necessary.
5. Pull pin (3) from slot (A) on shuttle, rotate
auxiliary pipe loader (2) down, and install
pin in slot (B).
Note: This step creates a temporary shuttle
stop position at 45°.
6. Repeat step 5 for rear auxiliary pipe loader.
7. Lower pipe lifters.
8. Load a pipe in auxiliary pipe loaders with lower end resting against pipe guide (1).
9. Step back from machine.
10. Move auxiliary shuttle in.
11. Raise pipe into column.
12. Move shuttle out (shuttle stop switch will stop shuttle movement at correct position for loading pipe).
13. Repeat steps 7-13 to load more pieces of pipe.
14. Close both auxiliary pipe loaders. Pins must be inserted in slot (A) and held in place with retaining pins.
•
If shuttle will not retract after completing single pipe operations, hold retract pipe shuttle switch and
momentarily press enhanced function control button to reset shuttles to normal operation (shuttles
will retract).
•
Use standard procedure for pipeloader operation.
CMW
Systems and Equipment - 164
JT3020 Mach 1/All Terrain Operator’s Manual
Pipeloader
Remove Single Pipe
Unload drill pipe loaded with auxiliary pipe
loaders.
1. Ensure pipe guide is still installed and not
in storage position.
2. Ensure pipe box is positioned properly.
See “Remove/Install Pipe Box” on
page 158.
3. Move shuttles out half way (45°).
4. Pull pin (3) from slot (A) on shuttle, rotate
auxiliary pipe loader (2) down, and install
pin in slot (B).
5. Repeat step 4 for rear auxiliary pipe loader.
6. Raise pipe.
7. Move shuttle in, auxiliary pipe loaders should be beneath pipe column.
8. Lower pipe into auxiliary pipe loaders.
9. Move shuttle out (shuttle stop switch will stop shuttle movement at correct position for removing pipe).
Crushing weight. If load falls or moves it could kill or crush you.
Use proper procedures and equipment or stay away.
10. Remove pipe from auxiliary pipe loaders and store properly.
11. Repeat steps 6-9 to unload remaining added drill pipe.
12. After all added drill pipe is unloaded with auxiliary pipe loaders:
•
Close both auxiliary pipe loaders. Pins must be inserted in slot (A) and held in place with retaining
pins.
•
Place pipe guide in storage position (shown) and secure in place with retaining pins.
•
Step away from pipeloader.
•
Finish loading remaining drill pipe using standard procedure. See “Remove Pipe” on page 124.
•
If shuttle will not retract after completing single pipe operations, hold retract pipe shuttle switch and
momentarily press enhanced function control button to reset shuttles to normal operation (shuttles
will retract).
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 165
Cruise Control
Cruise Control
During the bore, you can set the desired thrust/pullback, and rotation speeds to match ground conditions.
Cruise control enables the unit to maintain these settings hands-free. You can engage, disengage,
override, and resume these settings at any time.
IMPORTANT: In order for cruise control to function, front wrench must be open and shuttles must be
under pipe delivery chute. (fully retracted)
Engage
Thrust/Pullback and Rotation Cruise
Thrust/Pullback Cruise Only
1. Position joystick so that thrust or pullback and
rotation are at desired speeds.
1. Position joystick to desired thrust or pullback
setting.
2. Press set. Information Center will display
“Cruise ON”.
2. Press set. Information Center will display
“Cruise ON”.
3. Release joystick.
3. Release joystick.
4. Operator can control rotation with joystick.
In JT or AT Dirt modes, there is only clockwise
rotation.
In AT mode, there is clockwise and
counterclockwise rotation so the operator can
“wiggle” through cobble rock.
NOTICE: Counterclockwise rotation can “break
out” pipe joints downhole and unthread the joint.
Operator should not rotate counterclockwise long
enough to unthread a joint.
Adjust Settings
Setting
Instructions
Thrust or Pullback
•
To increase thrust or pullback speed with joystick in neutral position,
press resume.
•
To decrease thrust or pullback speed with joystick in neutral position,
press set.
•
To increase rotation speed, move joystick to left and press resume.
•
To decrease rotation speed, move joystick to left and press set.
Rotation
Note: To obtain fine adjustments, press and hold the enhanced functions control while making the
adjustment. See “Dual speed carriage control (enhanced function control)” on page 39.
CMW
Systems and Equipment - 166
JT3020 Mach 1/All Terrain Operator’s Manual
Cruise Control
Override
•
To override settings, move joystick out of neutral and beyond current setting. Unit will increase to
joystick setting.
•
To return to previous setting, release joystick.
Disengage
To disengage cruise control, move joystick out of neutral in opposite direction of carriage travel. “Cruise
ON” disappears from the Information Center display and carriage stops moving.
Resume
1. Position joystick out of neutral in direction to be resumed (forward or
backward).
2. Press resume. Thrust and rotation resume at the previous settings and “Cruise
ON” is shown on the Information Center.
RESUME
SET
c00ic113h.eps
CMW
/
/
JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 167
Interpret Diagnostic Codes
Interpret Diagnostic Codes
Electronic Controlled Engine Overview
This unit is equipped with a self-diagnostic computer-controlled fuel management system. A variety of
sensors send input data to an ECU (Electronic Control Unit) that compares inputs with pre-programed
memory and sends output voltage to a variety of actuators to adjust and operate the engine within
specified parameters.
Warning indicators on the gauge tell the operator when critical and non-critical faults develop. Non-critical
faults occur when engine sensors detect moderate trouble with coolant temperature, oil pressure, charge
air temperature, or fuel temperature. Non-critical faults cause the operator alert indicator to light. Critical
faults cause the engine shutdown indicator to light. In both cases, a fault code is stored in the ECU. If the
fault corrects itself, the engine will gradually return to normal power. The alert indicator will continue to
flash until the trouble goes away, but a fault code will remain stored.
Engine shutdown will occur due to critical faults in engine coolant temperature or oil pressure. Before
shutdown, the operator alert indicator will light continuously and the engine will begin a rapid power derate.
If the fault does not improve in 30 seconds the engine will shut down.
Reading Engine Diagnostic Codes
Problems with the electronic controlled engine usually are indicated by the operator alert indicator on the
left console and by a diagnostic code displayed on the diagnostic gauge.
IMPORTANT: For more information on the operator alert indicator and how to operate and read the
diagnostic gauge, see page 30.
Operator Alert Indicator
When a non-critical engine fault occurs, the operator alert indicator on the
left console will light. A fault code will be stored in the diagnostic gauge.
Engine Shutdown Indicator
When a critical engine fault occurs, the engine shutdown indicator will light.
A fault code will be stored in the diagnostic gauge, and the engine will shut
down within 30 seconds.
CMW
Systems and Equipment - 168
JT3020 Mach 1/All Terrain Operator’s Manual
Interpret Diagnostic Codes
Diagnostic Gauge
To display codes:
1. Press the selection switch to scroll through the gauge parameters until
CHECK DTC code is displayed.
IMPORTANT: For code explanations, see the following page.
2. Press the selection switch to scroll through all codes.
To clear active codes:
1. Turn ignition switch to STOP.
2. Turn ignition switch back to the start position.
To change display options:
1. Turn the ignition switch to STOP.
2. Press and hold the selection switch.
3. Turn the ignition switch to the on position.
4. Press and hold the selection switch to scroll through display options.
5. Release the switch to stop scrolling.
6. To turn options off or on, press the selection switch twice.
7. To save changes, continue scrolling until EXIT CFG is displayed, then press and hold.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 169
Interpret Diagnostic Codes
Engine Diagnostic Codes
Two-line
diagnostic code
Fault
Code
Description
Possible cause
SPN 629, FMI 12
111
controller # 1
engine control module critical internal
failure - bad component
SPN 612, FMI 2
115
system diagnostic code # 2
engine speed/position sensor circuit lost
both of two signals from the magnetic
pickup sensor - data erratic, intermittent or
incorrect
SPN 122, FMI 3
122
boost pressure
intake manifold pressure sensor circuit voltage above normal or shorted to high
source
SPN 102, FMI 4
123
boost pressure
intake manifold pressure sensor circuit voltage below normal or shorted to low
source
SPN 100, FMI 3
135
engine oil pressure
oil pressure sensor circuit, voltage above
normal or shorted to high source
SPN 100, FMI 4
141
engine oil pressure
oil pressure sensor circuit, voltage below
normal or shorted to low source
SPN 100, FMI 18
143
engine oil pressure
oil pressure sensor circuit, voltage below
normal operational rage, moderately
severe level
SPN 110, FMI 3
144
engine coolant temp
coolant temperature sensor circuit, voltage
below normal or shorted to high source
SPN 110, FMI 4
141
engine coolant temp
coolant temperature sensor circuit, voltage
below normal or shorted to low source
SPN 110, FMI 16
146
engine coolant temp
coolant temperature high, data valid but
above normal operating range, moderately
severe level
SPN 110, FMI 0
151
engine coolant temp
coolant temperature low, data valid but
below normal operating range, most
severe level
SPN 105, FMI 3
153
intake manifold #1 temp
intake manifold air temperature sensor
circuit, voltage above normal or shorted to
low source
SPN 105-FMI 4
154
intake manifold #1 temp
intake manifold air temperature sensor
circuit, voltage above normal or shorted to
high source
SPN 105, FMI 0
155
intake manifold #1 temp
intake manifold air temperature sensor
circuit, data valid but above normal
operational range, most severe level
CMW
Systems and Equipment - 170
JT3020 Mach 1/All Terrain Operator’s Manual
Interpret Diagnostic Codes
Two-line
diagnostic code
Fault
Code
Description
Possible cause
SPN 1080, FMI 4
187
5 volts DC supply
sensor supply voltage #2 circuit - voltage
below normal, or shorted to low source
SPN 111, FMI 3
195
coolant level
coolant level sensor circuit, voltage above
normal or shorted to high source
SPN 111, FMI 4
196
coolant level
coolant level sensor circuit, voltage below
normal or shorted to low source
SPN 111, FMI 18
197
coolant level
coolant level, data valid but below normal
operational range, moderately severe
level
SPN 1484, FMI 31
211
J1939 error
additional auxiliary diagnostic codes
logged, condition exists
SPN 175, FMI 3
212
oil temp
engine oil temp sensor 1 circuit, voltage
above normal or shorted to high source
SPN 175, FMI 4
213
oil temp
engine oil temp sensor 1 circuit, voltage
below normal or shorted to low source
SPN 175, FMI 0
214
oil temp
engine oil temp, data valid but above
normal operational range, most severe
level
SPN 108, FMI 3
221
barometric pressure
barometric pressure sensor circuit, voltage
above normal or shorted to high source
SPN 108, FMI 4
222
barometric pressure
barometric pressure sensor circuit, voltage
below normal or shorted to low source
SPN 1080, FMI 3
227
5 volts DC supply
sensor supply voltage #2 circuit, voltage
above normal or shorted to high source
SPN 109, FMI 3
231
coolant pressure
coolant pressure sensor circuit, voltage
above normal or shorted to high source
SPN 109, FMI 4
232
coolant pressure
coolant pressure sensor circuit, voltage
below normal operation range, moderately
severe level
SPN 109, FMI 18
233
coolant pressure
coolant pressure, data valid but below
normal operation range, most severe level
SPN 190, FMI 0
234
engine speed
engine speed high, data valid but above
normal operational range, most severe
level
SPN 111, FMI 1
235
coolant level
coolant level low, data valid but below
normal operational range, most severe
level
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 171
Interpret Diagnostic Codes
Two-line
diagnostic code
Fault
Code
Description
Possible cause
SPN 644, FMI 2
237
external speed input
external speed input (multiple unit
synchronization), data erratic, intermittent
or incorrect
SPN 611, FMI 4
238
system diagnostic code # 1
sensor supply voltage #3 circuit, voltage
below normal or shorted to low source
SPN 647, FMI 4
245
fan clutch output device
driver
fan control circuit, voltage below normal or
fan shorted to low source
SPN 171, FMI 3
249
ambient air temp
ambient air temp sensor circuit
SPN 171, FMI 4
256
ambient air temp
ambient air temp sensor circuit, voltage
below normal or shorted to low source
SPN 174, FMI 16
261
fuel temp
engine fuel temp, data valid but above
normal operational range, moderately
severe level
SPN 174, FMI 3
263
fuel temp
engine fuel temp sensor 1 circuit, voltage
above normal or shorted to high source
SPN 174, FMI 4
265
fuel temp
engine fuel temp sensor 1 circuit, voltage
below normal or shorted to low source
SPN 94, FMI 2
268
fuel delivery pressure
fuel pressure sensor circuit, data erratic,
intermittent or incorrect.
SPN 1347, FMI 4
271
fuel pump pressurizing
assembly 1
high fuel pressure solenoid valve circuit,
voltage below normal or shorted to low
source
SPN 1347, FMI 3
272
fuel pump pressurizing
assembly 1
high fuel pressure solenoid valve circuit,
voltage above normal or shorted to high
source
SPN 1347, FMI 7
281
fuel pump pressurizing
assembly 1
high fuel pressure solenoid valve 1,
mechanical system not responding
properly or out of adjustment
SPN 1347, FMI 7
275
fuel pump pressurizing
assembly 1
fuel pumping element (front), mechanical
system not responding properly or out of
adjustment
SPN 1043, FMI 4
284
internal sensor voltage
supply
engine speed/position sensor (crankshaft)
supply voltage circuit, voltage below
normal or shorted to low source
SPN 639, FMI 9
285
SAE J1939 datalink
SAE J1939 multiplexing PGN timeout
error, abnormal update rate
SPN 639, FMI 13
286
SAE J1939 datalink
SAE J1939 multiplexing configuration
error, out of calibration
CMW
Systems and Equipment - 172
JT3020 Mach 1/All Terrain Operator’s Manual
Interpret Diagnostic Codes
Two-line
diagnostic code
Fault
Code
Description
Possible cause
SPN 441, FMI 3
293
OEM temp
auxiliary temp sensor input 1 circuit,
voltage above normal or shorted to high
source
SPN 441, FMI 4
294
OEM temp
auxiliary temp sensor input 1 circuit,
voltage below normal or shorted to low
source
SPN 108, FMI 2
295
barometric pressure
barometric pressure sensor circuit, data
erratic, intermittent or incorrect
SPN 1388, FMI 14
296
auxiliary pressure
auxiliary pressure sensor input 1, special
instructions
SPN 1388, FMI 3
297
auxiliary pressure
auxiliary pressure sensor input 2 circuit,
voltage above normal or shorted to high
source
SPN 1388, FMI 4
298
auxiliary pressure
auxiliary pressure sensor input 2 circuit,
voltage below normal or shorted to low
source
SPN 251, FMI 2
319
real time clock power
real time clock power interrupt, data
erratic, intermittent or incorrect
SPN 651, FMI 5
322
injector cylinder 01
injector solenoid cylinder 1 circuit, current
below normal or open circuit
SPN 655, FMI 5
323
injector cylinder 05
injector solenoid cylinder 5 circuit, current
below normal or open circuit
SPN 653, FMI 5
324
injector cylinder 03
injector solenoid cylinder 3 circuit, current
below normal or open circuit
SPN 656, FMI 5
325
injector cylinder 06
injector solenoid cylinder 6 circuit, current
below normal or open circuit
SPN 652, FMI 5
331
injector cylinder 02
injector solenoid cylinder 2 circuit, current
below normal or open circuit
SPN 654, FMI 5
332
injector cylinder 04
injector solenoid cylinder 4 circuit, current
below normal or open circuit
SPN 110, FMI 2
334
engine coolant temp
coolant temp sensor circuit, data erratic,
intermittent or incorrect
SPN 630, FMI 2
341
calibration memory
engine control module data lost, data
erratic, intermittent or incorrect
SPN 630, FMI 13
342
calibration memory
electronic calibration code incompatibility,
out of calibration
SPN 629, FMI 12
343
controller 1
engine control module warning internal
hardware failure, bad intelligent device or
component
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 173
Interpret Diagnostic Codes
Two-line
diagnostic code
Fault
Code
Description
Possible cause
SPN 629, FMI 12
351
controller 1
injector power supply, bad intelligent
device or component
SPN 1079, FMI 4
352
5 volts DC supply
sensor supply voltage 1 circuit, voltage
below normal or shorted to low source
SPN 1079, FMI 3
386
5 volts DC supply
sensor supply voltage 1 circuit, voltage
above normal or shorted to high source
SPN 1043, FMI 3
387
internal sensor voltage
supply
accelerator pedal or lever position sensor
supply voltage circuit, voltage above
normal or shorted to high source
SPN 100, FMI 1
415
engine oil pressure
oil pressure low, data valid but below
normal operational range, most severe
level
SPN 97, FMI 15
418
water in fuel indicator
water in fuel indicator high, data valid but
above normal operational range, least
severe level
SPN 111, FMI 2
422
coolant level
coolant level, data erratic, intermittent or
incorrect
SPN 175, FMI 2
425
oil temp
engine oil temp, data erratic, intermittent
or incorrect
SPN 97, FMI 3
428
water in fuel indicator
water in fuel sensor circuit, voltage above
normal or shorted to high source
SPN 97, FMI 4
429
water in fuel indicator
water in fuel sensor circuit, voltage below
normal or shorted to low source
SPN 102, FMI 2
433
boost pressure
intake manifold pressure sensor circuit,
data erratic, intermittent or incorrect
SPN 627, FMI 2
434
power supply
power lost without ignition off, data erratic,
intermittent or incorrect
SPN 100, FMI 2
435
engine oil pressure
oil pressure sensor circuit, data erratic,
intermittent or incorrect
SPN 168, FMI 18
441
electrical potential
(voltage)
battery 1 voltage low, data valid but below
normal operational range, moderately
severe level
SPN 168, FMI 16
442
electrical potential
(voltage)
battery 1 voltage high, data valid but
above normal operational range,
moderately severe level
SPN 1043, FMI 4
443
internal sensor voltage
supply
accelerator pedal or lever position sensor
supply voltage circuit, voltage below
normal or shorted to low source
CMW
Systems and Equipment - 174
JT3020 Mach 1/All Terrain Operator’s Manual
Interpret Diagnostic Codes
Two-line
diagnostic code
Fault
Code
Description
Possible cause
SPN 157, FMI 0
449
injector metering rail 1
pressure
fuel pressure high, data valid but above
normal operational range, moderately
severe level
SPN 157, FMI 3
451
injector metering rail 1
pressure
injector metering rail 1 pressure sensor
circuit, voltage above normal or shorted to
high source
SPN 157, FMI 4
452
injector metering rail 1
pressure
injector metering rail 1 pressure sensor
circuit, voltage below normal or shorted to
low source
SPN 105, FMI 16
488
intake manifold
intake manifold 1 temp, data valid but
above normal operational range,
moderately severe level
SPN 1377, FMI 2
497
switch circuit
multiple unit synchronization switch circuit,
data erratic, intermittent or incorrect
SPN 611, FMI 2
523
system diagnostic code 1
OEM intermediate (PTO) speed switch
validation, data erratic, intermittent or
incorrect
SPN 702, FMI 3
527
circuit, voltage
auxiliary input/output 2 circuit, voltage
above normal or shorted to high source
SPN 93, FMI 3
528
switch, data
auxiliary alternate torque validation switch,
data erratic, intermittent or incorrect
SPN 703, FMI 3
529
circuit, voltage
auxiliary input/output 3 circuit, voltage
above normal or shorted to high source
SPN 558, FMI 4
551
accelerator pedal low idle
switch
accelerator pedal or lever idle validation
circuit, voltage below normal or shorted to
low source
SPN 157, FMI 16
553
injector metering rail 1
pressure
fuel pressure sensor error, data erratic,
intermittent or incorrect
SPN 157, FMI 18
559
injector metering rail 1
pressure
injector metering rail 1 pressure low, data
valid but below normal operational range,
moderately severe level
SPN 103, FMI 16
595
turbocharger 1 speed
turbocharger 1 speed high, data valid but
above normal operational range,
moderately severe level
SPN 167, FMI 16
596
alternate potential (voltage)
electrical charging system voltage high,
data valid but above normal operational
range, moderately severe level
SPN 167, FMI 18
597
alternate potential (voltage)
electrical charging system voltage low,
data valid but below normal operational
range, moderately severe level
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 175
Interpret Diagnostic Codes
Two-line
diagnostic code
Fault
Code
Description
Possible cause
SPN 167, FMI 1
598
alternate potential (voltage)
electrical charging system voltage low,
data valid but below normal operational
range, most severe level
SPN 103, FMI 18
687
turbocharger 1 speed
turbocharger 1 speed low, data valid but
below normal operational range,
moderately severe level
SPN 190, FMI 2
689
engine speed
primary engine speed sensor error, data
erratic, intermittent or incorrect
SPN 1172, FMI 3
691
turbocharger 1 compressor
inlet temp
turbocharger 1 compressor inlet temp
sensor circuit, voltage above normal or
shorted to high source
SPN 1172, FMI 4
692
turbocharger 1 compressor
inlet temp
turbocharger 1 compressor inlet temp
sensor circuit, voltage below normal or
shorted to low source
SPN 1136, FMI 3
697
sensor circuit, voltage
ECM internal temp sensor circuit, voltage
above normal or shorted to high source
SPN 1136, FMI 4
698
sensor circuit, voltage
ECM internal temp sensor circuit, voltage
below normal or shorted to low source
SPN 22, FMI 3
719
crankcase pressure
extended crankcase blow-by pressure
circuit, voltage above normal or shorted to
high source
SPN 22, FMI 4
729
crankcase pressure
extended crankcase blow-by pressure
circuit, voltage below normal or shorted to
low source
SPN 723, FMI 7
731
engine speed sensor 2
engine speed/position 2 mechanical
misalignment between camshaft and
crankshaft sensors, mechanical system
not responding properly or out of
adjustment
SPN 723, FMI 2
753
engine speed sensor 2
engine speed/position 2 camshaft sync
error, data erratic, intermittent or incorrect
SPN 611, FMI 31
757
electronic control module
electronic control module data lost,
condition exists
SPN 723, FMI 2
778
engine speed sensor 2
engine speed sensor (camshaft) error,
data erratic, intermittent or incorrect
SPN 166, FMI 2
951
cylinder power
cylinder power imbalance between
cylinders, data erratic, intermittent or
incorrect
SPN 627, FMI 2
1117
power supply
power lost with ignition on, data erratic,
intermittent or incorrect
CMW
Systems and Equipment - 176
JT3020 Mach 1/All Terrain Operator’s Manual
Interpret Diagnostic Codes
Two-line
diagnostic code
Fault
Code
Description
Possible cause
SPN 651, FMI 7
1139
injector cylinder 1
Injector cylinder 1, mechanical system not
responding properly or out of adjustment
SPN 652, FMI 7
1141
injector cylinder 2
Injector cylinder 2, mechanical system not
responding properly or out of adjustment
SPN 653, FMI 7
1142
injector cylinder 3
Injector cylinder 3, mechanical system not
responding properly or out of adjustment
SPN 654, FMI 7
1143
injector cylinder 4
Injector cylinder 4, mechanical system not
responding properly or out of adjustment
SPN 655, FMI 7
1144
injector cylinder 5
Injector cylinder 5, mechanical system not
responding properly or out of adjustment
SPN 656, FMI 7
1145
injector cylinder 6
Injector cylinder 6, mechanical system not
responding properly or out of adjustment
SPN 1563, FMI 2
1256
control module
identification input state
control module identification input state
error, data erratic, intermittent or incorrect
SPN 1563, FMI 2
1257
control module
identification input state
control module identification input state
error, data erratic, intermittent or incorrect
SPN 157, FMI 0
1911
injector metering rail
injector metering rail 1 pressure, data valid
but above normal operational range, most
severe level
SPN 32, FMI 3
2111
coolant temp
coolant temp 2 sensor circuit, voltage
above normal or shorted to high source
SPN 52, FMI 4
2112
coolant temp
coolant temp 2 sensor circuit, voltage
below normal or shorted to low source
SPN 52, FMI 16
2113
coolant temp
coolant temp 2, data valid but above
normal operational range, moderately
severe level
SPN 52, FMI 0
2114
coolant temp
coolant temp 2, data valid but above
normal operational range, most severe
level
SPN 2981, FMI 3
2115
coolant pressure
coolant pressure 2 circuit, voltage above
normal or shorted to high source
SPN 2981, FMI 4
2116
coolant pressure
coolant pressure 2 circuit, voltage below
normal or shorted to low source
SPN 2981, FMI 18
2117
coolant pressure
coolant pressure 2, data valid but below
normal operational range, moderately
severe level
SPN 611, FMI 3
2185
system diagnostic code 1
sensor supply voltage 4 circuit, voltage
above normal or shorted to high source
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 177
Interpret Diagnostic Codes
Two-line
diagnostic code
Fault
Code
Description
Possible cause
SPN 611, FMI 4
2186
system diagnostic code 1
sensor supply voltage 4 circuit, voltage
below normal or shorted to low source
SPN 703, FMI 14
2195
auxiliary equipment sensor
auxiliary equipment sensor input 3 engine
protection critical, special instructions
SPN 94, FMI 18
2215
fuel delivery pressure
fuel pump delivery pressure, data valid but
below normal operational range,
moderately severe level
SPN 94, FMI 1
2216
fuel delivery pressure
fuel pump delivery pressure, data valid but
above normal operational range,
moderately severe level
SPN 630, FMI 31
2217
calibration memory
ECM program memory (RAM) corruption,
condition exists
SPN 157, FMI 1
2249
injector metering rail 1
pressure
injector metering rail 1 pressure, data valid
but below normal operational range, most
severe level
SPN 611, FMI 16
2292
fuel inlet meter device
fuel inlet meter device, data valid but
above normal operational range,
moderately severe level
SPN 611, FMI 18
2293
fuel inlet meter device
fuel inlet meter device flow demand lower
than expected, data valid but below
normal operational range, moderately
severe level
SPN 633, FMI 31
2311
fuel control valve 1
fueling actuator 1 circuit error, condition
exists
SPN 190, FMI 2
2321
engine speed
engine speed/position sensor 1, data
erratic, intermittent or incorrect
SPN 723, FMI 2
2322
engine speed sensor 2
engine speed/position sensor 2, data
erratic, intermittent or incorrect
SPN 103, FMI 10
2345
turbocharger 1 speed
turbocharger speed invalid rate of change
detected, abnormal rate of change
SPN 2789, FMI 15
2346
system diagnostic code 1
turbocharger turbine inlet temp
(calculated), data valid but above normal
operational range, least severe level
SPN 2629, FMI 15
2347
system diagnostic code 1
turbocharger compressor outlet temp
(calculated), data valid but above normal
operational range, least severe level
SPN 647, FMI 3
2377
fan clutch output device
driver
fan control circuit, voltage above normal or
shorted to high source
CMW
Systems and Equipment - 178
JT3020 Mach 1/All Terrain Operator’s Manual
Interpret Diagnostic Codes
Two-line
diagnostic code
Fault
Code
Description
Possible cause
SPN 729, FMI 3
2555
inlet air heater driver 1
intake air heater 1 circuit, voltage above
normal or shorted to high source
SPN 729, FMI 4
2556
inlet air heater driver 1
intake air heater 1 circuit, voltage below
normal or shorted to low source
SPN 110, FMI 15
2963
engine coolant temp
engine coolant temp high, data valid but
above normal operational range, least
severe level
SPN 105, FMI 15
2964
intake manifold 1 temp
intake manifold temp high, data valid but
above normal operational range, least
severe level
SPN 102, FMI 2
2973
boost pressure
intake manifold pressure sensor circuit,
data erratic, intermittent or incorrect
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 179
Interpret Diagnostic Codes
Diagnostic Information
Use the Information Center to view condition of diagnostic system. Under normal operating conditions,
any diagnostic code that is recorded will be shown on the bottom line of the Information Center. Nonessential codes will remain for 10 seconds and then go away. Essential codes will remain until the
operator clears them from the display. If diagnostic codes are detected, the diagnostic light will either flash
on and off for 10 seconds to indicate a non-essential code or remain on for 3 seconds and off for half a
second to indicate an essential code.
Code Severity Levels
Diagnostic codes are given one of two levels of severity.
•
A non-essential code affects non-essential functions of the unit. If the system detects a non-essential
problem, a diagnostic code will be recorded and the diagnostic light will flash for 10 seconds and then
go out. Each time ignition is turned on, full operation will be available until the diagnostic system
detects a problem.
•
An essential code affects rotation, thrust, drilling fluid, or ground drive. If the system detects an
essential problem, a diagnostic code will be recorded and the diagnostic light will cycle on for three
seconds and off for 1/2 second. Some machine functions may not work until the problem is corrected.
Each time ignition is turned on, full operation will be available until the diagnostic system detects a
problem.
CMW
Systems and Equipment - 180
JT3020 Mach 1/All Terrain Operator’s Manual
Interpret Diagnostic Codes
Machine Diagnostic Codes
The following table lists the attributes of each diagnostic code. Information presented includes: code
number, condition causing code to be sent, result, and level of severity.
Code
Display
Condition
Result
Severity
12
START MSG
normal entry into test mode
code is not stored
n/a
13
12VOLT OUTPUT
no 12V power to main
controller
drill and drive are blocked
essential
14
5VOLTS OUTPUT
no 5V power from main
controller
drill and drive are blocked
essential
15
6VOLT DRIVER
incorrect voltage on 6V
driver on main controller
drive is blocked
essential
16
P12VOLT OUT
no 12V power to pipe
controller
drill fluid is blocked
essential
17
P5VOLTS OUT
no 5V power from pipe
controller
drill fluid is blocked
essential
18
P6 VOLT DRIVER
incorrect voltage on 6V
driver on pipe controller
code is stored
essential
19
MISC OUTPUT
unknown output driver
continuity problem
code is stored
nonessential
20
PMISC OUTPUT
unknown output driver
continuity problem in pipe
controller
code is stored
nonessential
21
FRWRNCH
CLOSE
no continuity to front wrench
close solenoid
code is stored
nonessential
23
REWRNCH
CLOSE
no continuity to rear wrench
close solenoid
code is stored
nonessential
25
WRNCH CW ROT
no continuity to wrench cw
rotate solenoid
code is stored
nonessential
31
WRNCH CCW
ROT
no continuity to wrench ccw
rotate solenoid
code is stored
nonessential
32
SHUTTLE EXT
no continuity to shuttle
extend solenoid
add pipe or remove pipe is
aborted and code is stored
nonessential
33
SHUTTLE RET
no continuity to shuttle
retract solenoid
add pipe or remove pipe is
aborted and code is stored
nonessential
34
PIPE LIFT
no continuity to pipe lift
solenoid
add pipe or remove pipe is
aborted and code is stored
nonessential
35
PIPE LOWER
no continuity to pipe lower
solenoid
add pipe or remove pipe is
aborted and code is stored
nonessential
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 181
Interpret Diagnostic Codes
Code
Display
Condition
Result
Severity
41
PIPE GRIP
no continuity to pipe grip
solenoid
add pipe or remove pipe is
aborted and code is stored
nonessential
42
PIPE REL
no continuity to pipe release
solenoid
code is stored
nonessential
44
LUBE FRONT
no continuity to lube front
solenoid
add pipe or remove pipe is
aborted and code is stored
nonessential
45
CARRAGE 2SPD
no continuity to carriage two
speed solenoid
code is stored
nonessential
46
AUX DUMP
no continuity to auxiliary
dump valve
add pipe or remove pipe is
aborted and code is stored
nonessential
47
PIPE BOX IN
no continuity to pipe box in
solenoid
code is stored
nonessential
48
PIPE BOX OUT
no continuity to pipe box out
solenoid
code is stored
nonessential
51
ROT CW/LT REV
no continuity to rotation cw/
left track reverse solenoid
cruise control, carve mode,
and drive are blocked
essential
52
ROT CCW/LT
FWD
no continuity to rotation ccw/
left track forward solenoid
cruise control, carve mode,
and drive are blocked
essential
53
THR FWD/RT
FWD
no continuity to thrust
forward right track solenoid
carve mode and drive are
blocked
essential
54
THR BWD/RT
REV
no continuity to thrust
backward/ right track
reverse solenoid
carve mode and drive are
blocked
essential
55
THR BRKREL
no continuity to left thrust
brake solenoid
cruise and carve are blocked
essential
57
DRV BRK REL
no continuity to ground
brake solenoid
code is stored
essential
58
DRIVE SELECT
no continuity to drive
selector valve
drive is blocked
essential
59
TKR CNT LIGHT
no continuity to tracker
control light
code is stored
nonessential
61
DFLUID PUMP
no continuity to drilling fluid
pump solenoid
code is stored
essential
63
DFLUID ENABLE
no continuity to fluid enable
solenoid
code is stored
essential
64
DFLUID 2SPD
no continuity to fluid twospeed solenoid
code is stored
nonessential
CMW
Systems and Equipment - 182
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Interpret Diagnostic Codes
Code
Display
Condition
Result
Severity
65
ENGINE FAN
no continuity to engine fan
solenoid
code is stored
nonessential
74
INNER ROT CW
no continuity to inner
rotation clockwise solenoid
code is stored
essential
75
INNER ROT CCW
no continuity to inner
rotation counter-clockwise
solenoid
code is stored
essential
76
THRUST LIMIT
no continuity to thrust limit
solenoid
code is stored
nonessential
81
MAIN PIPE ID
main controller has pipe ID
on CAN ID line
controller runs in pipeloader
service mode
essential
82
PIPE MAIN ID
pipe controller has main ID
on CAN ID line
controller runs in main
service mode
essential
83
MAIN INVAL ID
main controller has invalid
ID on CAN ID line
controller runs in main
service mode
essential
84
PIPE INVAL ID
pipe controller has invalid ID
on CAN ID line
controller runs in pipeloader
service mode
essential
85
MAIN NOSAV ID
main controller has no saved
ID
controller runs in main
service mode
essential
86
PIPE NOSAV ID
pipe controller has no saved
ID
Controller runs in pipeloader
service mode
essential
87
HARNESS POSN
ID state does not agree with
harness position
controller runs in CAN EDT
mode
essential
88
CAN BOOT TO
timeout has occurred while
waiting for CAN system to
boot
controller runs in service
mode
nonessential
91
CAN PHYS ERR
errors on the CAN Bus
totalling 275 have been
logged
code is stored
essential
92
MAIN BUS OFF
main controller has
shutdown CAN
communications
controller runs in main
service mode
essential
93
PIPE BUS OFF
pipe controller has shutdown
CAN communications
controller runs in pipeloader
service mode
essential
94
MAIN PROTOCOL
main controller has an
incorrect protocol message
code is stored
nonessential
95
PIPE PROTOCOL
pipe controller has an
incorrect protocol message
code is stored
nonessential
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 183
Interpret Diagnostic Codes
Code
Display
Condition
Result
Severity
96
MAIN NG FAIL
main controller has detected
node guard timeout
controller runs in main
service mode
essential
97
PIPE NG FAIL
pipe controller has missed a
node guard from the master
controller runs in pipeloader
service mode
essential
98
MAIN LOG FAIL
pipe controller has had an
internal software failure
controller runs in main
service mode
essential
99
PIPE LOG FAIL
pipe controller has had an
internal software failure
controller runs in pipeloader
service mode
essential
111
TETH NG FAIL
tether controller has missed
a node guard from the
master
drive is blocked
essential
112
ESID NG FAIL
ESID controller has missed
a node guard from the
master
code is stored
nonessential
113
ICTR NG FAIL
Information Center has
missed a node guard from
the master
code is stored
nonessential
131
THREAR HSW
no continuity to thrust rear
home switch
add pipe and remove pipe
are blocked
nonessential
132
THFRNT HSW
no continuity to thrust front
home switch
add pipe and remove pipe
are blocked
nonessential
133
SHUTTL HSW
no continuity to shuttle home
switch
add pipe and remove pipe
are blocked
nonessential
134
FWRNCH PSW
no continuity to front wrench
switch
add pipe and remove pipe
are blocked
nonessential
136
TH REAR STOP
no continuity to thrust rear
stop switch
add pipe and remove pipe
are blocked
nonessential
137
PIPE UP PSW
no continuity to pipe up
switch
pipe box movement is
blocked and code is stored
nonessential
138
FRONT BOX HSW
no continuity to front pipe
box switch
code is stored
nonessential
139
REAR BOX HSW
no continuity to rear pipe
box switch
code is stored
nonessential
141
ROTATE POS
no continuity to rotation
position sensor
code is stored
nonessential
143
DFLUID GPM
no continuity to drilling fluid
speed sensor
code is stored
nonessential
146
FLOAT POS
no continuity to float position
sensor
assisted makeup is blocked
and code is stored
nonessential
CMW
Systems and Equipment - 184
JT3020 Mach 1/All Terrain Operator’s Manual
Interpret Diagnostic Codes
Code
Display
Condition
Result
Severity
147
TKR CONTROL
no continuity to tracker
control input
code is stored
nonessential
149
ANCHOR ON
PSW
no continuity to anchor
pressure switch
code is stored
nonessential
151
DRL JOY L/R
drill joystick left/right out of
range
rotation, cruise control and
carve mode are blocked
essential
152
DRL JOY F/B
drill joystick forward/
backward out of range
cruise control and carve
mode are blocked
essential
153
DRV JOY L/R
drive joystick left/right out of
range
drive is blocked
essential
154
DRV JOY F/B
drive joystick forward/
backward out of range
drive is blocked
essential
156
DR FLUID POT
drilling fluid control out of
range
code is stored
essential
161
ROT PRES SEN
rotation pressure out of
range
code is stored
nonessential
162
THR PRES SEN
thrust pressure sensor out of
range
code is stored
nonessential
163
DFLD PRES
SENS
drilling fluid pressure sensor
out of range
code is stored
nonessential
165
SHUTL STOP SW
no continuity to shuttle stop
switch
shuttles are blocked
nonessential
171
PIPE GRIP RSW
no continuity to pipe grip
rocker switch
code is stored
nonessential
172
SHUTTLE RSW
no continuity to pipe shuttle
rocker switch
code is stored
nonessential
173
PIPE LIFT RSW
no continuity to pipe lift
rocker switch
code is stored
nonessential
174
PIPE BOX RSW
no continuity to pipe box
rocker switch
code is stored
nonessential
175
PIPE LUBE RSW
no continuity to pipe lube
rocker switch
code is stored
nonessential
181
FRONT WR RSW
no continuity to front wrench
rocker switch
code is stored
nonessential
182
REAR WR RSW
no continuity to rear wrench
rocker switch
code is stored
nonessential
183
ROT WR RSW
no continuity to rotating
wrench rocker switch
code is stored
nonessential
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 185
Interpret Diagnostic Codes
Code
Display
Condition
Result
Severity
184
THROTTLE RSW
no continuity to throttle
rocker switch
code is stored
nonessential
185
SET/RES RSW
no continuity to set/resume
rocker switch
code is stored
nonessential
191
JT/AT RSW
no continuity to JT/AT rocker
switch
code is stored
nonessential
192
INNER ROT RSW
no continuity to inner
rotation rocker switch
inner rotation is blocked
essential
193
INNER ROT POT
inner rotation control out of
range
inner rotation is blocked
essential
194
INNER ROT JOG
inner rotation jog switch out
of range
code is stored
nonessential
195
INNER ROT POS
no continuity to inner
rotation position sensor
dither compensation is
blocked
nonessential
196
IROT PRES SEN
inner rotation pressure
sensor out of range
code is stored
nonessential
221
LOW VOLTAGE
system voltage is below
12.5V
code is stored
nonessential
222
INNER ROT SPD
inner rotation position
sensor changing
dither compensation is
blocked
nonessential
234
ADDP/REMP SW
add pipe and remove pipe
inputs both on
add pipe and remove pipe
are blocked
nonessential
235
TH F/R HSW
front and rear home switch
inputs both on
add pipe and remove pipe
are blocked
nonessential
241
SHUTTLE RESP
shuttles not responding
correctly
add pipe and remove pipe
aborted and code stored
nonessential
251
FLOAT ZERO
float sensor is reading too
low
assisted makeup is blocked
and code is stored
nonessential
252
FLOAT RANGE
float sensor is reading out of
range
assisted makeup is blocked
and code is stored
nonessential
253
A2D SYNCH
questionable voltage
reading on controller circuit
board
code is stored
nonessential
254
SETUP TABLE
error reading setup table
information
add pipe & remove pipe are
blocked
essential
255
MISC CODE
undefinable diagnostic code
reported
code is stored
nonessential
CMW
Systems and Equipment - 186
JT3020 Mach 1/All Terrain Operator’s Manual
Interpret Diagnostic Codes
Code
Display
Condition
Result
Severity
412
START MSG
normal entry into test mode
code is not stored
nonessential
413
3VOLT POWER
3V power error
code is stored
nonessential
414
5VOLT OUTPUT
5V output error
code is stored
nonessential
415
MSC OUTPUT
misc output error
code is stored
nonessential
416
BKLIGHT PWR
backlight power error
backlight may not function
correctly
nonessential
417
LCD -20V PWR
lcd -20V power error
lcd may not function
correctly
nonessential
441
ICTR PHYS ERR
errors on CMW CAN Bus
totalling 275 have been
logged
code is stored
essential
442
1939 PHYS ERR
errors on the J1939 Bus
totalling 275 have been
logged
code is stored
essential
443
ICTR BUS OFF
Information Center has shut
down CMW CAN
communications
throttle, engine fan, and
some status lights no longer
work correctly
essential
444
1939 PYHS ERR
Information Center has shut
down J1939
communications
throttle & engine fan no
longer work correctly
essential
445
ICTR PROTOCOL
Information Center has an
incorrect CMW CAN
protocol message
code is stored
essential
446
1939 PROTOCOL
Information Center has an
incorrect J1939 protocol
message
code is stored
essential
447
ICTR NG FAIL
Information Center has
detected a CANWitch
nodeguard timeout
code is stored
essential
448
1939 NG FAIL
Information Center has
detected a J1939 nodeguard
timeout
code is stored
essential
449
ICTR LOG FAIL
Information Center has had
an internal CMW CAN
software failure
throttle, engine fan, and
some status lights no longer
work correctly
essential
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Systems and Equipment - 187
Interpret Diagnostic Codes
Code
Display
Condition
Result
Severity
450
1939 LOG FAIL
Information Center has had
an internal J1939 software
failure
throttle and engine fan no
longer work correctly
essential
461
SD CARD FAIL
Information Center has
detected an error with the
SD card
code is stored
nonessential
462
SD LOG FAIL
Information Center has had
a problem writing to the SD
card
code is stored
nonessential
463
SD FILE OPEN
Information Center has had
a problem opening a file on
the SD card
code is stored
nonessential
488
SETUP TABLE
error reading setup table
information
code is stored
nonessential
489
MISC CODE
invalid error report entry
code is stored
nonessential
490
RUN HRS
total number of run hours in
tenths of an hour
n/a
n/a
502
2.5V REF
2.5V reference error
internal reference failure,
ESID may not give valid
readings
nonessential
503
-5V REF
-5V reference error
internal reference failure,
ESID may not give valid
readings
nonessential
504
CLCK RESP
clock response error
clock may not be working
nonessential
505
LCD RESP
LCD response error
LCD display may not work
nonessential
506
LED RESP
LED response error
LED display may not work
nonessential
507
LCD CONTR
LCD contrast error
LCD contrast not saved
properly
nonessential
508
COP RESET
cop watchdog error
processor has reset,
unknown status of ESID
code
essential
510
STRB DVR
strobe driver output error
strobe may not function
nonessential
511
HORN DVR
horn driver output error
horn may not function
nonessential
CMW
Systems and Equipment - 188
JT3020 Mach 1/All Terrain Operator’s Manual
Interpret Diagnostic Codes
Code
Display
Condition
Result
Severity
512
BAT POWER
battery power/horn driver
error
strike hold on power may not
function
nonessential
513
TEST WIRE
no continuity on test wire for
testing ESID
Information Center may not
be able to reset ESID
nonessential
515
STR VOLT
strike voltage input error
code is stored
nonessential
516
STR COIL
strike current input error
code is stored
nonessential
517
POST AC V
self test ac voltage input
error
self test of ac voltage stake
nonessential
518
POST AC I
self test ac current input
error
self test of ac current coil
nonessential
519
POST DC V
self test dc voltage input
error
self test of dc voltage input
amplifier
nonessential
520
POST DC I
self test dc current input
error
self test of dc current input
amplifier
nonessential
521
V NOT GND
strike voltage input stake not
grounded error
self test of voltage stake
grounded
nonessential
541
ESID PHYS ERR
errors on the CAN Bus
totalling 275 have been
logged
code is stored
nonessential
542
ESID BUS OFF
ESID has shutdown CAN
communications
CAN information is no longer
transmitted to Information
Center
essential
588
EEP WRITE
EEProm write error
ESID may not be able to
record strike history
nonessential
589
MISC CODE
invalid error report entry
software error report
nonessential
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Complete the Job - 189
Complete the Job
Chapter Contents
Antifreeze Drilling Unit . . . . . . . . . . . . . . . . . . . . 190
•
Add Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
•
Reclaim Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
Rinse Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 192
Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Stow Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
CMW
Complete the Job - 190
JT3020 Mach 1/All Terrain Operator’s Manual
Antifreeze Drilling Unit
Antifreeze Drilling Unit
Your drilling unit can be left overnight in freezing conditions by filling fluid lines with a polyproplyene-based
antifreeze (p/n 265-644) with optional antifreeze system before shutdown.
Add Antifreeze
1. Fill antifreeze tank with 8 gal (30.3 L) of
approved antifreeze.
2. Move carriage to front of drill frame.
3. Position 5-gal (18.9-L) bucket under spindle.
4. Install plug at quick coupler for drilling fluid
pump (shown).
5. Open valve (shown) between antifreeze tank
and head of drilling fluid pump.
6. Turn drilling fluid flow control device
counterclockwise to zero position.
7. Start unit and set throttle to slow position.
8. Slowly turn drilling fluid flow control device
clockwise until indicator light comes on. If light
does not come on, press drilling fluid pump
switch.
9. Run drilling fluid pump until antifreeze comes
out of spindle.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Complete the Job - 191
Antifreeze Drilling Unit
Reclaim Antifreeze
1. Connect remote fluid system. See page 103.
2. Turn on remote fluid system engine.
3. Start drilling unit and run at low throttle.
4. Move carriage to front of drill frame.
5. Position 3-gal (11-L) bucket under spindle.
6. Turn drilling fluid pump on low speed.
7. Turn drilling fluid pump off when drilling fluid comes out of spindle.
8. Open hood and pour antifreeze into 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
JT3020 Mach 1/All Terrain Operator’s Manual
Complete the Job - 192
Rinse Equipment
Rinse Equipment
Using Washwand
Connect the washwand at quick connect (2) at
rear of unit. Close valve to stop water flow. Close
valve (1) to shut off flow to spindle.
IMPORTANT:
•
Never use high flow when using wash
wand.
•
Use extreme caution when working with
highly pressurized water.
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 “Connect Fluid System” on
page 103.
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
JT3020 Mach 1/All Terrain Operator’s Manual
Complete the Job - 193
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 on trailer or truck.
CMW
Complete the Job - 194
JT3020 Mach 1/All Terrain Operator’s Manual
Stow Tools
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Service - 195
Service
Chapter Contents
Service Precautions . . . . . . . . . . . . . . . . . . . . . . . 197
•
Welding Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
•
Washing Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
•
Working Under Drilling Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
Recommended Lubricants/Service Key . . . . . . . 199
•
Engine Oil temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
•
Approved Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
10 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
25 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
250 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
500 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
1000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
2000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
As Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Service - 196
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
are in the ground path.
•
Always disconnect the Engine Control Unit ground connection from the frame, harness
connections to the ECU, and other electronic components prior to welding on machine or
attachments.
Washing Precaution
NOTICE:
•
Water can damage electronics.
•
When cleaning equipment, do not spray electrical components with water.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Service - 197
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 cylinder locks from storage at rear of pipe box (2) and place over extended cylinder rods
(shown) with curved ends toward stabilizer shoes.
2. Lower unit until load is supported by cylinder locks.
Before working under area of drilling unit supported by frame tilt cylinder, make sure drilling unit is parked
on hard surface.
1. Remove drill frame support stored under rear step (1) and place under drill frame (shown).
2. Lower drill frame until load is supported by drill frame support.
Replace cylinder locks or drill frame support if damaged.
CMW
Service - 198
JT3020 Mach 1/All Terrain Operator’s Manual
Service Precautions
Opening/Closing Front Hood
To open:
1. Unlock hood at lower handle (1) and upper
latches (2), if hood is locked.
2. Twist lower handle (1) and lift hood upward
and outward.
3. Continue lifting hood and push inward until
up-latch (3) engages.
To close:
1. Disengage the up-latch (3) by holding it up as
the hood is pulled outward using the lower
handle (1).
2. Pull outward on the hood until it begins to
move downward.
3. Place other hand on top outer surface of hood
(4) and firmly push downward and inward until
hood is completely closed, latch upper
latches.
4. Lock hood at lower handle and upper latches, if desired.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Service - 199
Recommended Lubricants/Service Key
Recommended Lubricants/Service Key
Item
Description
DEO
Diesel engine oil meeting or exceeding CH-4 per the API service classification or E5
per the European Automobile Manufacturer’s Association (ACEA) and SAE viscosity
recommended by engine manufacturer (SAE 15W40)
NDO
30WT non-detergent oil
MPG
Multipurpose grease meeting ASTM D217 and NLGI 5
MPG
Pump seal grease, similar to 94050 Philube blue multipurpose
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)
DEAC
Diesel engine antifreeze/coolant meeting ASTM D5345 (prediluted) or D4985
(concentrate)
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 238.
For more information on engine lubrication and maintenance, see your 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 243 to record all required service to your machine.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Service - 200
Recommended Lubricants/Service Key
Engine Oil Temperature Chart
Temperature range anticipated before next oil change
Approved Coolant
This unit was filled with John Deere Cool-Gard coolant before shipment from factory. Add only John Deere
Cool-Gard (p/n 255-006) or any fully-formulated, ethylene glycol based, low-silicate, heavy-duty diesel
engine coolant meeting ASTM specification D5345 (prediluted) or D4985 (concentrate).
NOTICE:
•
Do not use water or high-silicate automotive-type coolant. This will lead to engine damage or
premature engine failure.
•
Do not mix heavy-duty diesel engine coolant and automotive-type coolant. This will lead to coolant
breakdown and engine damage.
•
Use only distilled water for mixing coolants. Do not use tap water.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Service - 201
Each Use
Each Use
Location
Task
Notes
DOWNHOLE
TOOL
AT Rockmaster tool
AT only; pump seal grease
(p/n 256-036)
Downhole Tool
Lube Rockmaster Tool
Lube drill head with pump seal grease (p/n 256036) before first use, every 8 hours, and after every
bore.
To lube:
1. Remove allen head plug.
2. Install zerk.
3. Rotate bit by hand and fill with pump seal
grease until it comes out front seal.
4. Remove zerk and replace plug.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Service - 202
10 Hour
10 Hour
Location
Task
DRILLING
UNIT
Check track tension and condition
Notes
Check fuel filter water separator
Check air filter indicator and clean dust trap
Check engine oil level
DEO
Check fluid pump piston seals
Check engine coolant level
DEAC
Check hydraulic hoses
Check hydraulic fluid level
THF
Check fluid pump oil level
NDO
Test control switches
Check pipe lube applicator
Check pipe auto lubricator spray nozzle
Check pipe auto lubricator TJC level
Check inner rotation dither
Drilling Unit
Check Track Tension and Condition
Check track tension and condition daily and adjust
or replace as needed.
To Adjust:
1. Pump MPG into fitting (shown) until the length
of the compressed spring, dimension (A), is
12.75” (323.85 mm).
2. Drive straight forward one machine length and
check tension again.
CMW
TJC
JT3020 Mach 1/All Terrain Operator’s Manual
Service - 203
10 Hour
Check Fuel Filter Water Separator
Check fuel filter water separators every 10 hours.
Drain water at plug (shown) as needed.
Check Air Filter Indicator and Clean
Dust Trap
Check air filter service indicator (3) and clean dust
trap (4) every 10 hours. Change filter elements (1,
2) when air filter service indicator (3) reaches 20 in
H2O. Reset air filter service indicator (3) after
changing filters.
Check Engine Oil Level
Check engine oil at dipstick (1) before operation
and every 10 hours thereafter. Check with unit on
level surface. Add DEO at fill (2) as necessary to
keep oil level at highest line on dipstick.
CMW
Service - 204
JT3020 Mach 1/All Terrain Operator’s Manual
10 Hour
Check Engine Coolant Level
Check coolant level, with engine cool, at sight
glass (1) of expansion tank every 10 hours.
Maintain coolant level at halfway point on sight
glass. If low, add approved coolant to fill (2).
IMPORTANT: See “Approved Coolant” on
page 200 for information on approved
coolants.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Service - 205
10 Hour
Check Hydraulic Hoses
Fluid or air pressure 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 - 206
JT3020 Mach 1/All Terrain 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. Add THF at
hydraulic fluid fill (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).
Check Fluid Pump Oil Level
Check fluid pump oil level at sight glass (1) every
10 hours. Add NDO at fill (2) as needed.
Check Fluid Pump Piston Seals
Check piston seals for signs of excessive leakage
every 10 hours. Replace if leakage becomes
excessive. See your Ditch Witch dealer for
replacement parts.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Service - 207
10 Hour
Test Control Switches
Check control proximity switches every 10 hours
and clean or replace as needed.
1. front pipe box switch
2. rear stop switch
3. rear home switch
4. shuttle home switch
5. rear pipe box switch
6. front home switch
7. shuttle stop switch
To test:
1. Turn ignition switch to the on position. Do not start engine.
2. Place metal object above target on each switch.
3. If yellow LED on switch lights, switch sensor is working.
Check Pipe Auto Lubricator Spray
Nozzle
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 199 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
Service - 208
JT3020 Mach 1/All Terrain Operator’s Manual
10 Hour
Check Pipe Auto Lubricator TJC Level
Check pipe auto lubricator TJC level every 10
hours. Change pail as needed. See “Change Auto
Lubricator TJC Pail” on page 227 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 199 for more information.
Check Inner Rotation Dither
Check movement of inner rod every 10 hours.
Inner rod should have between 90 and 180° of
movement in each direction. If inner rod does not
dither, use manual switch to finish bore and then
repair dither (see Repair Guide).
To check:
1. Select AT mode.
2. Close front wrench.
3. Put carriage on rear home switch.
4. Put engine at high idle.
5. Move joystick forward or to left slightly.
6. Inner rod should start dithering.
Clean Drilling Fluid Y-Strainer
Clean drilling fluid y-strainer every 10 hours.
Ensure that strainer is free of debris.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Service - 209
50 Hour
50 Hour
Location
Task
Notes
DRILLING
UNIT
Change fluid pump oil
Initial service, NDO
Check radiator
Change hydraulic filters
Initial service
Check ground drive gearbox oil level
2 gearboxes, MPL
Check rotation gearbox oil level
MPL
Inspect thrust rollers
Check hex
Drain water from hydraulic tank
Check thrust drive gearbox oil level
Check anchor drive gearbox oil level
Drilling Unit
Change Fluid Pump Oil (Initial Service)
Change fluid pump oil at first 50 hours and every
2000 hours thereafter.
To Change Oil:
1. Drain at plug (3). Ensure that magnetic drain
plug is cleaned of debris before reinstalling.
2. Add NDO at fill plug (2). Maintain fluid level at
fill plug (2). Inspect oil level at sight glass (1).
CMW
Service - 210
JT3020 Mach 1/All Terrain Operator’s Manual
50 Hour
Check Radiator
Check radiator for dirt, grass, and other debris
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.
•
Open rear hood and spray through radiator
toward engine.
•
If grease and oil are present on radiator, spray
with solvent and allow to soak overnight.
IMPORTANT: Be careful not to damage fins
with high pressure air or water.
Change Hydraulic Filters (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 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).
Check Ground Drive Gearbox Oil Level
Check oil level in both ground drive gearboxes
every 50 hours. Rotate plug (shown) until level with
center of gearbox. Open plug. If oil does not come
out, add MPL as needed. Never fill more than
halfway.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Service - 211
50 Hour
Check Rotation Gearbox Oil Level
IMPORTANT: Drill frame must be level for accurate reading.
Check rotation gearbox oil level every 50 hours.
Outer Rotation Gearbox:
Add MPL through plug (1) to level of sight plug (2)
as needed.
Inner Rotation Gearbox (AT only):
Add MPL through fill plug (1) until oil comes out at
plug (2).
CMW
Service - 212
JT3020 Mach 1/All Terrain Operator’s Manual
50 Hour
Inspect Thrust Rollers
Inspect thrust rollers (at each end of carriage)
every 50 hours. Clean or replace if they do not turn
freely.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Service - 213
50 Hour
Check Hex
Shine flashlight into spindle and check condition of
hex (1) every 50 hours. Replace if rounded.
To replace:
1. Remove saver sub. Do not remove indexing
dowels from spindle.
2. Slide hex (4) and spring (3) off of drive shaft.
3. Check condition of hex (1) and replace if
needed.
4. Check o-ring (2) on inner water swivel (seal kit)
and replace if needed.
5. Install new spring and hex.
6. Install saver sub. See “Change Inner Water Swivel (Seal Kit)” on page 230.
Drain Water from Hydraulic Tank
Drain water out of tank every 50 hours if using
environment friendly hydraulic fluid. To drain, turn
plug slightly until water comes out. After all water
has drained, tighten plug.
Check Thrust Drive Gearbox Oil Level
Check thrust drive gearbox oil level at drain plug
(2,4) every 50 hours. Add MPL at fill (1,3) as
needed.
CMW
Service - 214
JT3020 Mach 1/All Terrain Operator’s Manual
50 Hour
Check Anchor Driver Gearbox Oil Level
Check anchor driver gearboxes oil level at drain
plug (1) every 50 hours. Add MPL at fill (2) as
needed.
IMPORTANT: Gearbox must be level for
accurate reading.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Service - 215
250 Hour
250 Hour
Location
Task
DRILLING
UNIT
Inspect air intake system
Notes
Drilling Unit
Inspect Air Intake System
Inspect intake piping for cracked hoses, loose
clamps, or punctures. Tighten or replace parts as
necessary.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Service - 216
500 Hour
500 Hour
Location
Task
Notes
DRILLING
UNIT
Change engine oil and filter
DEO
Change hydraulic filters
Normal conditions
Change fuel filters
Check batteries
Drilling Unit
Change Engine Oil and Filter
Change engine oil and filter every 500 hours for
normal service. Drain oil (3), change filter (4), and
add 11.5 qt (10.9 L) of DEO at fill (2). Check oil
level at dipstick (1).
IMPORTANT: Use oil specified in temperature
chart found in “Recommended Lubricants/
Service Key” on page 199.
Change Hydraulic Filters (Normal
Conditions)
Change hydraulic filter every 500 hours. Change
filter more often if indicated by filter indicator.
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
JT3020 Mach 1/All Terrain Operator’s Manual
Service - 217
500 Hour
Change Fuel Filters
Replace fuel filters every 500 hours. See parts
manual or contact your Ditch Witch dealer for
correct replacement filter.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Service - 218
500 Hour
Check Battery
Check battery every 500 hours. Keep batteries
clean and terminals free of corrosion.
To clean:
1. Turn battery disconnect switch to the off
position.
2. Ensure that no ignition sources are near
batteries.
3. Loosen and remove battery cable clamps
carefully, negative (-) cable first.
4. Clean cable clamps and terminals with wire
brush or battery cleaning tool to remove dull
glaze.
5. Check for signs of internal corrosion in cables.
6. Apply MPG to terminals after cleaning to reduce corrosion.
7. Connect battery cable clamps, positive (+) cable first.
8. Tighten any loose connections.
9. Ensure that battery tiedowns are secure.
10. Turn battery disconnect switch to the on position.
Explosion possible. Serious injury or equipment damage could occur.
Follow directions carefully.
NOTICE: To avoid explosion, do not create sparks and do not short across battery terminals for any
reason.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Service - 219
1000 Hour
1000 Hour
Location
Task
Notes
DRILLING
UNIT
Change hydraulic fluid and filters
THF
Change ground drive gearbox oil
2 gearboxes, MPL
Change rotation gearbox oil
MPL
Change spindle brake oil
THF
Change thrust drive gearbox oil
2 gearboxes, MPL
Change anchor driver gearbox oil
2 gearboxes, MPL
Drilling Unit
Change Hydraulic Fluid and Filters
Change hydraulic fluid and filters every 1000
hours.
To change:
1. Drain hydraulic oil at drain (3).
2. Change hydraulic filters. See “Change
Hydraulic Filters (Normal Conditions)” on
page 216.
3. Add (2) THF.
IMPORTANT: Change oil and filter every 500
hours if jobsite temperature exceeds 100°F
(38°C) more than 50% of the time.
CMW
Service - 220
JT3020 Mach 1/All Terrain Operator’s Manual
1000 Hour
Change Ground Drive Gearbox Oil
Change oil in both ground drive gearboxes every
1000 hours.
To change:
1. Drain oil at plug (shown).
2. Rotate gearbox 90° and add MPL at fill plug.
IMPORTANT:
•
Drill frame must be parked on level surface
for accurate reading.
•
Use helper to assist in positioning gearbox
plugs for checking and adding oil.
•
Do not overfill.
3. Replace fill plug.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Service - 221
1000 Hour
Change Rotation Gearbox Oil
IMPORTANT: Drill frame must be level for accurate reading.
Outer Rotation Gearbox:
Drain oil at gearbox oil drain (3) every 1000 hours.
Replace drain plug. Add MPL at fill (1). Check level
at sight glass (2). Replace fill plug.
Inner Rotation Gearbox (AT only):
IMPORTANT: Drill frame must be level for
accurate reading.
Drain oil at gearbox oil drain (2) every 1000 hours.
Replace drain plug. Add MPL at fill (1). Replace fill
plug.
CMW
Service - 222
JT3020 Mach 1/All Terrain Operator’s Manual
1000 Hour
Change Spindle Brake Oil
Change oil every 1000 hours. Capacity is 5 oz (148
mL) of THF.
To change:
1. Ensure drill frame is level.
2. Remove bottom plug on brake housing (3).
3. After all oil drains, replace bottom plug and
remove either top plug (1) and side fill level
plug (2).
4. Add 5 oz (0.15 L) of oil until it comes out the oil
level hole (2).
5. Replace all plugs.
Change Thrust Drive Gearbox Oil
Change thrust drive gearbox oil every 1000 hours.
To change:
1. Ensure that drill frame is level.
2. Drain oil at gearbox oil drain (2, 4). Replace
drain plugs.
3. Add 16 oz. (0.47 L) MPL at fill plug (1).
Replace fill plug (1).
4. Add 42 oz. (1.24 L) of MPL at fill plug (3).
Replace fill plug (3).
Note: A pumping device will be necessary to
remove gearbox oil.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Service - 223
1000 Hour
Change Anchor Driver Gearbox Oil
Change anchor drive gearbox oil every 1000
hours.
To Change:
1. Ensure that gearbox is level.
2. Drain oil at gearbox oil drain (1). Replace drain
plug.
3. Add 16 oz. (0.47 L) MPL at fill plug (2).
Replace fill plug (2).
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Service - 224
2000 Hour
2000 Hour
Location
Task
Notes
DRILLING
UNIT
Change engine coolant
DEAC
Change fluid pump oil
NDO
Drilling Unit
Change Engine Coolant
Drain cooling system at drain (1) every two years
or 2000 hours. Add approved coolant according to
instructions below. Refill capacity is 23 qt (21.8 L).
NOTICE:
•
The use of non-approved coolant may lead
to engine damage or premature engine
failure and will void engine warranty.
•
See “Approved Coolant” on page 200 for
list of approved coolants.
•
Use only distilled water for mixing coolants.
Do not use tap water.
To fill:
1. Add coolant at radiator fill (2) at a rate of 3 gpm (11.4 L/min) or less until full.
2. Run engine with thermostat open (>195°F/90°C engine temperature) for several minutes.
3. Stop engine and let it cool.
4. Maintain coolant level at halfway point on sight glass (3).
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Service - 225
2000 Hour
Change Fluid Pump Oil
Change fluid pump oil every 2000 hours.
To Change:
1. Drain at plug (3). Ensure that magnetic drain
plug is cleaned of debris before reinstalling.
2. Add NDO at fill plug (2). Maintain fluid level at
fill plug (2). Inspect oil level at sight glass (1).
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Service - 226
As Needed
As Needed
Location
Task
Notes
DRILLING
UNIT
Change pipe auto lubricator pail
TJC
Change hydraulic filter
Any time system is opened
Check pipeloader pads
Check front pipe guide inserts
Check fluid pump ball valve
Check track tension and condition
Check track support slide pads
Change inner water swivel (seal kit)
Change engine drive belt
Change air filter
Check pipeloader chute opening
Check saver sub
Replace pipe glide blocks
Replace carriage slide bars
Replace fuses
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Service - 227
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 199 for more information.
Change Hydraulic Filter (Anytime
System Opened)
Change hydraulic filter anytime system is opened
for repair. Change filter and add THF as needed at
hydraulic fluid fill.
CMW
Service - 228
JT3020 Mach 1/All Terrain Operator’s Manual
As Needed
Check Pipeloader Inserts
Check pipeloader inserts at indicated areas for
wear. Flip gripper inserts for longer wear, or
replace as needed. See your Ditch Witch dealer
for replacement parts.
1. Wear pad
2. Shuttle wear pad
3. Shuttle gripper pad
4. Catch arm wear pad
IMPORTANT: Ensure bolts are tightened evenly
to enable inserts to slide freely and wear evenly.
Check Front Pipe Guide Inserts
Check front pipe guide inserts (2) for wear. Rotate
inserts for longer wear, or replace as needed. See
your Ditch Witch dealer for replacement parts.
To replace:
1. Remove lynch pins (1, one on each side).
2. Remove guide inserts (2).
3. Remove pin (1) and open pipe guide.
4. Remove guide inserts (2).
5. Replace in reverse order.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Service - 229
As Needed
Check Fluid Pump Ball Valve
Check ball valve for leaks. Tighten stem packing as
needed. See your Ditch Witch dealer for
replacement packing.
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 (shown) until the length
of the compressed spring, dimension (A), is
12.75” (323.85 mm).
2. Drive straight forward one machine length and
check tension again.
Check Track Support Slide Pads
Check track support slide pads. Replace as needed. See your Ditch Witch dealer for replacement parts.
CMW
Service - 230
JT3020 Mach 1/All Terrain Operator’s Manual
As Needed
Change Inner Water Swivel (Seal Kit)
Replace inner water swivel (seal kit) as needed.
See your Ditch Witch dealer for replacement parts.
To replace:
1. Remove saver sub. Do not remove indexing
dowels from spindle.
2. Remove hex (6) and spring (7) from drive
shaft.
3. Remove snap ring (5).
4. Remove seal (4) and main body (2).
IMPORTANT: Use care when handling
main body to avoid seal contamination. Do
not allow grease to touch inner seals
during installation.
5. Inspect dowel pin (1). To replace, drive new pin into different hole until top of pin is flush with shaft
larger diameter.
6. Slide new main body (1) onto drive shaft. Check o-ring (3) and replace if needed.
7. Lightly coat seal (3) with SAE 30 engine oil and install onto main body.
NOTICE: Do not run seals without lubrication. Damage will occur.
8. Slide snap ring (4) onto main body.
9. Compress seal kit until snap ring is properly seated.
10. Install hex (5) and spring (6).
11. Install saver sub. See page 233.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Service - 231
As Needed
Change Drive Belt
Change engine drive belt as needed.
JT Units:
1. Turn off engine and remove key.
2. Use a 1/2” drive rachet at pulley (1) to remove
tension.
3. Remove belt (2).
4. Install new belt.
All Terrain Units:
1. Turn off engine and remove key.
2. Remove snap ring (3) from groove and slide
pump coupler collar (4) back.
3. Use a 1/2” drive rachet at pulley (1) to remove
tension.
4. Remove belt (2).
5. Install new belt.
6. Slide pump coupler collar back into position
and reinstall snap ring.
Change Air Filter
Change air filter when air filter service indicator (3)
reads 20 in H2O.
To change:
1. Disengage clasps and remove end cup.
2. Remove primary element (1).
3. Remove secondary element (2), if dirty.
4. Wipe inside of housing and wash end cup (4).
5. Install new element(s).
6. Install end cup and engage clasps.
CMW
Service - 232
JT3020 Mach 1/All Terrain Operator’s Manual
As Needed
7. Reset air filter service indicator (3).
Check Pipeloader Chute Opening
Check chute openings and adjust per dimension as
needed.
1. JT chute opening (shown) = 3.35” (8.5 cm).
2. AT chute opening (shown) = 3.60” (9.1 cm).
Apply Loctite® 242 to bolts.
Check Wrench Jaw Inserts
Check wrench jaw inserts for wear and replace as
needed.
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Service - 233
As Needed
Check Saver Sub
Check saver sub (see “Replace Worn Saver Sub”
on page 154) and replace as needed. See your
Ditch Witch dealer for replacement parts.
To replace:
1. Remove eight bolts that attach lock collars to
spindle. Do not remove indexing dowels from
spindle.
2. Remove saver sub.
3. Remove and replace o-rings, if necessary.
4. Inspect water swivel, replace as needed. See
“Change Inner Water Swivel (Seal Kit)” on
page 230.
5. Coat inner drive shaft splines with EPG every
time saver sub is removed (shown). Apply
EPS to sliding shaft surfaces.
6. Install in reverse order and tighten eight bolts
in a cross pattern to 200 ft•lb (271 N•m). Apply
Loctite® 242 to bolts before installation.
Replace Pipe Guide Blocks
Check pipe guide blocks for wear. Replace as
needed.
To replace:
Remove pins (1) and remove guide blocks (2).
Install new pins. See your Ditch Witch dealer for
replacement parts.
CMW
Service - 234
JT3020 Mach 1/All Terrain Operator’s Manual
As Needed
Replace Carriage Wear Bars
Check carriage wear bars for wear. Replace as
needed. See your Ditch Witch dealer for
replacement parts.
Replace Fuses
Change fuses as needed. Refer to decal inside
panels to identify fuses.
CMW
JT3020 Mach 1/ All Terrain Operator’s Manual
Specifications - 235
Specifications
Dimensions
U.S.
Metric
L, overall machine length (driving) (per SAE J2022)
220 in
5.59 m
L, overall machine length (transport) (per SAE J2022)
221 in
5.61 m
W, overall machine width (per SAE J2022)
80 in
2.03 m
H, overall machine height JT/AT large box (transport) (per SAE J2022)
94 in
2.39 m
H, overall machine height JT/AT small box (transport) (per SAE J2022)
92 in
2.34 m
Entry angle (per SAE J2022)
10-16°
10-16°
Angle of approach
19°
19°
Angle of departure
18°
18°
Ground bearing pressure
10.9 psi
0.75 kg/cm2
Ground bearing pressure (All Terrain)
10.8 psi
0.74 kg/cm2
Ground clearance
5.7 in
144 mm
Operating mass
22,300 lb
10 120 kg
Operating mass (All Terrain)
22,200 lb
10 070 kg
Power Pipe
U.S.
Metric
Length (per SAE J2022), nominal
118 in
3.00 m
Joint diameter (per SAE J2022)
3.00 in
76 mm
Tubing diameter (per SAE J2022)
2.38 in
60 mm
CMW
Specifications - 236
JT3020 Mach 1/ All Terrain Operator’s Manual
Power Pipe
U.S.
Metric
Minimum bend radius
175 ft
53 m
Weight (per SAE J2022), lined
90 lb
41 kg
Weight of drill pipe and large box (48 pipe)
5500 lb
2500 kg
Weight of drill pipe and small box (24 pipe)
3200 lb
1450 kg
All Terrain Pipe
U.S.
Metric
Length (per SAE J2022), nominal
112 in
2.84 m
Joint diameter (per SAE J2022)
3.25 in
76 mm
Tubing diameter (per SAE J2022)
2.23 in
57 mm
Minimum bend radius
175 ft
53 m
Weight (per SAE J2022), lined
100 lb
45 kg
Weight of drill pipe and large box (35 pipe)
4800 lb
2180 kg
Weight of drill pipe and small box (20 pipe)
3100 lb
1410 kg
All Terrain Cobble Pipe
U.S.
Metric
Length (per SAE J2022), nominal
112 in
2.84 m
Joint diameter (per SAE J2022)
3.25 in
76 mm
Tubing diameter (per SAE J2022)
2.06 in
51 mm
Minimum bend radius
175 ft
53 m
Weight (per SAE J2022), lined
98 lb
44 kg
Operational
U.S.
Metric
Maximum spindle speed (per SAE J2022)
225 rpm
225 rpm
Maximum spindle speed (per SAE J2022) (AT inner spindle)
400 rpm
400 rpm
Maximum spindle torque
4000 ft•lb
5420 N•m
Maximum spindle torque (AT inner spindle)
800 ft•lb
1080 N•m
Carriage thrust travel speed
120 fpm
37 m/min
Carriage pullback travel speed
120 fpm
37 m/min
Thrust force
24,800 lb
110 kN
Thrust force (All Terrain mode)
16,500 lb
73 kN
CMW
JT3020 Mach 1/ All Terrain Operator’s Manual
Specifications - 237
Operational
U.S.
Metric
Pullback force
30,000 lb
133 kN
Bore diameter
4.5 in
114 mm
Bore diameter (All Terrain w/ Rockmaster 822)
4.75 in
121 mm
Bore diameter (All Terrain w/ Rockmaster 86)
5.50 in
140 mm
Backream diameter
soil dependent
Ground travel speed (forward)
2.4 mph
3.9 km/h
Ground travel speed (reverse)
2.2 mph
3.5 km/h
Power
U.S.
Metric
Displacement
275 in3
4.5 L
Bore
4.02 in
102 mm
Stroke
5.42 in
138 mm
manufacturer’s gross power rating (per SAE J1995)
148 hp
110 kW
estimated net power rating
138 hp
103 kW
rated speed
2300 rpm
2300 rpm
peak gross power @ 2000 rpm
156 hp
116 kW
Engine: Cummins QSB4.5
Fuel: diesel
Cooling medium: liquid
Injection: direct
Aspiration: turbocharged and charge air cooled
Cylinders: 4
Power
Drilling Fluid System (Onboard)
U.S.
Metric
Maximum drilling fluid pressure (per SAE J2022)
1500 psi
103 bar
Maximum drilling fluid flow (per SAE J2022)
50 gpm
189 L/min
CMW
Specifications - 238
JT3020 Mach 1/ All Terrain Operator’s Manual
Fluid Capacities
U.S.
Metric
Hydraulic reservoir
27 gal
102 L
Fuel tank *
42 gal
159 L
Engine oil, including filter
12 qt
11 L
Cooling system
23 qt
22 L
Antifreeze tank
8 gal
30 L
* Under normal operating conditions, a full tank of fuel will last 10 hours.
Battery
SAE reserve capacity 195 min, 12V, negative ground, SAE cold crank @ 0°F (-18°C), 950 amps.
Noise Levels
Operator 82 dBA sound pressure per ISO 6394
Exterior 101 dBA sound power per ISO 6393
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
JT3020 Mach 1/All Terrain Operator’s Manual
Support - 239
Procedure
Support
Procedure
Notify your dealer immediately of any malfunction or failure of Ditch Witch equipment.
Always give model, serial number, and approximate date of your equipment purchase. This information
should be recorded and placed on file by the owner at the time of purchase.
Return damaged parts to dealer for inspection and warranty consideration if in warranty time frame.
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
JT3020 Mach 1/All Terrain Operator’s Manual
Warranty - 240
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 SK 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
JT3020 Mach 1/All Terrain Operator’s Manual
Service Record - 243
Service Record
Service Performed
Date
Hours
CMW
Service Record - 244
Service Performed
CMW
JT3020 Mach 1/All Terrain Operator’s Manual
Date
Hours
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