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Ditch Witch JT4020 Mach1/All Terrain Operators Manual

1. IL p ace j290m008h eps Check Engine Coolant Level With engine cool check coolant level at fill neck in expansion tank every 10 hours Maintain coolant level at bottom of fill neck If low fill with approved coolant IMPORTANT See Approved Coolant on page 179 for information on approved coolant j290m009h eps JT4020 Mach 1 All Terrain Operator s Manual Service 183 10 Hour Check Air Filter Indicator and Clean Dust Trap 4 Check air filter indicator 1 and clean dust trap 4 every 10 hours Change filter elements 2 3 when red flag pops up Reset air filter service indicator after changing filter j290m010h eps 184 JT4020 Mach 1 All Terrain Operator s Manual 10 Hour Check Hydraulic Hoses Check hydraulic hoses for leaks every 10 hours CheckHoses eps WARNING JT4020 Mach 1 All Terrain Operator s Manual Service 185 10 Hour Check Hydraulic Fluid Level Check hydraulic fluid level every 10 hours Maintain fluid level at halfway point on sight glass 1 ee 2 1 when engine is off and fluid is cool Refill with THF at hydraulic fluid fill 2 IMPORTANT If hydraulic system must be opened fo
2. Backreamer Sandy Soft Soil Medium Hard Rocky Soft Hard Soil Soil Soil Soil Rock Rock Beavertail 3 1 1 1 3 4 4 Three Wing 4 3 3 2 1 1 4 Water Wing 4 3 2 1 2 2 4 Compact Fluted 1 1 2 2 2 3 4 Kodiak 4 3 3 2 1 2 4 Rhino Rock 4 4 4 4 3 2 1 Rockmaster 4 4 4 4 3 1 1 Compaction 1 2 3 4 4 4 4 Cone HC Hard 4 3 2 1 1 4 4 Condition ST Saw Tooth 2 2 1 2 2 3 4 MX Mixer 2 2 3 4 4 4 4 CT Cutter 3 2 1 2 3 4 4 EX Expander 1 2 3 4 4 4 4 Fluted Cone 1 1 2 2 2 3 4 IMPORTANT For soil definitions see the chart on the previous page JT4020 Mach 1 All Terrain Operator s Manual Systems and Equipment 137 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 V 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 in backreamer requires at least 1 47 gal ft Metric A 152 mm backreamer requires at least 18 24 L m 2 Multiply this number by distance per minute you plan to backream The answer is an estimate of amount of fluid you will need for each minute of backreaming U S 1 5 gal x 2
3. 98 Connect Drill Pipe 99 Drill First 100 JT Mode AT Dirt Mode 100 PAL MOOG o eu eae aan bdo 100 Swab the Hole 101 Enable Automated Pipeloader System 101 Conduct a Bore 92 JT4020 Mach 1 All Terrain Operator s Manual Add PIDE sone ee Mew 102 Correct Direction 104 Basic Blei Lus rons oes en Parc alienate rat eR Bar 104 aem ava tne ex ats sedet d s seis 105 Drill Head Position 105 Record Bore 106 Surface Drill Head 106 Assemble Backream String 107 Remove Pipe 109 Remove Pullback Device 111 Check Shuttle Stop Position 111 JT4020 Mach 1 All Terrain Operator s Manual Conduct a Bore 93 Position Equipment Position Equipment 1 Review bore plan and select drilling unit position and fluid unit position 2 Move equipment into selected positions Connect Fluid System 1 Connect fluid hose from mixing system to drilling fluid pump A 3 76 mm or larger non collapsable hose is required 2 Install y strainer between mixin
4. 170 Reclaim Antifreeze 171 Rinse Equipment 172 Disconnect 173 Stow Tools 173 Complete the Job 170 Antifreeze Drilling Unit JT4020 Mach 1 All Terrain Operator s Manual Antifreeze Drilling Unit Your drilling unit can be left overnight in freezing conditions by circulating a polyproplyene based antifreeze p n 265 644 through unit before shutdown Add Antifreeze 1 m o m Fill antifreeze tank with 8 gal 30 L of approved antifreeze Install plug on suction side of drilling fluid pump Open valve below antifreeze tank Install antifreeze reclaimer adapter in spindle Ensure valve shown is open Turn drilling fluid potentiometer counterclockwise to zero position Start unit and set throttle to slow position Set drilling fluid pump switch to on position Slowly turn drilling fluid potentiometer clockwise until indicator light comes on Run drilling fluid pump until antifreeze comes out of spindle Turn drilling fluid pump switch to off position Close valve on antifreeze reclaimer adapter Open valve below right operator s console shown Repeat steps 5 8 Close valve below right console when antifreeze runs out of valve below right console Turn drilling fluid pump switch to off position j290m001c eps
5. j290m038h eps JT4020 Mach 1 All Terrain Operator s Manual Service 209 As Needed Check Front Pipe Guide Blocks Check front pipe guide blocks for wear Rotate blocks for longer wear or replace as needed See your Ditch Witch dealer for replacement parts To replace 1 Remove lynch pins 1 on each side 2 Remove guide blocks 2 3 Replace in reverse order j290m039h eps Check Pipe Lubricator Insert Check pipe lubricator insert for wear replace as needed See your Ditch Witch dealer for replacement parts j290m016h eps Service 210 JT4020 Mach 1 All Terrain Operator s Manual As Needed Check Fluid Pump Ball Valve Check hydraulic ball valve for leaks Tighten stem packing as needed See your Ditch Witch dealer for replacement packing j290m040h eps Check Track Tension and Condition Check track tension and condition and adjust or replace as needed See your Ditch Witch dealer for replacement parts To adjust 1 Pump MPG into fitting A until spring height is 17 3 4 18 451 457 mm when measured through windows B 2 Drive straight forward one machine length and check tension again j290m041h eps JT4020 Mach 1 All Terrain Operator s Manual Service 211 As Needed Check Track Support Slide Pads Check track support slide pads R
6. o c00ic030h eps To raise push up To lower pull down IMPORTANT Lower right and left stabilizers to the ground together then adjust individually 4 Left stabilizer control lt gt 00 029 lower pull down IMPORTANT Lower left and right stabilizers to the ground together then adjust individually 5 Shuttle stop control 00 028 To lower shuttle stop push up To raise shuttle stop pull down IMPORTANT Look at pipe row indicator on drill frame to see which row shuttles will stop under 6 Back frame tilt control 00 027 lower pull 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 Controls 26 JT4020 Mach 1 All Terrain Operator s Manual Set Up Console Item Description Notes 7 Front frame tilt control ES 00 026 To lower pull 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 8 Selection switch To scroll th
7. pue opis Y uo w04 BUY 1no eounos Aue peseuound OU SI Yo peseuound sem jueudinbe JI 3ueuudinb3 V eJnjeuBis eJnjeuBis Jno diusjejeeq uoiM uoiM SJOQUINN 5 5 jeues 5 2 5 5 5 Sseuosseooy sjueuiuo epnv SJOQUNN Seuosseooy siueuluoenv SJOQUNN Jequunw IPPON Jequunw IPPON JequinN 9po2 1 diz diz Ayunog MO Aunog MO xog O d sseJppy xog O d JO sseJppy uonuenv uonuenv Auedwos s jaseyoind Auedwosy s jaseyoind Jv Jud 0 uoneuoJu d u231M uonjensibay u231M R150 R230 R300 Operator s Manual Service Record 223 Service Record
8. 68 Select 68 Apply 69 Plan Bore Path 70 Recommended Bend Limits 71 s Entry wnt 73 e Minimum 73 Minimum 74 Bore Path 74 64 JT4020 Mach 1 All Terrain Operator s Manual Prepare 75 Mak Boro Gt ends Meare ates 75 Prepare Entry 75 Check Supplies and Prepare Equipment 76 Check SUPpIIES ike eR PEE RE Neale ER oe ace ele 76 Prepare 1 77 e Select Drilling 78 Prepare Drilling 79 e Assemble Accessories 80 JT4020 Mach 1 All Terrain Operator s Manual Prepare 65 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 Revie
9. 17 If a Fiber Optic Cable is Damaged 17 If Machine Catches on 17 Safety 9 Safety CMW Safety 10 115 Tier 3 Operator s Manual Guidelines Guidelines Follow these guidelines before operating any jobsite equipment Complete proper training and read operator s manual before using equipment Contact your local One Call 811 in USA or the One Call referral number 888 258 0808 in USA and Canada to have underground utilities located before digging Also contact any utilities that do not participate in the One Call service 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 115 Tier 3 Operator s Manual Safety 11 Safety Alert Classifications Safety Alert Classification
10. c00ic373h eps Displays system voltage Should show 13 14V with engine running Controls 22 JT4020 Mach 1 All Terrain Operator s Manual Set Up Console Item Description Notes 6 Hydraulic fluid filter service indicator 4 00 024 Lights when hydraulic fluid filter needs replacing Change filter when indicator lights continuously and engine is warm 7 Hydraulic fluid temperature indicator a5 00 023 Lights when hydraulic fluid is overheating Check hydraulic fluid level 8 Engine shutdown indicator c00ic314h eps Lights when an 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 21 for more information IMPORTANT See Tier 3 Engine on page 157 for more information on diagnostic system and diagnostic codes To reset turn ignition switch to STOP then to run 9 Operator alert indicator 00 03 ens Lights when a non critical engine fault occurs A code will be stored in the ECU See Diagnostic gauge on page 21 for more information IMPORTANT See Tier 3 Engine on page 157 for more information on diagnostic system and diagnostic codes JT4020 Mach 1 All Terrain Operator s Manual Controls 23 Set Up Console
11. If carriage is at rear of drill frame light should be on If carriage is away from rear of drill frame light should be off 3 Shuttle home status light SHUTTLE c00ic053h eps If shuttle is retracted light should be on If shuttle is extended light should be off 4 Front home status light FRONT c00ic054h eps If carriage is at front of drill frame light should be on If carriage is away from front of drill frame light should be off 5 Front wrench status light WRENCH c00ic055h eps If front wrench is closed light should be on If front wrench is open light should be off JT4020 Mach 1 All Terrain Operator s Manual Controls 39 Right Control Console Item Description Notes 6 Control cycle light If nothing is being controlled green light should be off If system is waiting for an action before starting cycle light should flash on and off If something is being controlled light should be on c00ic056h eps ee If control cycle is interrupted light should flash twice quickly 7 Drilling fluid pump If pump is on light should be status light on If pump is off light should be off PUMP 00 057 Controls 40 JT4020 Mach 1 All Terrain Operator s Manual Right Control Console Controls 5 j130m003c eps 1 Drilling fluid pump switch 5 Tr
12. ERU EU EIS UU 151 tes rates Gaeta are Pavia 152 Disengage 152 RESUME 152 Machine Diagnostic Codes 152 Diagnostic Light 2 reiner ened eee 152 e Code Severity Levels 152 e Review Modes 153 e Diagnostic Code Interpretation 153 e Diagnostic Codes 154 Ne rs Engine ciclos e ulen nnana Aes 157 gt OVOLVIGW A ses asc 157 e Diagnostic Codes 157 JT4020 Mach 1 Terrain Operator s Manual Systems and Equipment 115 Anchor System Anchor System A WARNING Select Anchor Many anchor types are available Choose the correct anchor type based on jobsite conditions 3 5 cap bit hard soft rock asphalt concrete cobble auger bit soft soil to hard soil soft rock available in different sizes Systems Equipment 116 JT4020 Mach 1 All Terrain Operator s Manual Attach Anchor to Anchor Driver IMPORTANT Use tall caps p n 308 903 for front anchors and short caps p n 308 750 for side anchors 1 Raise anchor driver to top of anchor frame 2 Pull collar 1 up 3 Position lower part
13. eee eee Pis 30 Operation 15 33 Right Control Console 35 Gauges and Indicators 35 MR aoe eta ee waa eek E 37 COMMONS sid i cece eR 40 Anchoring System Console 43 JI AT System 45 Il S 46 Override 47 Battery isses states 49 dz 50 750 752 lt 53 he ee 53 CONTOS ea aienea ed UR ee ws acer 56 Controls 19 Controls fo Controls 20 Set Up Console JT4020 Mach 1 All Terrain Operator s Manual Gauges and Indicators 1 F j130m001h eps uel gauge Set Up Console 2 Tachometer with diagnostic display 3 Engine coolant temperature gauge 4 Engine oil pressure gauge 6 Hydraulic fluid filter service indicator 7 Hydraulic fluid temperature indicator 8 Engine shutdown indicator 9 Operator alert indicator 5 Voltmeter 10 Engine preheat indicator Item Description Notes 1 Fuel gauge Displays fuel level in tank Use only 2 diesel fuel
14. MPG Multipurpose grease meeting ASTM D217 and NLGI 5 MPG Pump seal grease similar to 94050 Philube blue multipurpose THF Tractor hydraulic fluid similar to Phillips 66 HG Mobilfluid 423 Chevron Tractor MPL Multipurpose gear oil meeting API service classification GL 5 SAE 80W90 io 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 concentrate Check level of fluid or lubricant um G DEAC Diesel engine antifreeze coolant meeting ASTM D5345 prediluted or D4985 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 217 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 e Use the Service Record on page 223 to record all required service to your machine JT4020 Mach 1 All Terrain Operator s Manual Service 179 Recommended Lubricants Service Key Engine Oil Temperature Chart 80 100 30 40 t130
15. AT DIRT AT JT 00 094 To select mode press left To select AT DIRT mode move to center To select JT mode press right Use AT or AT DIRT drilling mode when using AT pipe with inner shaft Use JT drilling mode when using JT pipe without inner shaft IMPORTANT See Prepare Drilling Unit on page 79 for how to set up unit for each drilling mode 2 Inner rotation hourmeter cO0icO90h eps Displays inner rotation operating time Use these times to schedule service for downhole tool and inner shaft See Service on page 175 Controls 46 JT4020 Mach 1 All Terrain Operator s Manual Seat Seat Tf CO 1 j07om045h eps 1 Seat slide control 2 Seat recline control Item Description Notes 1 Seat slide control To slide forward or backward move left To lock seat in position move right 00 095 5 2 Seat recline control To recline or raise seatback lift gt lock seatback in position 4 release 00 096 JT4020 Mach 1 All Terrain Operator s Manual Controls 47 Override Box Override Box jO7om038h eps 1 Drilling fluid flow override switch 2 Thrust pullback or left track override switch 3 Rotation or right track override switch Item Description Notes 1 Drilling fluid flow To turn fluid on move right Connect t
16. Remove drain plug 2 and drain oil Replace drain plug Drive unit to rotate fill plug 1 until level with center of gearbox Open fill plug and fill with MPL until level with plug opening Replace fill plug IMPORTANT Drill frame must be level for accurate reading JT4020 Mach 1 All Terrain Operator s Manual 1000 Hour j290m023h eps Use helper to assist in positioning gearbox plugs for checking and adding oil Do not overfill Change Rotation Gearbox Oil Drain oil at gearbox oil drain 3 every 1000 hours Fill with MPL at fill plug 1 until oil is level with sight plug opening 2 Replace plugs Capacity is 9 qt 8 5 L IMPORTANT Drill frame must be level for accurate reading j290m027h eps JT4020 Mach 1 All Terrain Operator s Manual Service 201 1000 Hour Change Spindle Brake Oil Change oil every 1000 hours Capacity is 5 oz 148 mL of THF To change 1 Remove outer rotation motor See Repair Guide 2 Loosen six bolts 1 holding spindle brake together Pull spindle brake apart until oil comes out Afte
17. Take soil samples from several locations along bore path to determine best bit and backreamer combinations Identify Hazards Identify safety hazards and classify jobsite See Classify Jobsite on page 68 6 om JT4020 Mach 1 All Terrain Operator s Manual Prepare 67 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 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 73 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 68 Classify Jobsite Inspect Jobsite JT4020 Mach 1 All Terrain Operator s Manual Classify Jobsite Follow U S Department of Labor regulations on excavating and trenching Part 1926 Subpart P and other similar regulations Contact One Call 888 258 0808 and any utility companies which do not subscribe to One Call Inspect jobsite and perimeter
18. To connect turn switch clockwise Me 00 097 Controls 50 ESID j070m042h eps 1 Alphanumeric display 2 Strike indicator 3 Alarm interrupt button 4 Voltage problem indicator oof JT4020 Mach 1 All Terrain Operator s Manual ESID Nu 4 4 OOOOOC ON 5 Ow e Of 8 5 Current problem indicator 6 OK indicator 7 Electrical power supply indicator 8 Self test button Item Description Notes 1 Alphanumeric display Display amount of current and voltage being detected as a percentage of strike condition The line with the V shows voltage reading and the line with the A shows current reading JT4020 Mach 1 All Terrain Operator s Manual ESID Controls 51 Item Description Notes 2 Strike indicator 00 077 Red lights on as values in display increase Light in triangle represents strike warning condition and will trigger alarm s and strobe s Remember that system can go from one or two lights to an electric strike immediately NOTICE The ESID does not indicate proximity to electric lines System will activate only when voltage and or amperage detected at the drilling unit are above threshold minimum l
19. c00ic375h eps In temperatures below 40 F 4 C use 1 diesel fuel Tank holds 55 gal 208 L JT4020 Mach 1 All Terrain Operator s Manual Controls 21 Set Up Console Item Description Notes 2 Tachometer amp Tachometer IMPORTANT For more information diagnostic gauge c00ic372h eps Displays engine RPM Diagnostic gauge Displays engine hours trip meter engine statistics and engine diagnostic codes To view information press the selection switch about the engine diagnostic system and codes see Engine Diagnostic Codes on page 157 IMPORTANT For more information about the selection switch see Selection switch on page 26 3 Engine coolant temperature gauge T WATER TEMP xu lt amp i ps c00ic376h eps Displays engine coolant temperature Normal coolant temperature is 1907220 F 88 105 C IMPORTANT Do not operate machine when coolant temperature exceeds 240 F 116 C If engine become too hot engine will shut down See Engine shutdown indicator on page 22 4 Engine oil pressure gauge c00ic374h eps Displays engine oil pressure Full load reading should be 35 65 psi 2 4 4 5 bar At idle reading should not drop below 15 psi 1 bar If there is no oil pressure for 5 seconds engine will shut down See Engine shutdown indicator on page 22 5 Voltmeter
20. engine oil Condition and Function drive chains e filters air oil hydraulic e fluid pump couplers tires and tracks pumps and motors drilling fluid mixer e hoses and valves water tanks 78 Select Drilling Mode Three drilling setups are available with this unit AT mode AT dirt mode JT mode Select the best setup based on jobsite conditions JT4020 Mach 1 All Terrain Operator s Manual Check Supplies and Prepare Equipment Mode Situation used Downhole tools Capabilities AT Rock soft rock other non compressible All Terrain drill pipe 25 000 Ib 111 soils Any other situation with difficult of thrust Rockmaster tool steering because of hard soil dither conditions inner rotation AT When one bore out of several can be All Terrain drill pipe 36 000 160 kN dirt better or more quickly done with of thrust beacon housing conventional downhole tools This bore p n 368 822 lt dither is such that changing to JT pipe is not P practical transition sub e inner rotation p n 401 143 e standard JT tools JT Soft or intermittent soft rock or other e JT drill pipe e 36 000 Ib 160 kN compressible soils standard JT tools of thrust no dither no inner rotation Once drilling mode has been selected configure drilling unit to match mode JT4020 Mach 1 All Terrain Operator s
21. liquid polymer suspension p n 259 808 e Quik Trol dry powder polymer p n 259 809 Bore Gel drilling fluid p n 259 807 e 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 e medium chain such as Baroid Quik Trol JT4020 Mach 1 All Terrain Operator s Manual Systems and Equipment 127 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 V Some things to remember when mixing bentonite Use clean water free of salt calcium or excessive chlorine e Use water
22. 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 107 023 Systems Equipment 132 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 Troubleshooting Tip If thrust and rotation are not enabled Check whether the green tracker control light located on drilling unit anchoring console is on If it is communication has probably stopped between tracker and display or tracker is set to incorrect code If communication cannot be restored install tracker control key shown in drilling unit Green tracker control light located on anchoring console will go off Thrust and rotation will function 5 Remove tracker control key shown from
23. Ree RE YS 86 Eoad REEL on Pye ce eon oe 87 We DOWN i dere RP ER Seder a are ee 88 usus utet ep cce Pek de mi uteris 89 Trailer eee 89 Transport 83 Transport Transport 84 JT4020 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 ic1319a eps Procedure Drilling Unit Use a crane capable of supporting the equipment s size and weight See Specifications on page 215 or measure and weigh equipment before lifting Use four lift points Attach securely to cross members jO70m040c eps JT4020 Mach 1 All Terrain Operator s Manual Transport 85 Lift Pipe Box Use crane capable of supporting the equipment s size and weight See Specifications on page 215 or measure and weigh equipment before lifting NOTICE Lift only one box of pipe at a time 5 ats If lift pin block is not installed see Pipe Boxes on H page 145 for installation procedure 07 051 Transport 86 JT4020 Mach 1 All Terrain Operator s Manual Haul Haul Inspect Trailer Check hitch for wear and cracks Lubricate if needed Check u bolts and
24. Service Performed Date Hours CMW Service Record 224 R150 R230 R300 Operator s Manual Service Performed Date Hours CMW
25. 107 050 JT4020 Mach 1 All Terrain Operator s Manual Complete the Job 171 Antifreeze Drilling Unit Reclaim Antifreeze 1 Hold hose on antifreeze reclaimer over top of antifreeze tank Open valve on reclaimer e Connect drilling fluid transfer hose from tanks to drilling fluid pump inlet Close valve below antifreeze tank Start unit and run at low throttle Turn drilling fluid pump on low speed gt Gr Turn drilling fluid pump off when drilling fluid comes out of reclaimer hose 8 Remove antifreeze reclaimer 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 Complete the Job 172 JT4020 Mach 1 All Terrain Operator s Manual Rinse Equipment Rinse Equipment Using Washwand PI Connect the washwand at quick connect 1 at rear of unit Open valve 2 to start water flow Close valve to M ud 1 stop water flow I 000 1 A e U ai JH 2 j100m081h eps AWARNING 2 27 Spray water onto equipment to remove dirt and mud Some pressure might be needed to remove dried mud from wrench area JT4020 Mach 1 All
26. 18 kg Bore Gel 75 Ib 340 g Quik Trol Add 5 1 gal 2 4 L of Dinomul in high torque situations coarse sand below 40 Ib 18 kg Bore Gel Add 5 1 gal 2 4 L of Dinomul in high water table 75 Ib 340 Quik Trol torque situations 75 10 340 9 No Sag gravel 50 Ib 23 kg Bore Gel Add 5 Ib 225 g of Barolift to reduce loss 75 Ib 340 g Quik Trol of returns 75 10 340 9 No Sag cobble 50 Ib 23 kg Bore Gel Add 5 Ib 225 of Barolift to reduce loss 75 Ib 340 g Quik Trol 75 10 340 9 No Sag of returns sand gravel clay or shale 35 40 Ib 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 Ib 225 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 Ib 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 Ib 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 Ib 18 23 kg Bore Gel Use 5 pt 235 mL of EZ Mud in reactive shales rock clay mixture 40 50 Ib 18 23 kg Bore Gel 5 pt 235 mL EZ Mud rock sand mixture 40 50 Ib 18 23 kg
27. 20 244 ft2in 74 4m 125 ft 8 in 38 3 4 56ft8in 17 3m 5ft5in 1 7 21 252ft2in 76 9m 137f5in 41 9 5 70 ft8 in 21 5 8 ft5 in 2 6 m 22 2597 79 1 m 149 ft 7 in 45 6 m 6 84 ft 5 25 8 12 ft 1 in 3 7 m 23 266 ft5in 81 2in 162 ft2 in 49 4 m 7 98 ft O 29 9 16 ft5 in 5 0 24 272 ft 8in 831 m 174 ft 11 in 53 3 m 8 111 ft4 in 33 9 21 ft5in 6 5 25 278 ft4in 84 8m _ 188 ft 0 in 57 3 m 9 124 ft 6 in 37 9 m 27 ft 0 in 8 2 26 283 ft 4 in 86 4 201 ft 5 in 61 4 m 10 137 ft3 in 41 9m 33 ft3 in 10 1 m 27 287 ft8 in 87 7 215 ft 0 in 65 5 m 11 149 ft 10 in 45 7 4041 in 12 2 m 28 291 ft5in 88 8m 228 ft9 in 69 7 12 16210 in 494 47 ft6 in 14 5 m 29 294 ft6in 89 8m 242 ft 8 in 74 0 13 173 ft 10 in 53 0 m 55 ft 6 in 16 9 m 30 296 ft 10 in 90 5 256 ft 9 in 78 3 m 14 185 ft3in 56 5 64 ft0 in 19 5 m 31 298 ft7in 91 0 270 ft 10 in 82 6 15 196 ft 3 in 59 8 7844 in 22 3 m 32 299 ft 8 in 91 3 m 285 ft 1 in 86 9 m 16 206 ft 10 in 63 0 82 ft 8 in 25 2 m 33 300ft0in 91 4m 300 ft 0 in 91 4 m 17 216 ft 11 in 66 1 92 ft 9 in 28 3 m 107 005 JT4020 Mach 1 All Terrain Operator s Manual Prepare 73 Plan Bore Path Entry Pitch Entry pitch is the slope o
28. 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 696
29. Ditch a AS Witch 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 2 312 006 683 845 EP674 093 other U S and foreign patents pending JT4020 Mach 1 All Terrain Operator s Manual Contents 7 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 5 part number revision level and publication date of this manual and factory contact information Safety 9 machine safety alerts and emergency procedures Controls 19 machine controls gauges and indicators and how to use them Operation Overview 59 an overview for completing a job with this machine planning setting up install
30. Minimum bend radius 300 ft 914 Weight with inner pipe SAE J2022 264 Ib 120 kg Pipe box weight large AT pipe box with 18 pipe 5580 Ib 2531 kg small AT pipe box with 9 pipe 3150 Ib 1429 kg Specifications 216 JT4020 Mach 1 All Terrain Operator s Manual Mach 1 Power Pipe U S Metric Length per SAE J2022 177 in 4 5m Joint diameter per SAE J2022 3 5 in 89 mm Tubing diameter per SAE J2022 2 81 in 71mm Minimum bend radius 190 ft 58m Weight per SAE J2022 158 Ib 71 kg Pipe box weight large JT pipe box with 32 pipe 6000 Ib 2721 kg small JT pipe box with 16 pipe 3100 Ib 1406 kg Operational U S Metric Spindle speed per SAE J2022 inner pipe 0 250 rpm 0 250 rpm outer pipe 0 240 rpm 0 240 rpm Spindle torque per SAE J2022 inner pipe max 2000 ftelb 2712 Nem outer pipe max 5000 ftelb 6780 Nem Carriage speed per SAE J2022 0 120 0 37 m min Pullback force per SAE J2022 40 000 Ib 178 kN Thrust force per SAE J2022 actual All Terrain mode 25 000 Ib 111 kN actual JT and AT dirt modes 36 000 Ib 160 kN Minimum bore diameter All Terrain with roller cone bit 6 25 in 159 mm JT with soil bit 5 in 127 mm Backream diameter variable variable Ground drive speed per SAE J2022 forward 0 2 5 mph 0 4 km h reverse 0 2 5 mph 0 4 km h JT4020 Mach 1 All Terrain Operator s Manual S
31. lifted off shuttles and then green control cycle light will flash IMPORTANT If you leave the seat during an add or remove pipe cycle turn automated pipeloader system off switch to manual control and then back to add pipe or remove pipe If you leave the seat between add or remove pipe cycles re enabling system is not needed Conduct a Bore 102 Add Pipe JT4020 Mach 1 All Terrain Operator s Manual Add Pipe 1 Press top of drilling unit throttle switch until engine is at full throttle 2 Enable automated pipeloader system automated pipeloader control only See Enable Automated Pipeloader System on page 101 3 Break joint at saver sub Manual Pipeloader Controls Automated Pipeloader Control Clamp pipe joint See Clamp Pipe on page 96 Locate drill head Engage front wrench until pipe is clamped and pressure develops Slowly move carriage back until movement stops Slowly rotate spindle counterclockwise Carriage will move back as threads separate After threads are fully separated stop rotation and move carriage to back of frame Clamp pipe joint See Clamp Pipe on page 96 Locate drill head Engage front wrench until pipe is clamped and pressure develops Slowly move carriage back until movement stops Slowly rotate spindle counterclockwise Carriage will move back as threads separate After threads are fully separated stop rotation and move carriage
32. performed in a specific order Numbered Lists Numbered lists contain illustration callouts or list steps that must be performed in order JT4020 Mach 1 All Terrain Operator s Manual Foreword 5 Foreword This manual is an important part of your equipment It provides safety information and operation instructions to help you use and maintain your Ditch Witch equipment Read this manual before using your equipment Keep it with the 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 Foreword 6 JT4020 Mach 1 All Terrain Operator s Manual JT4020 Mach 1 All Terrain Tier 3 Operator s Manual Issue number 2 0 OM 12 07 Part number 053 1088 Copyright 2006 by The Charles Machine Works Inc lt
33. 016 To turn on press top To turn off move to center To manually dither press and hold bottom and toggle manual inner rotation switch IMPORTANT To restart inner rotation after operator has left seat turn inner rotation off and then on 3 Manual inner rotation To rotate clockwise press IMPORTANT Inner spindle switch switch top must be held down To rotate counterclockwise press bottom To stop rotation release switch 00 015 4 Inner rotation speed To increase inner rotation control speed turn clockwise 77 To decrease inner rotation mm s speed turn counterclockwise cO0icO40h eps 5 Inner spindle Displays inner spindle speed tachometer 00 091 Controls 32 JT4020 Mach 1 All Terrain Operator s Manual Left Control Console Item Description Notes 6 Outer spindle tachometer 00 092 Displays outer spindle speed 7 Outer rotation speed control c00ic041h eps To increase outer rotation maximum speed above 140 rpm turn clockwise To decrease outer rotation maximum speed toward 140 rpm turn counterclockwise IMPORTANT Unless outer rotation speeds greater than 141 rpm are needed keep knob turned fully counterclockwise to maintain full torque 8 Set Resume switch RESUME set c00ic1
34. 241 mm 3 68 45 73 22 5 in 572 mm 20 65 256 52 10 254 4 08 50 67 23 584 21 58 268 05 10 5 267 4 50 55 86 23 5 597 22 53 279 83 11 289 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 12in 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 13 330 6 90 85 63 26 660 27 58 342 53 JT4020 Mach 1 All Terrain Operator s Manual Systems and Equipment 139 Hydratong Wrenches Hydratong Wrenches To attach or remove downhole tools use the Hydratong wrenches to join or break the joint Moving tools will kill or injure Shut off drill string power when anyone can e a d 2 be struck by moving or thrown tools Never use pipe wrenches drill string fz 1 join apply to threads and hand tighten joint 2 Attach Hydratong in either the join or break position 070 029 IMPORTANT Ensure arms crossed before using wrench Attach chain tongs 1 to both sides of joint Place tongs as close to joint as possible Remove snapper pins 2 from slide pins 3 and insert slide pins into wrench handles 4 Attach each end of hydraulic cylinder 5 to slide pins and insert snapper pins 3 Remove all slack from wrench and joint Systems Equipment 140 JT4020 Mach 1 All Terrain Operat
35. Bore Gel Use 5 pt 235 mL of No Sag for large diameter or longer bores fractured rock 50 Ib 23 kg Bore Gel 5 110 225 450 g No Sag Use 5 Ib 225 g of Barolift to reduce fluid loss to formation JT4020 Mach 1 All Terrain Operator s Manual Systems and Equipment 129 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 e 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 cup 25 L soda ash per tank Test and repeat until pH is between 9 and 10 e Check water hardness using hardness test strips Treat with soda ash if hardness exceeds 125 ppm Systems Equipment 130 JT4020 Mach 1 All Terrain Operator s Manual 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
36. Check engine coolant level DEAC Check air filter indicator and clean dust trap Check hydraulic hoses Check hydraulic fluid level THF Check fluid pump oil level SAE 30 NDO Test control switches Check pipe lube applicator Check pipe auto lubricator spray nozzle Check pipe auto lubricator TJC level TJC Check drilling fluid y strainer Drilling Unit Check Fuel Filter Water Separators Check fuel filter water separators every 10 hours Drain water at plug as needed LI 1 SSH j290m006h eps Service 182 JT4020 Mach 1 All Terrain Operator s Manual 10 Hour Check Engine Oil Level bo Check engine oil at dipstick 1 every 10 hours If low fill with DEO at oil fill 2 roll IMPORTANT See Recommended Lubricants E Service Key on page 178 for more information 29 engine oil
37. Item Description Notes 10 Engine preheat indicator c00ic180h eps Lights when air intake pre heater is operating NOTICE If indicator is on wait until it goes out before starting engine IMPORTANT If ignition switch is turned to start position before indicator goes out the system will be disabled and must be reset To reset turn ignition switch to STOP then to run 5 Controls 24 Controls JT4020 Mach 1 All Terrain Operator s Manual Set Up Console j130m002h eps 1 Hi auto fan speed switch 2 Work light switch 3 Right stabilizer control 4 Left stabilizer control 5 Shuttle stop control 6 Back frame tilt control 7 Front frame tilt control 8 Selection Switch Description Notes 1 High auto fan speed switch 8 c00ic378h eps For high speed press top For automatic speed press bottom IMPORTANT If switch is on high speed fan will run at full rom all the time If switch is on auto speed fan will speed will vary JT4020 Mach 1 All Terrain Operator s Manual Set Up Console Controls 25 Item Description Notes 2 Light switch 00 025 To turn on press top To turn off press bottom 3 Right stabilizer control
38. JT4020 Mach 1 All Terrain Operator s Manual 750 752 Display Controls 55 Item Description Notes 6 Display battery status indicator 00 087 Indicates display power from drilling unit If all five bars are not showing check display power connections 7 Beacon battery status indicator 00 088 5 Indicates beacon battery status See beacon instruction sheet 8 Beacon temperature indicator 00 089 5 Indicates beacon temperature See beacon instruction sheet fo Controls 56 Controls 1 Delete button 2 On Off button 3 Channel select button JT4020 Mach 1 All Terrain Operator s Manual 750 752 Display jO70m044h eps 5 4 Roll stop button 5 Recall button 6 Store button IMPORTANT Some items operate differently depending where data is being saved Internal refers to pipe data being saved to 750 Display memory External refers to pipe data being sent to a properly con nected laptop computer running a version of Trac Management System software Item Description Notes 1 Delete button To delete current pipe press Second function To delete all jobs in internal logging memory press with Recall button 00 071 Previous pipe number will appear numeric display when data is deleted JT4020 Mach 1 All Terr
39. axles for wear Replace if needed Check fasteners for wear and tightness Replace or tighten if needed Check battery for 12V charge Inspect lights for cleanliness and correct operation Inspect reflectors and replace if needed Check tire pressure Check lug nut torque with a torque wrench Adjust if needed Ensure trailer brakes are adjusted to come on in synchronization with tow vehicle brakes Check ramps and trailer bed for cracks Hitch Trailer Back tow vehicle to trailer Put manual transmission into first or reverse gear or automatic transmission into park Turn off ignition Set parking brake Connect trailer drawbar lunette or coupler to tow vehicle hitch and lock in place with lock pin If needed adjust drawbar lunette or coupler height to level load Connect safety chains to tow vehicle Connect breakaway switch cable to tow vehicle Do not connect to pintle hook or hitch ball Plug trailer electrical connector into tow vehicle connector Use jack crank to raise jack base and stow Remove wheel blocks JT4020 Mach 1 All Terrain Operator s Manual Transport 87 Haul Load A WARNING 2 Fasten and adjust seat belt Start drilling unit engine Move drilling unit to rear of trailer and align with ramps or center of trailer bed Slow engine to low throttle and slowly drive unit onto trailer Lower stabilizers to trailer floor Lower drill frame to trailer floor Stop engine when
40. 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 e essential code affects rotation thrust drilling fluid or ground drive If the system detects 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 JT4020 Mach 1 Terrain Operator s Manual Machine Diagnostic Codes Review Modes Systems and Equipment 153 IMPORTANT Do not turn off ignition Diagnostic codes are cleared each time ignition is turned off View All Codes View Codes Individually 1 Ensure that engine is running and no one is sitting in operator s seat Press and hold RESUME for two seconds Diagnostic light will flash code 12 flash pause flash flash longer pause to indicate review mode is operational After flashing code 12 all diagnostic codes detected since the last time the ignition was turned on are flashed three times each To save diagnostic codes continue normal operation Do not turn ignition off Once the problem has been corrected clear all codes by turning ignition off T Ensure that e
41. every 500 hours See parts manual or contact your Ditch Witch dealer for correct replacement filters c 00900000 j290m007h eps Service 198 JT4020 Mach 1 All Terrain Operator s Manual 500 Hour Check Batteries Check batteries every 500 hours Keep batteries clean and terminals free of corrosion To clean 1 Turn battery disconnect switch to off position 2 Ensure that no ignition sources are near batteries 5 3 Loosen and remove battery cable clamps carefully negative cable first 4 Clean cable clamps and terminals with wire m brush or battery cleaning tool to remove dull glaze j290m032h eps Check for signs of internal corrosion in cables Apply MPG to terminals after cleaning to reduce corrosion 5 6 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 on position WARNING Explosion possible Serious injury or equipment damage could occur Follow directions carefully NOTICE To avoid explosion do not create sparks and do not short ac
42. 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 within 10 3 m of a buried electric line electric within 10 3 m of a natural gas line natural gas in sand granite or concrete 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 JT4020 Mach 1 All Terrain Operator s Manual Prepare 69 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 diggi
43. 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 Systems Equipment 160 JT4020 Mach 1 All Terrain Operator s Manual Tier 3 Engine Two line Fault Description Possible cause diagnostic code Code 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 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 0 214 temp engine oil temp data valid but above normal operational range most severe level SPN 108 FMI 221 barometric pressure barometric pressure sensor circuit voltage above normal or shorted to high source SPN 108 FMI 4 222 barometric pressure ba
44. 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 115 Tier 3 Operator s Manual Safety 17 Emergency Procedures If a Gas Line is Damaged Fire or explosion possible Fumes could ignite and cause burns No CN smoking no flame no spark AN 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 a
45. of anchor and centering cap 3 inside anchor base 4 4 Guide top of anchor 2 into collar Raise and turn anchor slightly until collar clicks and locks onto anchor shaft IMPORTANT If collar will not lock remove anchor shaft and push plug inside collar to release ball Drive Anchors 1 Raise anchor shaft 2 to top of anchor frame 2 Use anchor rotation and thrust controls to drive anchor into ground 3 Anchor is set when centering cap 3 rests firmly on anchor base 4 4 Repeat process for other anchor NOTICE Failure to disconnect anchor drivers from anchor shafts will lead to anchor driver motor failure Anchor System 07 020 jO7om066h eps JT4020 Mach 1 All Terrain Operator s Manual Systems and Equipment 117 Anchor System Drive Additional Side Anchors 1 Raise collar to disconnect anchor shaft from anchor driver 2 Raise anchor driver to top of anchor frame 3 Remove spring clip from pin shown and remove pin 4 Swing anchor driver to outer position Place pin in second hole and replace spring clip Attach anchor to anchor driver and repeat steps 2 and 3 7 Disconnect anchors from anchor drivers before drilling NOTICE Failure to disconnect anchor drivers from anchor shafts will lead to anchor driver motor failure jO7om022c eps Remove Anchors 1 Use anchor rotation and thrust controls to slowly rem
46. 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 Remove downhole tools See page 111 Remove anchors See page 117 Rinse unit and downhole tools See page 172 Disassemble strike system and disconnect from fluid system See page 172 Stow tools See page 173 Load unit onto trailer See page 87 Storing Equipment 1 2 For cold weather storage antifreeze drilling unit See page 170 For long term storage disconnect battery disconnect switch JT4020 Mach 1 All Terrain Operator s Manual Prepare 63 Chapter Contents Gather 65 Review Job 65 e Notify One Call 65 Examine Pullback 65 Arrange for Traffic 65 e Plan for Emergency Services 65 Inspeet Site sewn 66 Identify Hazards 1 66 e Select Start and Points 67 Classify 68 Inspect Jobsite
47. unit anchoring console will go off and thrust and rotation will function Systems Equipment 134 JT4020 Mach 1 All Terrain Operator s Manual 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 4 recommended Bit Sandy Soft Soil Medium Hard Rocky Soft Hard Soil Soil Soil Soil Rock Rock Sand bit 1 2 4 4 4 4 4 Durabit 2 2 1 1 4 4 4 Tuff bit 2 1 1 1 2 3 4 Steep Taper Tuff bit 4 3 2 1 1 2 4 Barracuda bit 2 1 1 2 3 4 4 Steep Taper bit 4 3 2 1 1 2 4 Hard Surface bit 2 1 2 3 4 4 4 Glacier bit 4 4 4 3 1 2 4 Rhino bit 4 4 3 3 1 1 3 Jetting assembly 4 4 3 2 1 2 3 Rockmaster 4 4 3 2 1 1 1 Talon Rock bit 4 3 2 1 1 1 4 JT4020 Mach 1 All Terrain Operator s Manual Systems and Equipment 135 Downhole Tools Soil Description sandy soil sugar sa
48. unit is safely positioned on trailer bed ODN Attach tiedowns to drilling unit where tiedown decals are located Transport 88 JT4020 Mach 1 All Terrain Operator s Manual Haul Tie Down Points Tiedown points are identified by tiedown decals Securing to trailer at other points is unsafe and can damage machinery ic1320a eps Procedure Loop tiedowns around unit at tiedown points Make sure tiedowns are tight before transporting j290m004h eps 4020 Mach 1 All Terrain Operator s Manual Transport 89 Tow Unload A WARNING 2 Lower trailer or ramps Fasten and adjust seat belt Start drilling unit engine Remove tiedowns Raise stabilizers Raise drill frame NO a FON Slow engine to low throttle and slowly back unit down trailer or ramps Unhitch Trailer 1 Stop tow vehicle and trailer on level ground gi 2 Putmanual transmission into first or reverse gear or automatic transmission into park Turn off ignition Set parking brake Block trailer wheels Reverse Hitch Trailer steps to unhitch trailer from tow vehicle Tow Under normal conditions drilling unit should not be towed If unit breaks down and towing is necessary e tow for short distances at less than 1 mph 1 6 km h attach chains to indicated tow points facing towing vehicle use maximum towing f
49. vehicles wear high visibility clothing post appropriate warning signs CMW Safety 14 Pd ji CMW RT115 Tier 3 Operator s Manual Safety Alerts WARNING 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 CAUTION Hot parts may cause burns Do not touch until cool CAUTION Exposure to high noise levels may cause hearing loss Wear hearing protection CAUTION Fall possible Slips or trips may result in injury Keep area clean CAUTION Battery acid may cause burns Avoid contact CAUTION 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 RT115 Tier 3 Operator s Manual Safety 15 Emergency Procedures Emergency Procedures e AA WARNING Jobsite hazards could cause death or serious injury Use LN correct equipment and work methods Use and maintain proper safety 4 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 Zu Electric shock Contacting electri
50. with pH level between 9 and 10 Use water with hardness of less than 120 ppm Do not use bentonite containing sand e 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 130 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 f chemicals are added in the wrong order they will not mix properly and will form clumps e ftank 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 Sodaash 2 Bentonite 3 Polymer 4 Con Det Bore Gel contains premixed bentonite polymer and soda ash Use approximately 15 Ib 100 gal 7 kg 380 L in normal drilling conditions up to 45 16 100 gal 21 kg 380 in sand or gravel and up to 50 100 gal 23 kg 380 L in rock Systems Equipment 128 Basic Fluid Recipes JT4020 Mach 1 All Terrain Operator s Manual Drilling Fluid Soil type Mixture 100 gal 378 L of water Notes fine sand 35 Ib 16 kg Bore Gel coarse sand 35 Ib 16 kg Bore Gel 5 Ib 225 g No Sag Add 5 Ib 225 g of Quik Trol for additional filtrate control fine sand below water table 40 Ib
51. 020 Mach 1 All Terrain Operator s Manual Troubleshoot Strike System Electric Strike System When strike system detects a problem an error code will be displayed Anytime this happens press self test button to retest If error code is still displayed and does not appear in this chart have control module checked or replaced Other problem situations and their possible causes and solutions are listed in the chart below Problem Possible cause Possible solution No lights or readings showing after drilling unit key has been on at least one minute Problems in startup Push self test button If problem goes away retest strike system No power to strike system control module Check drilling unit electric system Check that harness from drilling unit to control module is connected Check that cable from drilling unit carries more than 10V Defective control module Have control module checked or replaced Screen is blank Strike system is not getting adequate power from drilling unit Check drilling unit electric system Check that harness from drilling unit to control module is connected Check that harness from drilling unit carries more than 10V Defective control module Have control module checked or replaced OK indicator is on but electrical power supply indicator is off Strike system is not getting adequate power from drilling unit Check drilling unit elec
52. 0icO65h eps To start engine insert key and turn clockwise To stop engine turn key counterclockwise IMPORTANT If wrenches are engaged when engine is stopped with ignition switch wrenches will release and then engage when unit is started JT4020 Mach 1 All Terrain Operator s Manual Controls 43 Anchoring System Console Anchoring System Console jO7om041h eps 1 Left rotation control 3 Right rotation control 2 Left thrust control 4 Right thrust control Item Description Notes 1 Left rotation control To drive anchor push To remove anchor pull sA aly 00 066 2 Left thrust control To move anchor down push To move anchor up pull 11 00 067 Controls 44 JT4020 Mach 1 All Terrain Operator s Manual Anchoring System Console Item Description Notes 3 Right rotation control sA ty cO0icO66h eps To drive anchor push To remove anchor pull 4 Right thrust control l TY I1 J 00 067 To move anchor down push To move anchor up pull JT4020 Mach 1 All Terrain Operator s Manual Controls 45 JT AT System JT AT System 1 Mode selector switch 2 Inner rotation hourmeter Item Description Notes 1 Mode selector switch
53. 13h eps To resume operation or increase operation levels press top To set operating conditions or reduce operation levels press bottom See Cruise Control on page 151 JT4020 Mach 1 All Terrain Operator s Manual Left Control Console Operation Controls jO70m032h eps 1 Engine throttle switch 2 Operator s station pivot control switch 3 Horn 4 Fluid flow control 6 Drill Park Drive switch 5 Operator s station pivot lock Controls 33 Item Description Notes 1 Engine throttle switch 00 042 decrease speed press bottom To further increase or decrease speed press additional times 2 Operator s station pivot control switch EY 00 043 To pivot into drilling position lift pivot lock and press left To pivot into driving position press right Controls 34 JT4020 Mach 1 All Terrain Operator s Manual Left Control Console Item Description Notes 3 Horn To sound horn press c00ic044h eps 4 Fluid flow control To increase flow turn clockwise To decrease flow turn counterclockwise gt 00 045 5 Operator s station pivot To unlock lift and hold while lock pivoting operator s station into drilling position Control will lock wh
54. 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 injector metering rail 1 pressure data valid pressure 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 15 2346 system diagnos
55. 551 accelerator pedal low idle accelerator pedal or lever idle validation switch circuit voltage below normal or shorted to low source SPN 157 16 553 injector metering rail 1 fuel pressure sensor error data erratic pressure intermittent or incorrect SPN 157 18 559 injector metering rail 1 injector metering rail 1 pressure low data pressure 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 18 597 alternate potential voltage electrical charging system voltage low data valid but below normal operational range moderately severe level JT4020 Mach 1 Terrain Operator s Manual Systems and Equipment 165 Tier 3 Engine Two line Fault Description Possible cause diagnostic code Code 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 sen
56. 6 0 Aiad 99 Od A9 38 39 150 VINOHVTMO AHHZdd 60 SSV IO 15414 SSANISNG 931715 GALINA JHL NI qaniv al AYWSS393N 3971504 ON wopog 5 eur siu eseeld jueuudinbe uoyAA yoya syuey L JseJejui JO sjonpoud uo se Se jueuudinbe siy uo sejepdn 9AI9991 3141 SN pue Y uo 1no eounos Aue peseuound OU SI YoU sem nof JI V 541115 GALINA JHL NI 6866 ZZ0EZ Anad 99 Od fS410M eu A9 38 TIIM ADVLSOd VWOHVTHO AHHZd 60 SSV IO 18015 TIVIN A1d3H SSANISNGA qaniv al AYWSS393N 3971504 ON 5 siu eseeld jueuudinbe syuey L seJejui JO sjonpoud UO uoneuuojul Se jueuudinbe siy uo sejepdn 5141 Sn
57. Correctly This consists of two steps up and break out joints slowly Do not ram pipes together during makeup or force them apart during breakout Carefully time rotation with carriage travel speed during makeup and use floating carriage to lessen stress on threads during breakout Always connect and disconnect joints slowly and deliberately This will help prevent thread crossing galling and shoulder swelling e Torque joints fully Once the joint is connected and the shoulder faces are touching torque them to full machine torque Improperly torqued joints will damage the shoulder faces and threads and will cause joints to leak or break while drilling or backreaming Do not Overwork the Pipe Never exceed the bend radius for your pipe See Plan Bore Path on page 70 Do not oversteer NOTICE Bending pipe more sharply than recommended will damage pipe and cause failure JT4020 Mach 1 All Terrain Operator s Manual Systems and Equipment 145 Pipe Boxes Pipe Boxes Remove install Pipe Box AN A WARNING 2 Position Lift Pin Block The pipe box has 3 lift pin block holes e Use center hole to keep pipe box level for transporting pipe boxes and loading onto level drill frame e Use side holes to angle box for loading onto angled drill frame Systems Equipment 146 JT4020 Mach 1 All Terrain Operator s Manual Pipe Boxes Remove Pipe Box 1 Insert lift pin block 2 see page 145 and sec
58. JT4020 Mach 1 All Terrain Operator s Manual Issue 2 0 053 1088 JT4020 Mach 1 All Terrain Operator s Manual Overview 1 Overview Chapter Contents Serial Number Location 2 Intended lt 3 Unit Components 3 Operator 4 About This Manual 4 Bulleted 22222 4 Numbered ebur 4 Overview 2 JT4020 Mach 1 All Terrain Operator s Manual Serial Number Location Serial Number Location Record serial numbers and date of purchase in spaces provided Drilling unit serial number is located as shown j290m001h eps Item Date of manufacture Date of purchase Drilling unit serial number Engine serial number Trailer serial number JT4020 Mach 1 All Terrain Operator s Manual Overview 3 Intended Use Intended Use The JT4020 Mach 1 All Terrain is a self contained horizontal directional drilling unit capable of drilling through solid rock cobblestone broken rock gravel and other soil rock mixes as well as less extreme soil conditions It is designed to install buried cable and pipe at distances to 1 000 300 m depending on soil conditions The unit is designed for operation in temperatures typically experience
59. 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 Condition Result Severity 12 normal review mode entry code is not stored n a 13 no 12V power to controller drill and drive are blocked essential 14 no 5V power from controller drill and drive are blocked essential 15 unknown output driver continuity code is stored non problem essential 21 no continuity to front wrench clamp code is stored non solenoid essential 23 no continuity to rear wrench clamp code is stored non solenoid essential 25 no continuity to wrench cw rotate code is stored non solenoid essential 31 no continuity to wrench ccw rotate code is stored non solenoid essential 32 no continuity to shuttle extend add pipe or remove pipe is aborted non solenoid and code is aborted essential 33 no continuity to shuttle retract add pipe or remove pipe is aborted non solenoid and code is aborted essential 34 no continuity to pipe lift solenoid add pipe or remove pipe is aborted non and code is aborted essential 35 no continuity to pipe lower solenoid add pipe or remove pipe is aborted non and code is aborted essential 41 no continuity to pipe grip solenoid add pipe or remove pipe is aborted non and code is aborted essential 42 no continuity to pipe release soleno
60. Manual Prepare 79 Check Supplies and Prepare Equipment Prepare Drilling Unit AT Mode e Verify unit has not been converted to JT mode Ensure All Terrain saver sub shuttle stops pipe gripper pads pipe guide blocks pipe wiper shuttle stop wrench jaw blocks and pipe lifter pads are installed nspect Rockmaster tool and select bit based on jobsite conditions Use drill bit type anchors Load All Terrain pipe and pipe box onto unit e Check position of rear lubricator relative to threads Lubricator should line up with threads when pipe is fully against front of pipe box Adjust if needed Move mode selector switch to AT position AT Dirt Mode Verify unit has not been converted to JT mode Ensure All Terrain saver sub shuttle stops pipe gripper pads pipe guide blocks pipe wiper shuttle stop wrench jaw blocks and pipe lifter pads are installed e Use transition sub p n 401 143 between All Terrain pipe and beacon housing p n 368 822 Select soil bit based on jobsite conditions Use auger type anchors if in soft soil conditions Load All Terrain pipe and pipe box onto unit e Check position of rear lubricator relative to threads Lubricator should line up with threads when pipe is fully against front of pipe box Adjust if needed Move mode selector switch to AT DIRT position 80 JT4020 Mach 1 All Terrain Operator s Manual Check Supplies and Prepare Equipment JT Mode IMP
61. ORTANT Use conversion kit p n 101 136 and refer to installation instructions p n 051 329 Install saver sub pipe gripper pads pipe guide blocks pipe wiper shuttle stop wrench jaw blocks and pipe lifter pads sized to handle Mach 1 pipe e Use standard transition sub and beacon housing Select soil bit based on jobsite conditions Use auger type anchors Load JT pipe and pipe box onto unit IMPORTANT Do not put JT pipe into a large All Terrain pipe box Pipe can jam and box be damaged Use JT pipe box e Check position of rear lubricator relative to threads Lubricator should line up with threads when pipe is fully against front of pipe box Adjust if needed Move mode selector switch to JT position 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 Lighting Kit If you will need additional light plug lighting kit into provided outlet Contact your Ditch Witch dealer for further information JT4020 Mach 1 All Terrain Operator s Manual Drive 81 Drive Chapter Contents Start 82 Steer Unit 82 Shut Down Unit 82 Drive 82 JT4020 Mach 1 All Terrain Operator s Manual S
62. SET To increase outer rotation speed limit move joystick to left and press To decrease outer rotation speed limit move joystick to left and press Systems Equipment 152 JT4020 Mach 1 All Terrain Operator s Manual Machine Diagnostic Codes Override To override settings move joystick out of neutral and beyond current setting Unit will increase to new setting e To return to previous setting release joystick Disengage To disengage cruise control move joystick out of neutral and in opposite direction of carriage travel Green control cycle light will go off Resume 1 Position joystick out of neutral in forward or backward direction 2 Press RESUME Green control cycle light will come on Machine Diagnostic Codes Diagnostic Light Use the red diagnostic light to learn the condition of the diagnostic system Under normal operating conditions the diagnostic light will light steadily for two seconds after ignition is turned on to indicate light is working It will then go out and remain out unless a diagnostic code is recorded 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 to indicate an essential code Code Severity Levels Diagnostic codes are given one of two levels of severity non essential code affects non essential functions of the unit If the system detects a non essential problem a
63. Systems and Equipment 151 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 box Engage Thrust Pullback and Outer Rotation Control Thrust Pullback Control Only 1 Position joystick so that thrust or pullback and outer rotation are at desired speeds 2 Press SET Green control cycle light will come on 3 Release joystick 1 Position joystick to desired thrust or pullback setting 2 Press SET Green control cycle light will come on Release joystick Operator controls rotation with joystick Adjust Settings Seiting Instructions Thrust or Pullback increase thrust or pullback speed while joystick is in neutral position press RESUME decrease thrust or pullback speed while joystick is in neutral position press SET Outer Rotation To increase outer rotation speed move joystick to left and press RESUME To decrease outer rotation speed move joystick to left and press SET Outer Rotation Speed IMPORTANT Outer pipe rotation speed is automatically limited when inner Limit AT Mode rotation is on RESUME
64. TANT A variety of nozzles and bits are available to suit your particular job conditions See Downhole Tools on page 134 for more information or contact your Ditch Witch dealer Insert nozzle into beacon housing JT and AT dirt modes only Attach bit to beacon housing Install beacon following beacon instructions for battery replacement beacon positioning 5 Install beacon housing lid See Beacon Housings on page 135 Follow beacon instructions to check beacon operation 7 Follow tracker instructions to calibrate beacon Conduct a Bore 98 JT4020 Mach 1 All Terrain Operator s Manual Assemble Drill String Attach Transition Sub Use either machine torque or Hydratong wrenches to attach transition sub Machine Torque 1 Pull transition sub into front wrench Close wrench Lube joints Slowly make up joint RON Use full machine torque to tighten joint fully Hydratong 1 Lube joints with TJC 2 Attach Hydratong to the joint in the join position and tighten joint See Hydratong Wrenches on page 139 Attach Beacon Housing 1 Attach downhole tool to transition sub and hand tighten 2 Attach Hydratong to the joint in the join position and tighten joint See Hydratong Wrenches on page 139 JT4020 Mach 1 All Terrain Operator s Manual Conduct a Bore 99 Assemble Drill String Connect Drill Pipe 1 oO m o Start drilling unit engine Align transition sub in front wren
65. Task Notes DOWNHOLE Rebuild 2 tool 2500 760 m TOOLS Downhole Tools Rebuild 2 Tool Rebuild downhole tool every 25 hours or 2500 760 m as measured by inner rotation hourmeter Use rebuild kit p n 191 120 or seal kit p n 191 239 available at your Ditch Witch dealer JT4020 Mach 1 All Terrain Operator s Manual 50 Hour 50 Hour Service 189 Location Task Notes DRILLING Drain water from hydraulic tank Change fluid pump oil initial service SAE 30 NDO Change hydraulic filters initial service Check ground drive gearbox oil level 2 gearboxes MPL Check rotation gearbox oil level MPL Check thrust drive gearbox oil level 4 gearboxes MPL Check radiator for debris Lube vise wrenches MPG Lube saver sub wrench collar and sliding output shaft EPL spray Check hex DOWNHOLE Rebuild 1 5 and grade tools 5 000 1524 m TOOLS Drilling Unit Drain Water from Hydraulic Tank Drain water out of tank every 50 hours To drain turn plug slightly until water comes out After all water has drained tighten plug Q j290m012h eps 190 JT4020 Mach 1 All Terrain Operator s Manual 50 Hour Change Fluid Pump Oil Initial Service Change fluid pump oil after first 50 hours and every 1000 hours thereafter Maintain fluid level at halfway point on sight glass or at petcock level 2 Drain at plug 3 Fill a
66. Terrain Operator s Manual Disconnect Disconnect Disconnect and store the following hoses and cables if used electric cable electric strike system voltage stake fluid hose Stow Tools Complete the Job 173 Make sure all Hydratong wrenches bits pullback devices and other tools are loaded on trailer Complete the Job 174 JT4020 Mach 1 All Terrain Operator s Manual Stow Tools JT4020 Mach 1 All Terrain Operator s Manual Chapter Contents Service Precautions 176 Welding 176 Washing Precaution 176 Working Under Drilling 177 Recommended Lubricants Service Key 178 Engine Oil Temperature 179 Approved Coolant 179 Each USC 180 10 181 20 TREE 188 EDU RT 189 B erem 195 500 S EERRRERLSGSES 196 1000 199 2000 203 oui 204 As 205 Service 175 Service Service 176 JT4020 Mach 1 All Terrain Operator s Manual Service Precautions Service Precautio
67. acement procedure jO7om031c eps Replace Worn Saver Sub Precondition a new saver sub the same way you do new pipe See Precondition New Pipe on page 141 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 to the back of the string and move every other pipe forward one position JT4020 Mach 1 All Terrain Operator s Manual Drill Pipe Use Drill Pipe Correctly Align the Joints Always carefully align the male and female ends of pipe before screwing them together Poor alignment can damage the threads and destroy the usefulness of the joint Clamp Pipe Correctly Clamp on pipe when joint is between wrenches but as near front wrench as possible 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 96 for more information Systems and Equipment 143 107 034 LJ roe 107 032 Systems Equipment 144 JT4020 Mach 1 All Terrain Operator s Manual Drill Pipe Make Up and Break Out Joints
68. ack devices or product to end of backreamer beacon housing assembly JT4020 Mach 1 All Terrain Operator s Manual Conduct a Bore 109 Remove Pipe Remove Pipe 1 Enable automated pipeloader system automated pipeloader control only See Enable Automated Pipeloader System on page 101 2 Stop carriage when alignment pin becomes visible behind rear wrench Clamp pipes See Clamp Pipe on page 96 4 Break front joint e Turn rear wrench counterclockwise to break joint Disengage rear wrench and rotate wrench clockwise 5 Grip pipe Manual Pipeloader Controls Automated Pipeloader Conirol Open grippers Lift pipe off shuttles e Extend shuttles to spindle position Close grippers Leave grippers loose enough to allow pipe to rotate Lower lifters Press RESUME Green control cycle light will come on e Shuttles will extend grippers will grip fully and relax open pipe lifters will lower and then green control cycle light will flash 6 Separate front joint Slowly rotate spindle counterclockwise and move carriage back to separate pipe Continue to move carriage back until pipe is properly positioned in rear wrench Conduct a Bore 110 7 Break rear joint JT4020 Mach 1 All Terrain Operator s Manual Remove Pipe Manual Pipeloader Controls Automated Pipeloader Control Engage rear wrench Slowly rotate spindle counterclockwise
69. acker control key 2 Dual speed carriage Two speed ground drive 6 Engine shutdown override control control T 7 Ignition switch Drilling fluid quick fill switch Track and carriage control Item Description Notes 1 Drilling fluid pump To turn on press once switch To turn off press once gt 00 060 JT4020 Mach 1 All Terrain Operator s Manual Right Control Console Controls 41 Item Description Notes 2 Dual speed carriage Two speed ground drive control H 00 058 Carriage travel speed To increase push and hold To return to normal carriage speed release Ground drive speed For high ground drive speed push once To return to low ground drive speed push once Use during bore or pullback when no pipe is in spindle to save time IMPORTANT Drill Park Drive switch must be in drill position Use when driving straight IMPORTANT Drill Park Drive switch must be in drive position Unit will be in low speed each time unit is started 3 Drilling fluid quick fill switch 00 059 5 For full pump flow to fill pipe with fluid press and hold To return fluid flow to flow control setting release 4 Track and carriage control F BSN NM E E c00ic061h eps Track control To move forward push To move ba
70. ain Operator s Manual 750 752 Display Controls 57 Item Description Notes 2 On Off button ON OFF c00ic112h eps To turn on press To turn off press again 3 Channel select button CH SEL c00icO73h eps To display current channel press and release To switch channels press and hold Second function To start a new job press with Recall button Init and job number will be displayed Unit defaults to channel one each time unit is turned on IMPORTANT Make sure display and tracker are set to the same channel 4 Roll stop button c00ic074h eps This feature is not yet available 5 Recall button 00 075 see data about pipe press and release Second function To access second functions press with other buttons Internal shows data about previous pipe External shows data about next pipe Controls 58 JT4020 Mach 1 All Terrain Operator s Manual 750 752 Display Item Description Notes 6 Store button 00 076 To display serial number press and hold while pressing on off button To store current pipe data press Second function To download all jobs stored in internal logging memory e Press with Recall button Connect display to PC running Trac Management System software Pipe number will appea
71. ame Step away from drilling unit Remove Single Pipe Unload all drill pipe loaded with auxiliary pipe loaders Pipe in fourth row of pipe box can be unloaded only when all other rows are empty 1 Ensure shuttle stop is fully lowered Move shuttles out fully Pull and hold pins 1 on each shuttle and slide out auxiliary pipe loaders 2 j070m037c eps Systems Equipment 150 Remove pipe stop stored on outside of drill frame and attach to front of pipe box Raise pipe in row 4 Move pipe to auxiliary pipe loaders Move shuttles in Lower pipe into auxiliary pipe loaders Move shuttles out JT4020 Mach 1 All Terrain Operator s Manual Pipe Boxes 107 038 Crushing weight If load falls or moves it could kill or crush you Use proper procedures and equipment or stay away NOTICE Drill pipe is heavy Have enough people on hand to manually add or remove single pipe to pipe box Remove pipe from auxiliary pipe loaders and store properly Repeat steps 5 8 to unload remaining added drill pipe e Close both auxiliary pipe loaders Remove pipe stop and store it on drill frame e Step away from pipeloader After all added drill pipe is unloaded with auxiliary pipe loaders e Finish loading remaining drill pipe into row 4 using standard procedure See Remove Pipe on page 109 JT4020 Mach 1 All Terrain Operator s Manual
72. and move carriage back until joint is loosened Do not fully separate joint Disengage rear wrench Move carriage back until front end of pipe is aligned with front end of pipe box or alignment pin is even with tab on frame Engage rear wrench Slowly rotate spindle counterclockwise and move carriage back until joint is loosened Do not fully separate joint Disengage rear wrench Move carriage back until front end of pipe is aligned with front end of pipe box or alignment pin is even with tab on frame Close grippers Press RESUME Green control cycle light will on e Rotate spindle counterclockwise and move carriage back until saver sub is separated from pipe Grippers will close and then green control cycle light will flash Move carriage to back of frame e Rotate spindle counterclockwise and move carriage back until saver sub is separated from pipe Move carriage to back of frame 8 Ensure shuttle stop is positioned correctly See Check Shuttle Stop Position on page 111 9 Load pipe into pipe box Manual Pipeloader Controls Automated Pipeloader Control Move shuttle under pipe box to shuttle e Press RESUME Green control cycle light stop will come on Release grippers and raise lift arms to e Shuttles will retract under edge of pipe box place pipe in box and then green control cycle light will flash Move carriage forward until it clea
73. ange Engine Coolant Drain cooling system at drain every two years or 2000 hours Drain cooling system at drain 3 and refill at radiator cap 2 with approved coolant Capacity is 7 7 gal 29 L Check level at sight glass 1 j290m036h eps 204 JT4020 Mach 1 All Terrain Operator s Manual 5000 Hour 5000 Hour DRILLING Change engine coolant UNIT Drilling Unit Change Engine Coolant Drain cooling system at drain every two years or 2000 hours Drain cooling system at drain 3 oe refill at radiator 2 with approved coolant Capacity is 7 7 gal 29 L Check level at sight glass 1 3 j290m036h eps JT4020 Mach 1 All Terrain Operator s Manual As Needed As Needed Service 205 Location Task Notes DRILLING Change air filter UNIT Change auto lubricator TJC pail TJC Change hydraulic filters any time system is opened Check pipeloader inserts Check and adjust carriage rollers Check anchor driver glide strips Check front pipe glide blocks Check pipe lubricator insert Check fluid pump ball valve Check track tension and condition Check track support slide pads Check saver sub Replace fuses Change inner water swivel seal kit Drilling Unit Change Air Filter Change air filter when red band on air filter service in
74. anual 500 Hour 500 Hour Location Task Notes DRILLING Change hydraulic fluid and filters extreme temperatures UNIT Change engine oil and filter DEO Change fuel filters Check batteries Drilling Unit Change Hydraulic Fluid and Filters Extreme Temperatures aN A 5 lo Change hydraulic fluid and three filters every 500 hours if jobsite temperature exceeds 100 F 38 C more than 50 of the time Drain hydraulic fluid change filters 1 2 and refill with THF at hydraulic fluid fill Tank capacity is 36 gal 136 L IMPORTANT If hydraulic system must be opened for repair install new filter p n 157 486 for first 50 hours of operation If this filter becomes plugged in fewer than 20 hours replace with clean filter After 50 hours of normal operation replace with clean filter j290m021h eps JT4020 Mach 1 All Terrain Operator s Manual Service 197 500 Hour Change Engine Oil and Filter Change engine oil and filter 3 every 500 hours Drain oil 4 change filter 3 and refill with 24 qt 21 L of DEO at fill 2 Capacity is 20 1 qt 19 L Check oil at dipstick 1 IMPORTANT Except as noted above use oil specified in temperature chart found in Recommended Lubricants Service Key on page 178 j290m031h eps Change Fuel Filters Replace fuel filters
75. ator s Manual Pipe Boxes Add Single Pipe o O 1 Place grid mats on the ground on pipe box side of drilling unit Connect mats 3 Connect bonding cable to drilling unit shown in inset Na 4 Position entire drill pipe box on mat shown 5 Ensure shuttle stop is fully lowered Jprom seceps 6 Move shuttles out fully 7 Pulland hold pins 1 on each shuttle and slide out auxiliary pipe loaders 2 107 037 8 Remove pipe stop stored on outside of drill frame and attach to front of pipe box jO7om038c eps JT4020 Mach 1 All Terrain Operator s Manual Systems and Equipment 149 Pipe Boxes Crushing weight If load falls or moves it could kill or crush you Use 2 proper procedures and equipment or stay away ar NOTICE Drill pipe is heavy Have enough people on hand to manually add or remove single pipe to pipe box 9 Load a pipe in auxiliary pipe loaders and rest it against pipe stop 10 Move auxiliary pipe loaders under row 4 11 Raise pipe into row 4 12 Move shuttles all the way out 13 Repeat steps 9 12 to load more pieces of pipe into row 4 14 Move pipe to pipeloader grippers Raise last pipe into row 4 Move shuttles out Lower pipe into front grippers 15 Before operating pipeloader e Close both auxiliary pipe loaders Remove pipe stop and store it on drill fr
76. ator s Manual Conduct a Bore 107 Assemble Backream String Assemble Backream String Conduct Bore 108 JT4020 Mach 1 All Terrain Operator s Manual Assemble Backream String j07om074h eps JT mode AT dirt mode AT mode 1 backreamer 2 transition sub 3 4020 Mach 1 drill pipe 1 backreamer 2 transition sub p n 400 685 3 4020 All Terrain drill pipe 1 backreamer 2 transition sub p n 400 685 3 4020 All Terrain drill pipe IMPORTANT If no part number is listed contact your Ditch Witch dealer about available options 1 Select backreaming devices See Backreamers on page 136 2 Determine fluid rate requirements and install appropriate nozzles to provide sufficient flow See Backream Fluid Requirements on page 137 and Nozzles on page 134 Attach backreamer to beacon housing if tracking backream Install beacon following beacon instructions for battery replacement e beacon positioning 139 Install beacon housing lid See Beacon Housings page 135 Follow beacon instructions to check beacon operation Follow tracker instructions to calibrate beacon Use Hydratong wrenches to attach transition sub to drill pipe string See Hydratong Wrenches on 9 Use Hydratong wrenches to attach backreamer beacon housing assembly to transition sub See Hydratong Wrenches on page 139 10 Attach additional pullb
77. c filters anytime system is opened for repair Change filters 1 2 Check fluid level and add THF at hydraulic oil fill if necessary IMPORTANT f ambient temperature exceeds 100 F 37 C for 50 of time change oil and filter every 500 hours f hydraulic system must be opened for repair install new filter p n 157 486 for j29om02h eps first 50 hours of operation If this filter becomes plugged in fewer than 20 hours replace with clean filter After 50 hours of normal operation replace with clean filter For major repairs with likely system contamination change hydraulic fluid also 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 Shuttle wear pads 2 Pipe gripper inserts 3 Slide pads IMPORTANT Ensure bolts are tightened evenly to enable inserts to slide freely and IESomOSTh eps wear evenly Service 208 JT4020 Mach 1 All Terrain Operator s Manual As Needed Check and Adjust Carriage Rollers Check and adjust carriage rollers replace as needed j290m046h eps Check Anchor Driver Glide Strips Check anchor driver glide strips for wear Tighten or replace as needed See your Ditch Witch dealer for replacement parts
78. c 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 e explosion popping noises e arcing electricity If any of these occur or if strike alarm sounds or flashes assume an electric strike has occurred CMW Safety 16 RT115 Tier 3 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 f alarm sounds again stay where you are and wait for electric company to shut off power f alarm does not sound and there is
79. 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 JT4020 Mach 1 All Terrain Operator s Manual Systems and Equipment 119 Electric Strike System Assemble Voltage Detector 1 2 Clip voltage limiter to voltage stake Drive voltage stake into ground at least 6 2 away from any part of system 070 021 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 ESID control module will perform internal tests which check everything but alarms and strobe If green OK indicator and electrical power supply indicator lights remain on press self test button to perform total test of strike system During this test All lights should glow Alphanumeric readout should display numbers Alarms and strobes on all connected units should sound If this test is successful OK indicator and electrical power supply indicator lights will remain on Use Electric Strike Simulator to test voltage and current sensors See page 123 Systems Equipment 120 JT4
80. ch Clamp tool in front wrench See Clamp Pipe on page 96 Load pipe sure shuttle stop is positioned correctly See Check Shuttle Stop Position on page 111 e Lubricate threads in front wrench applicator at back of pipeloader Grip pipe Move pipe to spindle Connect pipe Move carriage forward until saver sub nears male pipe thread e Continue to move carriage forward and rotate spindle until pipe screws into saver sub Relax grippers Move carriage forward until front end of pipe is aligned with transition sub male thread Use machine power to slowly rotate spindle and drill pipe onto transition sub male thread Raise pipe that is in pipe box Open grippers Move shuttle back against shuttle stop Lower pipe completely into shuttle Slowly tighten to full machine torque Disengage front wrench and move carriage back to top of frame Stop drilling unit engine Reinstall blocks on guides Conduct a Bore 100 JT4020 Mach 1 All Terrain Operator s Manual Drill First Pipe Drill First Pipe DANGER cu INS JT Mode AT Dirt 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 75 4 Slowly move carriage forward Drill in 13 4 m before steering 5 Monitor gauges AT Mode 1 on drilling fluid 2 Visually check for drilling fluid flow 3 Ch
81. ckward pull To steer move light or left while moving Carriage control To move carriage forward push To move carriage backward pull To rotate spindle counterclockwise breakout move right To rotate spindle clockwise makeup move left IMPORTANT Drill Park Drive switch must be in drive position See Steer Unit on page 82 for more information IMPORTANT Drill Park Drive switch must be in drill position See Prime Drilling Fluid Pump on page 94 for more information Controls 42 JT4020 Mach 1 All Terrain Operator s Manual Right Control Console Item Description Notes 5 Tracker control key N oX c00icO63h eps To allow tracker operator to stop thrust and rotation move key to enable position up To override tracker control mode move key to disable position right IMPORTANT Remove key and keep in tracker operator s possession See Tracker Control on page 131 1 Engine shutdown override control c00ic178h eps Press to delay engine shutdown for 30 seconds after cycling ignition switch to STOP This control allows a temporary override of engine shutdown NOTICE After 30 seconds engine will again shut down unless fault condition has been cleared on diagnostic gauge IMPORTANT See Tier 3 Engine on page 157 for more information on Tier 2 operation 2 Ignition switch cO
82. d 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 unit can be used with Ditch Witch drilling fluid units and Ditch Witch locating equipment It should be operated serviced and repaired only by persons familiar with its particular characteristics and acquainted with the relevant safety procedures Unit Components j290m002h eps 1 Carriage 6 Drill frame 2 Spindle 7 Operator s station 3 Pipeloader 8 Tracks 4 Vise wrenches 9 Stabilizer 5 Anchoring system Overview 4 JT4020 Mach 1 All Terrain Operator s Manual Operator Orientation Operator Orientation 1 1 Front of unit AA 2 Right side of unit T 3 Rear of unit iam 4 Leftside of unit qn 4 2 E 3 jO7om054c eps 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
83. dicator 1 pops up To change 1 Loosen clamp ring and remove end cup 4 Remove elements 2 3 Wipe inside of housing and wash end cup Install new elements Install end cup and tighten clamp ring Reset air filter service indicator j290m010h eps Service 206 JT4020 Mach 1 All Terrain Operator s Manual As Needed Change Auto Lubricator TJC Pail Check pipe auto lubricator TUC 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 j290m018h eps 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 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 178 for more information JT4020 Mach 1 All Terrain Operator s Manual Service 207 As Needed Change Hydraulic Filters Anytime System Opened aN Change three hydrauli
84. drilling unit outer right console Keep in tracker operator s possession 6 Drill and track bore JT4020 Mach 1 All Terrain Operator s Manual Tracker Control 070 024 107 025 JT4020 Mach 1 All Terrain Operator s Manual Systems and Equipment 133 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 107 026 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 42 for more information NOTICE If you are not using tracker control turn off drilling unit before changing downhole tools Change downhole tools If you are tracking backreamer s path turn on tracker and enable code transmission After 8 16 seconds green tracker control light on drilling unit 07 025 anchoring console will go off and thrust and rotation will function If you are not tracking backreamer s path install tracker control key shown on drilling unit Green tracker control light on drilling
85. e 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 1 and spring 2 off of drive shaft Check condition of drive pin 3 and replace if needed 4 Check o ring on inner water swivel seal kit and replace if needed j290m029h eps 5 Install new spring and hex Install saver sub See page 211 Downhole Tools Rebuild 1 5 and Grade Tools Rebuild downhole tool every 50 hours or 5 000 1524 m as measured by inner rotation hourmeter Use rebuild kit p n 191 120 or seal kit p n 191 239 available at your Ditch Witch dealer j290m030h eps JT4020 Mach 1 All Terrain Operator s Manual 250 Hour 250 Hour Service 195 Location Task Notes DRILLING Change hydraulic filters UNIT Drilling Unit Change Hydraulic Filters Change three hydraulic filters 1 2 every 250 hours Change filters more often if indicated by filter indicator IMPORTANT If hydraulic system must be opened for repair install new filter p n 157 486 for first 50 hours of operation If this filter becomes plugged in fewer than 20 hours replace with clean filter After 50 hours of normal operation replace with clean filter j290m021h eps Service 196 JT4020 Mach 1 All Terrain Operator s M
86. educe entry pitch This also increases setback To increase minimum depth D2 increase entry pitch This also reduces 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 107 010 5 Minimum depth Entry pitch A Setback B Depth to begin steering S 8 ft 5 in 2 6 20 71 ft 7 in 21 8 m 2 ft 7 in 0 8 m 9 ft 10 in 3 0 m 22 77 ft 2 in 23 5 2 ft 10 in 0 9 m 11 ft 4 in 3 5 m 24 82 ft 8 in 25 2 m 3 ft 0 in 0 9 m 12 ft 11 in 3 9 m 26 88 ft 1 in 26 9 3 ft 3 in 1 0 m 14 ft 7 in 4 5 m 28 93 ft 5 in 28 5 3 ft 6 in 1 1 m 16 ft 5 in 5 0 m 3096 98 ft 8 in 30 1 m 3 ft 9 in 1 1 m 18 ft 3 in 5 6 m 32 103 ft 10 in 31 7 4 ft O in 1 2 IMPORTANT Numbers in table based on 300 91 4 m minimum bend radius Rockmaster housing 6 25 in bit and half of first drill pipe L totaling 13 4 m in the ground before steering 4020 Mach 1 All Terrain Operator s Manual Prepare 75 Prepare Jobsite Prepare Jobsite d rmm 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 i
87. elease 5 Pipe lubricator switch c00ic034h eps To fill applicator at back of pipeloader press left To apply joint compound to threads at wrenches press right JT4020 Mach 1 All Terrain Operator s Manual Controls 29 Left Control Console Item Description Notes 6 Front wrench clamp To unclamp press top switch lt gt To clamp press bottom k J gt lt RH 00 033 7 Pipe gripper switch To close press top To open press bottom 00 035 8 Pipe shuttle switch To move toward pipe box press top To move toward spindle press bottom 00 036 Controls 30 JT4020 Mach 1 All Terrain Operator s Manual Left Control Console Drilling Controls j070m031h eps 1 Spindle brake switch 5 Inner spindle tachometer 2 Inner spindle switch 6 Outer spindle tachometer 3 Manual inner rotation switch 7 Outer rotation speed control 4 Inner rotation speed control 8 Set resume switch Item Description Notes 1 Spindle brake switch To engage press top IMPORTANT Use when making directional change To disengage press bottom 00 037 JT4020 Mach 1 All Terrain Operator s Manual Controls 31 Left Control Console Item Description Notes 2 Inner spindle switch e 00
88. en operator s station reaches driving position 6 Drill Park Drive switch To drill press left Drill icon IMPORTANT Lighted icon on switch will light indicates unit is ready to perform that function To set parking brake move to center Parking brake icon will light SY CA To drive press right Drive icon will light c00ic046h eps JT4020 Mach 1 All Terrain Operator s Manual Controls 35 Right Control Console Right Control Console Gauges and Indicators jO7om034h eps 1 Drilling fluid flowmeter 3 Drilling fluid pressure gauge 2 Thrust pressure gauge 4 Rotation pressure gauge Item Description Notes 1 Drilling fluid flowmeter Displays approximate rate of IMPORTANT Monitor the flowmeter drilling fluid flow and records and drilling fluid pressure gauge amount of drilling fluid used carefully to see if values are rising or falling at the same time If they are not nozzle might be plugged c00ic050h eps 2 Thrust pressure gauge Displays hydraulic fluid pressure to thrust motor during thrust and pullback c00ic047h eps Controls 36 JT4020 Mach 1 All Terrain Operator s Manual Right Control Console Item Description Notes 3 Drilling fluid pressure gauge c00ic048h eps Displays drilling fluid pressure in the drilling fluid hard line IMPORTANT Monitor this gauge and drill
89. eplace as needed See your Ditch Witch dealer for replacement parts SE NL cu oup OOP umm j290m042h eps Check Saver Sub Check saver sub and replace as needed See your Ditch Witch dealer for replacement parts To replace 1 Remove eight bolts shown that attach saver sub to spindle Do not remove indexing dowels from spindle Remove and replace o ring if necessary Install in reverse order and torque eight bolts a cross pattern to 225 10 305 Nem eS Apply Loctite 242 to bolts before installation j290m043h eps Service 212 JT4020 Mach 1 All Terrain Operator s Manual As Needed Replace Fuses Pe Change fuses as needed One group of fuses is located behind a bolt on panel between the ROPS Refer to decal inside panel to identify fuses The other group of fuses is located inside a door on the side of the left control console Refer to decal inside door to identify fuses LL S j290m044h eps JT4020 Mach 1 All Terrain Operator s Manual Service 213 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 Remove snap ring 5 4 Remove seal 4 and mai
90. erify that stake is fully in the ground or properly grounded to machine frame JT4020 Mach 1 All Terrain Operator s Manual Systems and Equipment 123 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 Move simulator switch to current and press test button 4 Watch screen and lights above display on strike system Three or four lights should turn on e Current A should show 30 50 in display To test for current at strike levels 1 Puttwo or three loops through current transformer 2 Follow steps above to test Display should show the following All lights should turn on Alarm and strobe should turn on With two loops Current A should be 80 110 Strike indication might go on and off With three loops Current should be 130 160 Strike indication should be continuous NY e Systems and Equipment 124 JT4020 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 Clip one lead
91. escription of the procedure In addition draw a simple sketch of the site and record depth and rough location of pullback The Trac Management System Plus is also available for plotting and tracking your bore path It utilizes the 750 Tracker 750 Display a tracking beacon and special software The display can store jobs in its memory or the system can be run in the field using a laptop computer equipped with the Windows 95 or higher operating system See your Ditch Witch dealer for details Surface Drill Head e DANGER Moving tools will kill or injure Shut off drill string power when anyone can e 2 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 71 m Clean area around exit point If using tracker control mode tracker operator turns off tracker to disable drilling unit thrust pullback and rotation hydraulics Tracker operator waits for green light to enter pit and change tools If not using tracker control mode tracker operator signals to drilling unit operator to stop engine before changing downhole tools 4 Turn fluid flow control to off position as soon as drill head emerges 5 Clean drill head especially around threads 6 Use Hydratong to remove drill head Keep threads clean See Hydratong Wrenches on page 139 JT4020 Mach 1 Terrain Oper
92. f pipe before checking pitch JT4020 Mach 1 All Terrain Operator s Manual Correct Direction Procedure Conduct a Bore 105 1 Locate drill head Take readings available with your beacon and locating equipment such as depth e pitch left right information e temperature beacon roll 2 Compare position to bore plan Determine direction drilling should go 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 ue 107 048 JT mode AT mode 1 Rotate pipe to clock position you intend to travel 2 Push pipe into ground AT mode 1 Rotate outer pipe to clock position you intend to travel 2 Engage spindle brake 3 Engage inner rotation and push pipe into ground To move forward without changing direction JT mode AT dirt mode AT mode 1 Rotate pipe 2 Push pipe into ground 1 Rotate outer pipe 2 Engage inner rotation and push pipe into ground Conduct a Bore 106 JT4020 Mach 1 All Terrain Operator s Manual Record Bore Path 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 d
93. f 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 H2 Subtract ground pitch from drilling unit pitch 2 With Measurements Measure from the ground to front end of drill frame H1 C 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 jO7om006c eps Divide H2 H1 by C then multiply by 100 This is your pitch H2 C X 100 IMPORTANT A shallow entry pitch A1 allows you A2s to reach horizontal sooner and with less bending A Ts Increasing entry pitch A2 makes bore path longer and deeper jO7om007c eps Minimum Setback B1 Setback is the distance from the entry point to where pipe becomes horizontal 1 NOTICE setback is too small 82 you will B2 exceed bend limits and damage the pipe jO7om008c eps 74 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 JT4020 Mach 1 All Terrain Operator s Manual Plan Bore Path SS D1 D2 jO7om009c eps To reduce minimum depth D1 r
94. ft min 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 Systems Equipment 138 JT4020 Mach 1 All Terrain Operator s Manual Downhole Tools Backream Fluid Requirements Backreamer product Gal ft L m Backreamer product Gal ft L m diameter diameter in 13 mm 0 01 0 13 13 5 in 343 mm 7 44 92 35 1in 25 mm 0 04 0 51 14 in 356 mm 8 00 99 31 1 5 38 0 09 1 14 14 5 368 8 58 106 54 2 51 mm 0 16 2 03 15in 381 mm 9 18 114 01 2 5 in 64 mm 0 25 3 17 15 5 in 394 mm 9 80 121 74 3in 76 mm 0 37 4 56 16 406 10 44 129 72 3 5 in 89 0 5 6 21 16 5 419 11 11 137 95 4 in 102 mm 0 65 8 11 17in 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 19 483 14 73 182 92 6 5 165 1 72 21 41 19 5 495 15 51 192 68 178 mm 2 00 24 83 20 508 16 32 202 68 7 190 mm 2 29 28 50 20 521 17 15 212 94 8in 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
95. functions that occur when control is put at a combined position Operator must be in seat for control to function Conduct a Bore 95 A A c00ic061h eps Carriage Movement Rotation Direction forward clockwise makeup reverse counterclockwise breakout 1104 Conduct a Bore 96 JT4020 Mach 1 All Terrain Operator s Manual Clamp Pipe Clamp Pipe Turning shaft can kill you or crush arm or leg Stay away 9 aly NOTICE Clamping anywhere else on the pipe will weaken the pipe Pipe can later break even when operating under normal loads Clamp on pipe when joint is centered between wrenches 1 and 2 Always clamp on the larger 1 2 diameter areas on either side of the tool joint face rer c 17 107 043 JT4020 Mach 1 All Terrain Operator s Manual Conduct a Bore 97 Assemble Drill String Assemble Drill String 107 046 JT mode AT dirt mode AT mode 1 beacon housing 1 beacon housing 1 Rockmaster tool 2 bit 2 bit 3 transition sub ey Nd 3 JT4020 All Terrain drill pipe 4 14020 Mach 1 drill pipe 3 transition sub p n 401 143 4 4020 All Terrain drill pipe IMPORTANT If no part number is listed contact your Ditch Witch dealer about available options Prepare Beacon Housing 1 Select nozzles JT and AT dirt modes only and bit IMPOR
96. g 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 188 07 057 Start System 1 Start drilling unit and remote fluid unit Allow both engines to warm up IMPORTANT Ensure that mixture of drilling fluid matches drilling conditions 2 Enable tracker control mode if desired See Tracker Control on page 131 3 Press top of drilling unit throttle switch until engine is at full throttle 4 Press and hold quick fill fluid pump switch until pipe fills and fluid pressure begins to rise Conduct Bore 94 JT4020 Mach 1 All Terrain Operator s Manual Prime Drilling Fluid Pump Prime Drilling Fluid Pump EXE A WARNING Z9 Prime drilling fluid pump each time the 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 JT4020 Mach 1 All Terrain Operator s Manual Operate Carriage Control Operate Carriage Control The thrust rotation control has eight positions which allow the four basic functions to be combined The chart below summarizes
97. ge circuit voltage below normal or shorted to low source Systems Equipment 164 JT4020 Mach 1 All Terrain Operator s Manual Tier 3 Engine Two line Fault Description Possible cause diagnostic code Code SPN 157 FMI 0 449 injector metering rail 1 fuel pressure high data valid but above pressure normal operational range moderately severe level SPN 157 FMI 3 451 injector metering rail 1 injector metering rail 1 pressure sensor pressure circuit voltage above normal or shorted to high source SPN 157 FMI 4 452 injector metering rail 1 injector metering rail 1 pressure sensor pressure 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 527 circuit voltage auxiliary input output 2 circuit voltage above normal or shorted to high source SPN 93 FMI 528 switch data auxiliary alternate torque validation switch data erratic intermittent or incorrect SPN 703 FMI 529 circuit voltage auxiliary input output 3 circuit voltage above normal or shorted to high source SPN 558 FMI 4
98. h plug 1 to level of sight plug 2 with IMPORTANT Drill frame must be level for accurate reading E 5 BB j290m026h eps Service 192 JT4020 Mach 1 All Terrain Operator s Manual Check Thrust Drive Gearbox Oil Level Check oil level in four thrust drive gearboxes every 50 hours Fill to level of fill plug 1 with MPL as needed IMPORTANT Drill frame must be level for accurate reading Check Radiator For Debris Check radiator for dirt grass and other foreign matter every 50 hours Clean out with compressed air or spray wash if required Be careful not to damage fins with high pressure air or water Check more often if operating in dusty or grassy conditions NOTICE Be careful not to damage fins with high pressure air or water 50 Hour j290m049h eps j290m024h eps JT4020 Mach 1 All Terrain Operator s Manual Service 193 50 Hour Lube Vise Wrenches Lube ten zerks with MPG every 50 hours j290m025h eps Lube Saver Sub Wrench Collar and Sliding Output Shaft Lube with EPL spray every 50 hours j290m028h eps Service 194 JT4020 Mach 1 All Terrain Operator s Manual 50 Hour Check Hex Shine flashlight into spindl
99. heck connections and wiring harness Defective control module Have control module checked or replaced EC2 code displays and current problem indicator is on Improper connections with control module Check cable connections on control module and current transformer Defective current transformer 1 Disconnect current transformer 2 Check for 20 40 ohms from pin 1 to pin 4 20 40 ohms from pin 1 to pin 2 and less than 1 ohm from pin 2 to 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 Defective control module Have control module checked or replaced EV2 code displays and voltage problem indicator is on Improper connections with control module Check cable connection on control module Defective voltage limiter Have voltage limiter checked or replaced Defective control module Have control module checked or replaced Systems Equipment 122 ESID Diagnostic Codes JT4020 Mach 1 All Terrain Operator s Manual Electric Strike System Code Definition Action DC 10 strobe output error e verify that strobe light is properly connected to machine harness check for broken or shorted wires in the harness e perform a self test of the ESID module during self test check for 12V at p
100. iage forward until saver sub meets pipe Continue to slowly advance carriage and rotate spindle until pipe threads tighten Press RESUME Green control cycle light will come on Grippers will relax and then green control cycle light will flash 6 Connect new pipe 10 Monitor gauges 12 Manual Pipeloader Controls Automated Pipeloader Control e Slowly move carriage forward and rotate spindle until pipe threads tighten e fully torque joint slowly rotate pipe until spindle stops turning e Open wrench Open grippers fully Retract shuttles against shuttle stop Lower pipe lifters Slowly move carriage forward and rotate spindle until pipe threads tighten To fully torque joint slowly rotate pipe until spindle stops turning Open wrench Press RESUME Green control cycle light will come on Grippers will open shuttles will retract pipe lifters will lower and then green control cycle light will flash Press and hold quick fill fluid pump switch until pipe fills and fluid pressure begins to rise Rotate spindle Slowly move carriage forward Adjust rotation speed control according to bit size and soil conditions Engage and set cruise control as desired See Cruise Control on page 151 Locate drill head with tracker at least every half length of pipe Conduct Bore 104 JT4020 Mach 1 All Terrain Operator s Manual Correct Direction Correct Direction Cor
101. ial 222 inner rotation position sensor not dither compensation is blocked non changing essential 223 no continuity to engine fan command hydraulic fan goes to high speed non signal essential 233 drill and drive inputs both on drill and drive are blocked essential 234 add pipe and remove pipe inputs both add pipe and remove pipe are non on blocked essential 235 front home and rear home inputs both add pipe and remove pipe are non on blocked essential 241 shuttles not responding correctly add pipe or remove pipe is aborted non and code is stored essential 242 front wrench not responding correctly add pipe or remove pipe is aborted non and code is stored essential 254 error reading setup table information add pipe and remove pipe are essential blocked 255 undefinable diagnostic code reported code is stored non essential JT4020 Mach 1 All Terrain Operator s Manual Systems and Equipment 157 Tier 3 Engine Tier 3 Engine Overview Tier 3 is 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 cluster tell the operator when critical and non critical faults develop Non critical faults occur when engine sensors detect moderate trouble with coolan
102. id add pipe or remove pipe is aborted non and code is aborted essential 43 no continuity to lube rear solenoid add pipe or remove pipe is aborted non and code is aborted essential 44 no continuity to lube front solenoid add pipe or remove pipe is aborted non and code is aborted essential 45 no continuity to carriage two speed code is stored non solenoid essential 51 no continuity to rotation cw solenoid cruise control is blocked essential 52 no continuity to rotation solenoid cruise control is blocked essential JT4020 Mach 1 Terrain Operator s Manual Machine Diagnostic Codes Systems and Equipment 155 Code Condition Result Severity 53 no continuity to thrust forward cruise control is blocked essential solenoid 54 no continuity to thrust backward cruise control is blocked essential solenoid 55 no continuity to left track forward drive is blocked essential solenoid 111 no continuity to left track reverse drive is blocked essential solenoid 112 no continuity to right track forward drive is blocked essential solenoid 113 no continuity to right track reverse drive is blocked essential solenoid 114 no continuity to drilling fluid pump code is stored essential solenoid 115 no continuity to variable rotation code is stored non solenoid essential 122 no continuity to check valve solenoid code is stored non esseniial 124 no continuity to inner r
103. imits 3 Alarm interrupt button n b c00ic078h eps To turn off strike alarm at drilling unit press 4 Voltage problem indicator f 00 078 Red light indicates a voltage indicator problem See Troubleshoot Strike System on page 120 5 Current problem indicator 4 00 080 Red light indicates a current indicator problem See Troubleshoot Strike System on page 120 Controls 52 JT4020 Mach 1 All Terrain Operator s Manual ESID Item Description Notes 6 OK indicator cO0icO56h eps Green light means system self test detected no problems Strike system is ready to operate 7T Electrical power supply indicator c00ic081h eps Green light means control box has sufficient electrical power for operation Strike system is ready to operate if OK indicator is also on 8 Self test button 00 075 To start manual self test press To reset system after a strike has been detected press Checks all systems and circuits except voltage limiter NOTICE See If an Electric Line is Damaged on page 16 JT4020 Mach 1 All Terrain Operator s Manual Controls 53 750 752 Display 750 752 Display Indicators iN7AMNAh anc 1 Beacon temperature display Depth estimate 2 P
104. in 5 GRN YEL of ESID power connection and at BLK RED ground circuit DC 11 horn output error e verify that horn is properly connected to machine harness check broken or shorted wires in the harness perform a self test of the ESID module during self test check for 12V at pin 1 BRN of ESID power connection and at BLK RED ground circuit DC 12 12V DC battery power error check battery charge DC 15 strike voltage input error e verify that voltage limiter is properly connected to ESID module check for broken or shorted wires in the voltage limiter e perform a self test of the ESID module if code does not clear contact Trenchless Product Support DC 16 strike current coil input error e verify that current coil is properly connected to the current coil and to the ESID module e check broken or shorted wires in the cable e perform a self test of the ESID module if code does not clear contact Trenchless Product Support DC 17 self test AC voltage input error verify that voltage limiter cable is properly connected DC 18 self test AC current input error verify that current coil and cable are properly connected DC 19 self test DC voltage input error verify that voltage limiter cable is properly connected DC 20 self test DC current input error verify that voltage limiter cable is properly connected DC 21 voltage limiter not properly e verify that voltage limiter is connected securely to grounded voltage stake e v
105. ing product and restoring the jobsite with cross references to detailed procedures Prepare 63 procedures for inspecting and classifying the jobsite planning the installation path and preparing the jobsite for work Drive 81 procedures for startup cold start driving and shutdown A 02 Transport 83 procedures for lifting hauling and towing Conduct a Bore 91 procedures for drilling and backreaming my Systems and Equipment 113 amp NS downhole tools and drill pipe anchor electric strike tracker control and fluid Systems Complete the Job 169 I procedures for backfilling and restoring the jobsite and rinsing and storing E equipment 4 Service 175 service intervals and instructions for this machine including lubrication replacement of wear items and basic maintenance a Contents 8 JT4020 Mach 1 All Terrain Operator s Manual Support 219 the warranty policy for this machine and procedures for obtaining warranty consideration and training 115 Tier 3 Operator s Manual Chapter Contents lt 10 Safety Alert Classifications 11 Safety Alerts 12 Emergency Procedures 15 Electric Strike 15 If an Electric Line is Damaged 16 If a Gas Line is
106. ing fluid flowmeter carefully to see if values are rising or falling at the same time If they not nozzle might be plugged 4 Rotation pressure gauge c00ic049h eps Displays hydraulic fluid pressure to rotation motor when spindle is turned clockwise Inner rotation pressure is displayed when inner rotation is on and front wrench is open Outer rotation pressure is displayed when front wrench is closed and during backreaming JT4020 Mach 1 All Terrain Operator s Manual Controls 37 Right Control Console Lights j070m033h eps 1 Diagnostic light red 2 Rear home status light 3 Shuttle home status light 4 Front home status light 5 Front wrench status light 6 Control cycle light green 7 Drilling fluid pump status light Item Description Notes 1 Diagnostic light red c00ic051h eps If system is OK light should be off If system may not be getting power light should be on If a non essential diagnostic code is recorded light should flash on and off for 10 seconds If an essential diagnostic code is recorded light should flash on for three seconds and off for half a second See Machine Diagnostic Codes on page 152 Controls 38 JT4020 Mach 1 All Terrain Operator s Manual Right Control Console Item Description Notes 2 Rear home status light REAR 00 052
107. 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 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
108. ipe 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 178 for more information j290m017h eps To clean 1 Rotate handle to the upward or cleanout position A Operate pump until obstruction is flushed Rotate handle to the downward or spray position B Clean nozzle guard necessary pull handle nozzle insert out of housing to clean with fine wire solvent Check Pipe Auto Lubricator TJC Level Check pipe auto lubricator level every 10 hours Change pail as needed See Change Auto Lubricator on page 206 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 178 for more information j290m018h eps Service 188 JT4020 Mach 1 All Terrain Operator s Manual 25 Hour Clean Drilling Fluid Y Strainer Q Clean drilling fluid y strainer every 10 hours Ensure that strainer is free of debris 5 941 j290m020h eps 25 Hour Location
109. itch slope indicator and percentage indicator Display battery status indicator 3 Roll indicator Beacon battery status indicator 4 Target indentifier indicator Beacon temperature indicator IMPORTANT Some items operate differently depending where data is being saved Internal refers to pipe data being saved to 750 Display memory External refers to pipe data being sent to a properly con nected laptop computer running a version of Trac Management System software Item Description Notes 1 Beacon temperature Indicates beacon temperature display in degrees Centigrade and degrees Farenheit ore zie 043 00 286 Controls 54 JT4020 Mach 1 All Terrain Operator s Manual 750 752 Display Item Description Notes 2 Pitch slope indicator and percentage indicator a um Lt 99 00 083 Indicates pitch beacon percent of grade Internal shows pipe label and stored pitch External shows desired pitch 3 Roll indicator c00ic084h eps Indicates beacon roll angle 4 Target identifier indicator c00ic085h eps Indicates approximate beacon location Only one set of arrows is active at a time 5 Depth estimate cO0icO86h eps Indicates beacon depth estimate Internal shows job number and stored depth External shows desired depth
110. l 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 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 a manner inconsistent with manufacturer s recommendations engines and engine accessories these covered by original manufacturer s warranty Tires belts and other parts which 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 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
111. l pipe more sharply than recommended will damage pipe and cause failure over time Changes in pitch must be equally distributed over the length of a pipe Maximum changes in pitch within 1 2 300 600 mm of pipe create sharp bends that will damage pipe Monitor the pitch of each pipe with the 750 Display on the operator s console See 750 752 Display on page 53 Bend Radius JT4020 All Terrain drill pipes have a tested minimum bend radius of 300 91 4 This means that a 90 degree bend in the bore path e has a radius A of 300 91 4 requires approximately 471 143 6 m of drill pipe B NOTICE Bending drill pipe more sharply than recommended will damage the pipe and cause failure over time f bend radius is reduced drill pipe life is reduced f bend radius is increased drill pipe life is increased jO7om003c eps 07 004 IMPORTANT Use the charts on the next page to keep bends within safe limits 72 JT4020 Mach 1 All Terrain Operator s Manual Plan Bore Path Pipe By Pipe Bend Limits Pipe Forward B Deflection A Pipe Forward B Deflection A C C 1 14 ft 3 in 4 3 m 0 ft 4 in 0 1 m 18 226ft6in 69 0m 103 ft3 in 31 5 m 2 28 ft 6 in 8 7 m 1 ft 4 in 0 4 m 19 235ft7in 71 8m 114 ft3 in 34 8 m 3 4218 13 0 3 ft1in 0 9 m
112. l stop under Row one is closest to operator For example row four farthest from operator is shown See Shuttle stop control on page 25 IMPORTANT Stopping shuttles under the wrong row can result in drill pipes falling out of pipe box j070m073h eps Conduct a Bore 112 JT4020 Mach 1 All Terrain Operator s Manual Check Shuttle Stop Position JT4020 Mach 1 All Terrain Operator s Manual Systems and Equipment 113 Systems and Equipment Chapter Contents Anchor 115 e Select 115 Attach Anchor to Anchor Driver 116 e Drive 116 Drive Additional Side Anchors 117 Remove amp uude 117 Electric Strike System 118 9 2 PEG EX iua Ru 118 e Assemble Voltage Detector 119 e Test Strike System 119 e Troubleshoot Strike System 120 e Use Electric Strike Simulator 123 Drilling Fluid 124 e Guidelines 126 EP nde em e p 126 Bentonite I eee 127 MIXTURES u
113. m093c eps Temperature range anticipated before next oil change Approved Coolant This unit was filled with coolant before shipment from factory Add only 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 premature engine failure e 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 180 JT4020 Mach 1 All Terrain Operator s Manual Each Use Each Use Location Task Notes DOWNHOLE Lube drill head pump seal grease TOOLS p n 256 036 NOTICE See Drill Pipe on page 141 for information and precautions regarding drill pipe Downhole Tools Lube Drill Head Lube drill head with pump seal grease p n 256 036 every 8 hours and after every bore To lube 1 Remove hex plug Install zerk Rotate drill head by hand and fill with pump seal grease until it comes out at front seal 4 Remove zerk Replace hex plug jO7om039h eps JT4020 Mach 1 All Terrain Operator s Manual Service 181 10 Hour 10 Hour Location Task Notes DRILLING Check fuel filter water separators UNIT Check engine oil level DEO
114. mp 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 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 high fuel pressure solenoid valve circuit assembly 1 voltage below normal or shorted to low source SPN 1347 FMI 272 fuel pump pressurizing high fuel pressure solenoid valve circuit assembly 1 voltage above normal or shorted to high source SPN 1347 FMI 7 281 fuel pump pressurizing high fuel pressure solenoid valve 1 assembly 1 mechanical system not responding properly or out of adjustment SPN 1347 FMI 7 275 fuel pump pressurizing fuel pumping element front mechanical assembly 1 system not responding properly or out of adjustment SPN 1043 FMI 4 284 internal sensor voltage engine speed position sensor crankshaft supply 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 da
115. n body 2 j290m045h eps 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 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 211 Service 214 JT4020 Mach 1 All Terrain Operator s Manual As Needed JT4020 Mach 1 All Terrain Operator s Manual Specifications 215 Specifications H e IIT CO Dimensions U S Metric L length per SAE J2022 337in 8 6m W width per SAE J2022 87 in 2 2m H height over exhaust stack per SAE J2022 96 in 2 4m Angle of approach 17 17 Angle of departure 13 13 Weight per SAE J2022 JT mode 27 670 Ib 12 550 kg AT mode 28 170 Ib 12 778 kg All Terrain Pipe U S Metric Length without inner pipe per SAE J2022 171 in 4 3m Joint diameter per SAE J2022 4 13 in 105 mm Tubing diameter per SAE J2022 3 63 in 92 mm
116. nd 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 107 284 and torque bolts to 580 10 800 Nem Beacon Housings Beacon Installation To ensure beacon is installed correctly in rock housing place battery end of beacon away from bit end of housing Lid Installation 1 Clean all threads bolt holes and mating surfaces 2 Follow torque sequence shown 3 Use removable thread locker Loctite or equivalent if desired 4 Torque bolts to 60 70 ftelb 81 95 Nem Repeat torque sequence 07 058 Systems Equipment 136 JT4020 Mach 1 All Terrain Operator s Manual 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
117. nd 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 e Immediately call your local emergency phone number and utility company e If jobsite is along street stop traffic from driving near jobsite e 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 e If fire is small and fire extinguisher is available attempt to extinguish fire e cannot be extinguished leave area as quickly as possible and contact emergency personnel CMW Safety 18 RT115 Tier 3 Operator s Manual Emergency Procedures CMW JT4020 Mach 1 All Terrain Operator s Manual Chapter Contents Set Up 20 Gauges and Indicators 20 CONTOS 5255 oe eta Ware eae eee 24 Left Control Console 27 Pipeloading Controls 27 Drilling Cohtrols
118. ng 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 M 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 70 JT4020 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 T
119. ngine is running and no one is sitting in operator s seat Press and hold SET for two seconds Diagnostic light will flash code 12 flash pause flash flash longer pause to indicate review mode is operational After code 12 is flashed e Press RESUME to see same code again or press SET to see next code e Continue pressing SET until all diagnostic codes detected since the last time the ignition was turned on are flashed Cycle is complete when code 12 flashes again To save diagnostic codes continue normal operation Do not turn ignition off Once the problem has been corrected clear all codes by turning ignition off Diagnostic Code Interpretation Diagnostic codes are displayed through a series of light flashes and pauses Count number of flashes and pauses to interpret code Example Flash flash flash pause flash flash longer pause represents code 32 Tips for interpreting codes In View All Codes mode the green control cycle light will come on the first time the red diagnostic light flashes a code The green control cycle light will then go off and the red diagnostic light will flash the code two more times Codes are displayed from lower to higher numbers Only numbers 1 5 are used in codes Code 11 is not used Code 12 signals successful entry into and exit from review mode Systems Equipment 154 Machine Diagnostic Codes JT4020 Mach 1 All Terrain Operator s Manual
120. ns A WARNING Welding Precaution Washing Precaution JT4020 Mach 1 All Terrain Operator s Manual Service 177 Service Precautions Working Under Drilling Unit Crushing weight could cause death or serious injury Use proper procedures and equipment or stay away Use safety supports as indicated when working under drilling unit j290m005h eps Before working under front end of drill frame install jackstands under frame Before working under area of drilling unit supported by a stabilizer make sure drilling unit is parked on hard surface 1 Remove cylinder lock pinned to frame 1 and place over extended cylinder rod 2 2 Reinstall pins to secure cylinder lock to rod 3 Raise stabilizer until load is supported by cylinder lock 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 tube stored under frame 3 and place under drill frame Shown in inset 2 Lower drill frame until load is supported by drill frame support tube Service 178 JT4020 Mach 1 All Terrain Operator s Manual Recommended Lubricants Service Key Recommended Lubricants Service Key Item Description 0 DEO SAE 15W40 multi viscosity diesel engine oil meeting or exceeding API service classification CH 4 or ACEA specification E3 NDO SAE 30 non detergent engine oil
121. nseren sx a ae 127 Basic Fluid Recipes 128 Drilling Fluid Requirements 129 Funnel VISCOSIy ios ng bodes Y Ru D Re pes 130 Tracker Control 131 COVerIVIGW o sicut iacu durs ME 131 Operation seen 131 Systems Equipment 114 JT4020 Mach 1 All Terrain Operator s Manual Downhole Tools 134 1 022168 a Sc ox ne Mahara veniam 134 IBIS yd te Re Ts A UE 134 Housings ubere bea 135 Backreamers 136 e Backream Fluid Requirements 137 Hydratong Wrenches 139 eek RE 141 e Perform Regular Drill Pipe 141 e Use Drill Pipe Correctly 143 Pipe BOXeS 145 Remove Install Pipe 145 e Add Remove Single Pipe to Pipe Box 147 Cruise Control 22 2 RE ARTS 151 Engage deri 151 Adjust Settings sex ee cob
122. o drill connector B to override switch control fluid flow To turn fluid off move left O 00 068 5 Controls 48 JT4020 Mach 1 All Terrain Operator s Manual Override Box Item Description Notes 2 Thrust pullback or left track override switch x m cO0icO69h eps For thrust or to move track forward move up For pullback or to move track backward move down Connect to drill connector B to control thrust pullback Connect to drive connector A to control left track IMPORTANT When connected to connector A drill fluid switch functions as an operator presence switch 3 Rotation or right track override switch h YX 00 070 For counterclockwise rotation or to move track forward move up For clockwise rotation or to move track backward move down Connect to drill connector B to control rotation Connect to drive connector A to control right track IMPORTANT When connected to connector A drill fluid switch functions as an operator presence switch JT4020 Mach 1 All Terrain Operator s Manual Controls 49 Battery Battery jO7om001c eps 1 Battery disconnect switch Description Notes 1 Battery disconnect To disconnect turn switch IMPORTANT Use when servicing switch counterclockwise unit and during long term storage
123. ol if desired See page 131 Drill first pipe See page 100 JT mode AT dirt mode AT mode Swab the hole to remove cuttings AT mode only See page 101 Record bore path See page 106 Enable automated pipeloader system See page 101 Add pipe See page 102 Drill remaining pipes in pipe box Correct direction See page 104 Engage cruise control See page 151 Operation Overview 61 Remove empty pipe box and add full box see page 145 or add up to a single row of drill pipe to empty box see page 147 to complete bore 10 Surface drill head See page 106 Remove drill head Grease downhole tool AT mode Operation Overview 62 JT4020 Mach 1 All Terrain Operator s Manual Backreaming Backreaming RON 6 Assemble backream string See page 107 Start drilling unit and adjust throttle Set drilling fluid flow Check that fluid flows through all nozzles See page 134 Remove pipe from bore See page 109 Remove full pipe box and add empty box see page 145 or remove up to a single row of drill pipe from full box see page 147 to complete backream Remove pullback device See page 111 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
124. oose clock position and set spindle brake 4 Rotate inner spindle clockwise 5 Slowly move carriage forward Drill first pipe as straight as possible 6 Monitor gauges e If inner rotation pressure approaches 1600 psi 110 bar slow carriage travel j finner rotation stalls stop carriage thrust If inner rotation does not resume pull pipe back JT4020 Mach 1 All Terrain Operator s Manual Conduct a Bore 101 Swab the Hole Swab the Hole IMPORTANT Swab hole after each pipe is drilled to remove cuttings and keep the hole clear AT Mode only Some conditions may require more frequent swabbing 1 Move carriage forward until wrench springs are fully compressed 2 Move carriage to rear of drill frame with drilling fluid and inner rotation on 3 Move carriage forward until carriage touches rear wrench to leave gap between end of bore and drill head shown 107 047 Enable Automated Pipeloader System Add Pipe Remove Pipe 1 Open front wrench and retract shuttles for add 1 Open front wrench and retract shuttles for pipe function to work remove pipe function to work 2 Press top of add pipe manual remove pipe 2 Press bottom of add pipe manual remove pipe switch Green control cycle light will come on switch Green control cycle light will come on 3 Grippers will open pipe will be lowered and 3 Grippers will open pipe will be lowered and then green control cycle light will flash
125. operly connected to ESID module check for broken or shorted wires in the voltage limiter perform a self test of the ESID module if code does not clear contact Trenchless Product Support DC 16 strike current coil input error verify that current coil is properly connected to the current coil and to the ESID module e check for broken or shorted wires the cable perform a self test of the module if code does not clear contact Trenchless Product Support DC 17 self test AC voltage input error verify that voltage limiter cable is properly connected DC 18 self test AC current input error verify that current coil and cable are properly connected DC 19 self test DC voltage input error verify that voltage limiter cable is properly connected DC 20 self test DC current input error verify that voltage limiter cable is properly connected DC 21 voltage limiter not properly grounded e verify that voltage limiter is connected securely to voltage stake verify that stake is fully in the ground or properly grounded to machine frame Systems Equipment 126 JT4020 Mach 1 All Terrain Operator s Manual Drilling Fluid Drilling Fluid For productive drilling and equipment protections use these recommended Baroid products available from your Ditch Witch dealer Soda ash e Quik Gel dry powder bentonite p n 259 804 E Z Mud liquid polymer p n 259 805 Liqui Trol
126. or s Manual 10 Disconnect hoses and remove Hydratong components Hydratong Wrenches To join scribe straight line across joint on both sides of separating line A To join scribe second line B on moveable side of joint in the opposite direction of tightening action Refer to table for correct dimension Connection Dimension transition sub to JT4020 All 3 8 9 5 mm Terrain pipe transition sub to beacon 1 2 13 mm housing transition sub to JT4020 1 2 13 mm Mach 1 pipe 7 7 1h eps Connect Hydratong power pack Attach hoses from power pack to cylinder 1 Attach leads 4 to 12V battery B 4 To tighten or loosen joint move shuttle valve handle 2 toward gauge 3 and press power switch 1 To reposition chain tongs and continue tightening or loosening joint move handle away from gauge s 0 then back toward gauge and then press power switch 07 030 Monitor gauge and refer to decal to achieve approximately 4000 0 5420 Nem of torque Then tighten joint until second line B meets first A IMPORTANT Gauge gives an estimate of torque Use scribe line to get exact torque Move handle to center neutral position to relieve pressure JT4020 Mach 1 All Terrain Operator s Manual Systems and Equipment 141 Drill Pipe Drill Pipe Perform Regular Drill Pipe Care Precondition New Pipe Repeat
127. orce of 1 5 times unit weight disengage track planetaries Transport 90 JT4020 Mach 1 All Terrain Operator s Manual 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 070 041 A Normal operation B Towing To attach chains to tow points determine which points are facing towing vehicle If back tow points are facing towing vehicle choose option A or B E j070m039c eps Option A Loop chain through both tow points and attach to common cross member Always pull straight back Option B Loop chain through each tow point and attach chains to towing vehicle Always pull straight back If front tow points are facing towing vehicle loop chain through tow point and pull straight forward 070 042 JT4020 Mach 1 All Terrain Operator s Manual Conduct a Bore 91 Conduct a Bore Chapter Contents Position Equipment 93 Connect Fluid System 93 Start System 93 Prime Drilling Fluid Pump 94 Operate Carriage Control 95 Clamp Pipe 96 Assemble Drill 0 97 Prepare Beacon Housing 97 Attach Transition Sub 0 0 2 eee 98 Attach Beacon Housing
128. otation code is stored non clockwise solenoid essential 125 no continuity to inner rotation code is stored non counterclockwise solenoid essential 131 no continuity to thrust rear home add pipe and remove pipe are non switch blocked esseniial 132 no continuity to thrust front home add pipe and remove pipe are non switch blocked esseniial 133 no continuity to shuttle home switch add pipe and remove pipe are non blocked essential 134 no continuity to front wrench switch add pipe and remove pipe are non blocked essential 135 no continuity to hydraulic fan speed hydraulic fan compensation is blocked non sensor essential 144 drive joystick left right out of range drive is blocked essential 145 drive joystick forward backward out of drive is blocked essential range 151 drill joystick left right out of range rotation and cruise control are blocked essential 152 drill joystick forward backward out of thrust and cruise control are blocked essential range Systems Equipment 156 JT4020 Mach 1 All Terrain Operator s Manual Machine Diagnostic Codes Code Condition Result Severity 154 drilling fluid potentiometer out of code is stored essential range 155 rotation potentiometer out of range code is stored non essential 214 no continuity to inner rotation position dither compensation is blocked non sensor essential 221 System voltage is below 12 5V code is stored non essent
129. ove anchor shaft from ground 2 Repeat process for other anchor s Systems Equipment 118 JT4020 Mach 1 All Terrain Operator s Manual Electric Strike System Electric Strike System Any time you drill in an electric jobsite electric strike system must be properly set up tested and used You must wear protective boots and gloves meeting the following standards Boots must have high tops and meet the electric hazard protection requirements of ANSI 2 41 1991 when tested at 14 000V 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 69 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
130. oving 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 e 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 AX WARNING Moving parts could cut off hand or foot Stay away X CMW RT115 Tier 3 Operator s Manual Safety 13 Safety Alerts AX WARNING 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 AX WARNING 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 WARNING Fire or explosion possible Fumes could ignite and cause burns No smoking no flame no spark WARNING Moving traffic hazardous situation Death or serious injury could result Avoid moving
131. pecifications 217 Power U S Metric Engine Cummins QSB 6 7 Fuel diesel Cooling medium ASTM D5345 Cylinders 6 Displacement 409 in 6 71 Bore 4 21 in 107 mm Stroke 4 88 in 124 Power manufactuer s gross power rating per SAE J1995 190 hp 142 kW rated speed 2400 rpm 2400 rpm estimated net power per SAE 1349 175 hp 131 kW Drilling Fluid System U S Metric Maximum drilling fluid flow per SAE J2022 JT mode 120 454 L min AT mode 70 gpm 265 L min Maximum drilling fluid pressure per SAE J2022 1300 psi 90 bar Fluid Capacities U S Metric Fuel tank 55 gal 208 L Hydraulic reservoir 36 gal 136 L Engine oil including filter 20 qt 191 Engine cooling system 31 qt 29L Antifreeze tank 8 gal 301 Under normal operating conditions a full tank of fuel will last 10 14 hours Specifications 218 JT4020 Mach 1 All Terrain Operator s Manual Baitery SAE reserve capacity 195 min 12V negative ground SAE cold crank 18 C 2 batteries 950A each Noise Levels Exterior 109 dBA sound power per ISO 6395 Operator 90 dBA sound pressure per ISO 6394 Specifications are called out according to SAE recommended practices Specifications are general and subject to change without notice If exact measurements are required equipment should be weighed and measured Due to selected options deli
132. r all oil is drained tighten bolts to rejoin brake j290m033h eps 5 Refill with 5 oz 148 mL of THF at fill plug 2 Do not overfill 6 Reinstall outer rotation motor See Repair Guide Change Fluid Pump Oil Change oil after first 50 hours and every 1000 hours thereafter Maintain fluid level at halfway point on sight glass or at petcock level 2 Drain at plug 3 Fill at cap 1 with SAE 30 non detergent engine oil Capacity for 70 gom pump is 4 qt 3 8 L Capacity for 120 pump is 10 at 1 9 4 L Il j290m014h eps Service 202 JT4020 Mach 1 All Terrain Operator s Manual 1000 Hour Lube Saver Sub Wrench Collar and Sliding Output Shaft Lube with EPL spray every 50 hours j290m028h eps Check Engine Drive Belt Check engine drive belt every 1000 hours Check for cracked stretched or loose belt Replace belt as needed Belt tensioner cannot be adjusted or repaired Replace if faulty To check belt tension e Visually check gap between stops Replace belt before stops touch IMPORTANT e As belt stretches stops will move closer j290m036h eps together See engine manual for information on checking automatic tensioner and changing belts JT4020 Mach 1 All Terrain Operator s Manual Service 203 2000 Hour 2000 Hour DRILLING Change engine coolant UNIT Drilling Unit Ch
133. r in numeric display when data is stored IMPORTANT Pipe data cannot be stored without a valid depth estimate JT4020 Mach 1 All Terrain Operator s Manual Operation Overview 59 Operation Overview Chapter Contents ERE ES 60 Setting Up at Jobsite 60 III 61 62 Leaving Jobsite 62 Storing Equipment 62 Operation Overview 60 Planning NOOR OD Gather information about jobsite See page 65 Inspect jobsite See page 66 Classify jobsite See page 68 Plan bore path See page 70 Select drilling mode based on jobsite conditions See page 78 Check supplies and prepare equipment See page 76 Load equipment See page 87 Setting Up at Jobsite o gt YO DN Prepare jobsite See page 75 Unload drilling unit from trailer See page 86 Assemble drill string See page 97 Position drilling unit and frame See page 93 Assemble strike system See page 119 Anchor drilling unit See page 115 Connect fluid system See page 93 Calibrate tracker with beacon that will be installed in beacon housing See tracker operator s manual JT4020 Mach 1 All Terrain Operator s Manual JT4020 Mach 1 All Terrain Operator s Manual Drilling Drilling 1 o uoc Start system See page 93 Engage tracker contr
134. r 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 Systems Equipment 166 JT4020 Mach 1 All Terrain Operator s Manual Tier 3 Engine Two line Fault Description Possible cause diagnostic code Code 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 control module identification input state identification input state error data erratic intermittent or incorrect SPN 1563 FMI 2 1257 control module control module identification input state identification input state error data erratic intermittent or incorrec
135. r repair install new filter p n 157 486 for first 50 hours of operation If this filter becomes plugged in fewer than 20 hours replace with clean filter After 50 hours of normal operation replace with clean filter j290m011h eps Check Fluid Pump Oil Level Check fluid pump oil level at sight glass or petcock 2 every 10 hours Maintain fluid level at halfway point on sight glass or at petcock level Fill at cap 1 with SAE 30 non detergent engine oil j290m013h eps Service 186 JT4020 Mach 1 All Terrain Operator s Manual 10 Hour Test Control Switches Test control proximity switches every 10 hours 1 Drive position switch 2 Drill position switch 3 Rear stop switch 4 Rear home switch 5 Shuttle home switch 6 Front home switch j290m015h eps 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 Lube Applicator Check pipe lube applicator every 10 hours Replace if damaged or badly worn j290m016h eps JT4020 Mach 1 All Terrain Operator s Manual Service 187 10 Hour Check Pipe Auto Lubricator Spray Nozzle Check p
136. rac 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 74 and use these measurements to help plan your bore JT4020 Mach 1 All Terrain Operator s Manual Prepare 71 Plan Bore Path Recommended Bend Limits Ditch Witch drill pipes are designed to bend slightly during operation Slight bending allows for steering and correcting direction Bending beyond recommended limits will cause damage that might not be visible This damage adds up and will later lead to sudden drill pipe failure IMPORTANT Consider recommended bend limits during any bend not just during bore entry Pipe Pitch Ditch Witch drill pipe is tested to bend at a maximum percent pitch For JT4020 All Terrain drill pipe make sure pitch A changes no more than 5 over the full length of each pipe NOTICE Bending dril
137. rcuit 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 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 JT4020 Mach 1 All Terrain Operator s Manual Systems and Equipment 163 supply Tier 3 Engine Two line Fault Description Possible cause diagnostic code Code 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 3 386 5 volts DC supply sensor supply voltage 1 circuit voltage above normal or shorted to high source SPN 1043 3 387 internal sensor voltage accelerator pedal or lever position sensor
138. recting 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 e Steering ability depends on soil condition bit drill head and nozzle used roll of drill head and distance pushed without outer rotation e All corrections should be made as gradually as possible See Recommended Bend Limits on page 71 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 AT Dirt 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 e 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 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 e Pull back 6 152 mm o
139. rometric 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 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 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 JT4020 Mach 1 All Terrain Operator s Manual Systems and Equipment 161 Tier 3 Engine Two line Fault Description Possible cause diagnostic code Code SPN 644 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 fan control circuit voltage below normal or driver fan shorted to low source SPN 171 FMI 249 ambient air temp ambient air te
140. ross battery terminals for any reason JT4020 Mach 1 Terrain Operator s Manual 1000 Hour 1000 Hour Service 199 Location Task Notes DRILLING Change hydraulic fluid and filters normal conditions UNIT Change ground drive gearbox oil 2 gearboxes MPL Change rotation gearbox oil MPL Change spindle brake oil THF Change fluid pump oil SAE 30 non detergent Lube saver sub wrench collar and sliding output shaft Check engine drive belt EPL gel Drilling Unit Change Hydraulic Fluid and Filters Normal Conditions as Change hydraulic fluid and three filters every 1000 hours for normal service Drain hydraulic fluid change filters 1 2 and refill with THF at hydraulic fluid fill Tank capacity is 36 gal 136 L IMPORTANT f ambient temperature exceeds 100 F 37 C for 50 of time change oil and filter every 500 hours f hydraulic system must be opened for j290m021h eps repair install new filter p n 157 486 for first 50 hours of operation If this filter becomes plugged in fewer than 20 hours replace with clean filter After 50 hours of normal operation replace with clean filter Service 200 Change Ground Drive Gearbox Oil Change oil in both ground drive gearboxes every 1000 hours Capacity is 1 6 qt 1 5 L To change 1 2 3
141. rough engine statics and diagnostic codes on diagnostic gauge display push JT4020 Mach 1 All Terrain Operator s Manual Left Control Console Left Control Console Pipeloading Controls j07om030h eps 1 Add pipe manual remove pipe switch 2 Pipe lift switch 3 Rear wrench clamp switch 4 Rear wrench rotation switch Item Controls 27 5 Pipe lubricator switch 6 Front wrench clamp switch 7 Pipe gripper switch 8 Pipe shuttle switch Description Notes 1 Add pipe manual remove pipe switch OY y c00ic031h eps To select add pipe automated pipeloader function press top To use manual pipeloader controls move to center To select remove pipe automated pipeloader function press bottom See Add Pipe on page 102 See Remove Pipe on page 109 Controls 28 JT4020 Mach 1 All Terrain Operator s Manual Left Control Console Item Description Notes 2 Pipe lift switch M gt P 00 032 lower press top To raise press bottom 3 Rear wrench clamp switch t3 kH 00 033 To press top To clamp press bottom 4 Rear wrench rotation switch 00 038 rotate counterclockwise press top To rotate clockwise press bottom To stop rotation r
142. rs end of pipe box Green control cycle light will come on Lube front threads e Shuttles will retract to shuttle stop front threads will be lubed grippers will release pipe pipe lifters will raise until pipe is off shuttles and then green control cycle light will flash 10 Attach saver sub to next pipe Move carriage forward until saver sub touches pipe Rotate spindle and move carriage forward just enough to allow saver sub to connect to pipe e Slowly tighten joint to full machine torque 11 Disengage front wrench to release pipe JT4020 Mach 1 All Terrain Operator s Manual Conduct a Bore 111 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 e DANGER Moving tools will kill or injure Shut off drill string power when anyone can 2 2 be struck by moving or thrown tools Never use pipe wrenches drill string Ic aN 1 Press bottom of drilling unit throttle switch until engine is at low throttle Turn off drilling fluid Turn off drilling unit engine Clean pullback device 4 o m Use Hydratong wrenches to remove pullback device See Hydratong Wrenches on page 139 Check Shuttle Stop Position Look at shuttle stop position indicator to verify which row of pipe shuttles wil
143. s c00ic314h eps Systems and Equipment 158 JT4020 Mach 1 All Terrain Operator s Manual Tier 3 Engine Diagnostic Gauge To display codes 1 Press the selection switch to scroll through the gauge parameters until FMI SPN 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 c00ic372h eps 1 Turn ignition switch to STOP 2 Turn ignition switch back to START To change display options 1 Turn the ignition switch to STOP Press and hold the selection switch Turn the ignition switch to ON Press and hold the selection switch to scroll through display options Release the switch to stop scrolling To turn options off or on press the selection switch twice NOOR ODN To save changes continue scrolling until EXIT CFG is displayed then press and hold JT4020 Mach 1 All Terrain Operator s Manual Tier 3 Engine Engine Diagnostic Codes Systems and Equipment 159 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
144. s 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 DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury AX WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury Watch for two other words NOTICE and IMPORTANT NOTICE can keep you from doing something that might damage the machine or someone s property It can also alert you against unsafe practices IMPORTANT can help you do a better job or make your job easier in some way CMW Safety 12 RT115 Tier 3 Operator s Manual Safety Alerts Safety Alerts Turning shaft will kill you or crush arm or leg Stay away DANGER Electric shock Contacting electric lines will cause death or serious injury Know location of lines and stay away DANGER Deadly gases Lack of oxygen or presence of gas will cause sickness or death Provide ventilation DANGER M
145. sor error data erratic intermittent or incorrect SPN 1172 FMI 3 691 turbocharger 1 compressor turbocharger 1 compressor inlet temp inlet temp sensor circuit voltage above normal or shorted to high source SPN 1172 FMI 4 692 turbocharger 1 compressor turbocharger 1 compressor inlet temp inlet temp sensor circuit voltage below normal or shorted to low source SPN 1136 FMI 3 697 sensor circuit voltage 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 cylinde
146. supply 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 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 FMI3 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 battery 1 voltage low data valid but below voltage normal operational range moderately severe level SPN 168 FMI 16 442 electrical potential battery 1 voltage high data valid but voltage above normal operational range moderately severe level SPN 1043 FMI 4 443 internal sensor voltage accelerator pedal or lever position sensor supply volta
147. t 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 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 2185 system diagnostic code 1 sensor supply voltage 4 circuit voltage above normal or shorted to high source JT4020 Mach 1 Terrain Operator s Manual Systems and Equipment 167 Tier 3 Engine Two line Fault Description Possible cause diagnostic code Code SPN 611 FMI 4 2186 system diagnostic code 1 sensor supply voltage 4 circuit voltage below normal or shorted to low source SPN 703
148. t cap 1 with SAE 30 non detergent engine oil Capacity for 70 gom pump is 4 qt 3 8 L Capacity for 120 gom pump is 10 qt 9 4 L Change Hydraulic Filters Initial Service Change three hydraulic filters after first 50 hours Replace filters every 250 hours thereafter Change filters more often if indicated by filter indicator IMPORTANT If hydraulic system must be opened for repair install new filter p n 157 486 for first 50 hours of operation If this filter becomes plugged in fewer than 20 hours replace with clean filter After 50 hours of normal operation replace with clean filter j290m014h eps j290m021h eps JT4020 Mach 1 All Terrain Operator s Manual Service 191 50 Hour Check Ground Drive Gearbox Oil Level bo Check oil level in both ground drive gearboxes every 50 hours To check 1 Drive unit to rotate plug 1 until level with center of gearbox 2 Open plug and fill with MPL until level with plug opening 3 Replace plug yg IMPORTANT j290m022h eps e Drilling unit must be on level ground for accurate reading Use helper to assist in positioning gearbox plugs for checking and adding oil Do not overfill Check Rotation Gearbox Oil Level Check rotation gearbox oil level every 50 hours X Fill throug
149. t enters the ground To help ensure that the first pipe does not bend dig a small starting hole so that the first pipe is drilled into a vertical surface To prevent bending or straining pipe position drilling unit for straight entry jO7om011c eps 76 JT4020 Mach 1 All Terrain Operator s Manual 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 hydraulic wrench see Hydratong Wrenches on page 139 transition sub anchoring equipment and accessories bits screens nozzles see Downhole Tools on page 134 adapters pipe beacon housings marking flags or paint water and additional hoses fuel drilling fluid additives see Drilling Fluid on page 126 spare fuses keys backreamers swivels pulling devices see Backreamers on page 136 wash down hose and spray gun duct tape spray lubricant tool joint compound see Recommended Lubricants Service Key on page 178 electrically insulating boots and gloves personal protective equipment such as hard hat and safety glasses notepad and pencil JT4020 Mach 1 All Terrain Operator s Manual Prepare 77 Check Supplies and Prepare Equipment Prepare Equipment Fluid Levels e fuel hydraulic fluid engine coolant battery charge
150. t 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 Engine Diagnostic Codes Problems with the Tier 3 engine usually are indicated by the operator alert indicator on the set up 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 21 Operator Alert Indicator When non critical engine fault occurs the operator alert indicator the gauge cluster will light A fault code will be stored in the diagnostic gauge 00 037 Engine Shutdown Indicator When an 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 second
151. talink SAE J1939 multiplexing configuration error out of calibration Systems Equipment 162 JT4020 Mach 1 All Terrain Operator s Manual Tier 3 Engine Two line Fault Description Possible cause diagnostic code Code SPN 441 FMI 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 14 296 auxiliary pressure auxiliary pressure sensor input 1 special instructions SPN 1388 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 ci
152. tart Unit Start Unit Standard Procedure 1 Insert key 2 Turn ignition switch to the run position key on engine off Engine preheat indicator on setup console at operator s station will light Wait for engine preheat indicator to go off before starting Run engine at low throttle for 5 minutes Steer Unit To steer drilling unit follow instructions for type of steering desired steer while moving forward push forward and then move to left or right SS Drilling unit will gradually turn to left or right 5 steer while moving backward pull back and then move to left or right Drilling Ss unit will gradually turn to left or right R S c00ic061h eps For tight steering in low speed move control to center position and then to a corner Tracks will counter rotate and turn drilling unit in a tight circle Shut Down Unit 1 Stop track movement Engage parking brake Run engine at low throttle for 3 minutes to cool Turn ignition switch to STOP aoe oN Remove key JT4020 Mach 1 All Terrain Operator s Manual Chapter Contents Lift 84 POINTS EE aae eee a 84 Procedure oc nh wd 84 oe os ea ca ca a ai 86 Inspect Traller eae Rm rede eed 86 Trailer 222545 ate BRE Wie Melee
153. 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 Recommended Lubricants Service Key on page 178 for correct lubricant 2 Join pipe and tighten joint 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 Recommended Lubricants Service Key on page 178 for correct lubricant Clean the Threads Clean the threads as needed with high pressure water and detergent NOTICE Do not use gasoline or other petroleum based solvents This prevents tool joint compound from sticking to the joints and will reduce thread life Systems Equipment 142 JT4020 Mach 1 All Terrain Operator s Manual Drill Pipe Use Caps and Plugs Before transporting in dusty conditions or prolonged storage install caps and plugs to male and female ends of pipe and to saver sub lt gt Because each pipe comes in contact with the saver sub check saver sub regularly for wear Replace it when it is worn or it will damage your drill pipe See Lube Saver Sub Wrench Collar and Sliding Output Shaft on page 196 for repl
154. tic code 1 turbocharger turbine inlet temp calculated data valid but above normal operational range least severe level SPN 2629 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 fan control circuit voltage above normal or driver shorted to high source Systems and Equipment 168 JT4020 Mach 1 All Terrain Operator s Manual Tier 3 Engine Two line Fault Description Possible cause diagnostic code Code 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 JT4020 Mach 1 All Terrain Operator s Manual Complete the Job 169 Complete the Job Chapter Contents Antifreeze Drilling Unit 170 Add Antifreeze
155. 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 gt 1 4L 2 With finger over bottom of funnel fill with fluid from the container through the screen until fluid reaches the bottom of the screen Move funnel over 1 qt 95 L container 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 107 033 JT4020 Mach 1 All Terrain Operator s Manual Systems and Equipment 131 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 Use tracker control any time you change downhole tools or during other times when the drill string is exposed Tracker control works by stopping communication between the tracker and the display When this happens the green tracker control light on the drilling unit comes on and thrust and rotation are disabled Operation Enable Thrust and Rotation 1 Start drilling unit
156. to back of frame While carriage is moving green control cycle light will come on Grippers will grip pipe will be lubed and then green control cycle light will flash 4 Load pipe Manual Pipeloader Controls Automated Pipeloader Control Make sure shuttle stop is properly positioned on pipeloader see Check Shuttle Stop Position on page 111 and lift arms are completely lowered Close grippers Lube upper pipe threads Move pipe to spindle and lube lower threads Raise pipe in box Make sure shuttle stop is properly positioned on pipeloader See Check Shuttle Stop Position on page 111 When carriage is moved to back of drill frame press RESUME Green control cycle light will come on Pipe will be moved to spindle front threads will be lubed pipe in box will be lifted and then green control cycle light will flash JT4020 Mach 1 All Terrain Operator s Manual Add Pipe 5 Connect pipe to saver sub Conduct a Bore 103 Manual Pipeloader Controls Automated Pipeloader Control IMPORTANT Always rotate clockwise unless breaking pipe joint Rotating counterclockwise will separate joints Move carriage forward until saver sub meets pipe Continue to slowly advance carriage and rotate spindle until pipe threads tighten Relax grippers IMPORTANT Always rotate clockwise unless breaking pipe joint Rotating counterclockwise will separate joints Move carr
157. to frame Clip other lead to one voltage limiter mount Move simulator switch to voltage and press test button Qv deo Watch screen and lights above display on strike system Alllights should turn on Alarm and strobe should turn on Voltage V should show 90 110 It is normal for simulator voltage levels to drift below strike level When this happens light in triangle should go off and alarm and strobe should stop working If the level drifts above strike level again light alarm and strobe should be turned on again ESID Diagnostic Codes Code Definition Action DC 10 strobe output error e verify that strobe light is properly connected to machine harness check for broken or shorted wires in the harness perform a self test of the ESID module during self test check for 12V at pin 5 GRN YEL of ESID power connection and at BLK RED ground circuit DC 11 horn output error verify that horn is properly connected to machine harness check for broken or shorted wires in the harness e perform a self test of the ESID module during self test check for 12V at pin 1 BRN of ESID power connection and at BLK RED ground circuit DC 12 12V DC battery power error check battery charge JT4020 Mach 1 All Terrain Operator s Manual Systems and Equipment 125 Electric Strike System Code Definition Action DC 15 strike voltage input error e verify that voltage limiter is pr
158. tric system Check that harness from drilling unit to control module is connected Check that harness from drilling unit carries more than 10V Defective control module Have control module checked or replaced Electrical power supply indicator is on but OK indicator is off Problem detected during test Check for error code and have control module checked or replaced Defective control module Have control module checked or replaced JT4020 Mach 1 Terrain Operator s Manual Electric Strike System Systems and Equipment 121 Problem Possible cause Possible solution Strobe light on drilling unit does not work during total test Improper connections with control module Check connections and wiring harness Defective strobe light 1 Disconnect strobe and connect to external 12V power source 2 If strobe does not work replace it Defective control module Have control module checked or replaced Alarm on drilling unit does not work during total test Improper connections with control module Check connections and wiring harness Defective alarm 1 Disconnect strobe and connect to external 12V power source 2 If strobe does not work replace it Defective control module Have control module checked or replaced Strobe light and alarm on drilling unit do not work during total test Improper connections with control module C
159. ure with lift pin 1 and lynch 6 2 Raise pipe with pipe lifter on machine Move support pins 4 from top of pipe box 3 and insert under both ends of pipe box Secure with lynch pins Attach chain to lift pin block Loosen four pin retainer bolts 8 Two bolts are located on each end of the pipe box 6 Pull rear pins 5 and front pin 7 and lift box off drill frame See Pipe Box on page 85 for more information 107 035 Install Pipe Box IMPORTANT Reference numbers for this procedure refer to illustration on previous page 1 Guide pipe box onto centering pin on rear of pipeloader frame Lower completely onto frame 2 Insert rear and front pins 5 7 3 To bolt pipe box onto drill frame tighten four retainer bolts 8 Two bolts are located on each end of the pipe box 4 Raise pipe with pipe lifter on machine Remove bottom support pins 4 from both ends of pipe box Store support pins in holes on top of pipe box 8 JT4020 Mach 1 Terrain Operator s Manual Systems and Equipment 147 Pipe Boxes Add Remove Single Pipe to Pipe Box Load a single drill pipe or up to a whole row of drill pipe into fourth row of pipe box to finish bore without changing pipe boxes Pipe can be added as soon as fourth row of pipe has been started and other rows are empty A DANGER A WARNING aw Systems Equipment 148 JT4020 Mach 1 All Terrain Oper
160. vered equipment may not necessarily match that shown Pierce Airrow Series Operator s Manual Support 219 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 Warranty 220 Pierce Airrow Series Operator s Manual 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 wil
161. w blueprints or other plans and make sure you have taken bore enlargement during backreaming and pullback into account Check for information about existing or planned structures elevations or proposed work that may be taking place at the same time Notify One Call Services Call area One Call or similar services and have existing lines located and marked Call any utilities in your area that do not subscribe to One Call Examine Pullback Material Ask for a sample of the material you will be pulling back Check its weight and stiffness Contact the manufacturer for bend radius 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 66 JT4020 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 e obstacles such as buildings railroad crossings or streams Signs of utilities See Inspect Jobsite on page 68 e traffic access e Soil type and condition e water supply Sources of locator interference rebar railroad tracks etc

Ditch Witch JT4020 Mach1/All Terrain Operators Manual

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