Home

Ditch Witch JT520 Operators Manual

1. 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 CMW JT520 Operator s Manual Downhole Tools Backream Fluid Requirements Systems and Equipment 105 Backreaming is only successful when enough fluid reaches the bore The amount of fluid needed depends on size of bore and soil condition Follow these steps to find the minimum amount of fluid needed in perfect conditions IMPORTANT Use more fluid than recommended or the backream might be dry and unsuccessful Instructions Example 1 Find amount of fluid needed for your size of backreamer See the table on the next page U S A 6 backreamer requires at least 1 47 gal ft Metric A 152 mm backreamer requires at least 18 24 2 Multiply this number by distance per minute you plan to backream The answer is an estimate of amount of fluid you will need for each minute of backreaming U S 1 5 gal x 2 ft min gal for ea
2. 109 e Use Drill Pipe Correctly 111 CMW JT520 Operator s Manual Systems and Equipment 87 Anchor System Anchor System AWARNING Drive Anchor 1 Use anchor control to drive anchor into ground 2 Anchor is set when cap 1 rests firmly on centering tube 2 Remove Anchor Use anchor control to slowly remove anchor shaft from ground j25om009h eps CMW Systems and Equipment 88 JT520 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 Z 41 1991 when tested at 14 000 volts Tuck legs of pants completely inside boots Gloves must have 17 000 AC maximum use voltage according to ASTM specification D120 87 If working around higher voltage use gloves and boots with appropriately higher ratings NOTICE The strike system does not prevent electric strikes or detect strikes before they occur If alarms are activated a strike has already occurred and equipment is electrified Read and follow Electric Jobsite Precautions on page 49 Review safety procedures before each job FCC Statement This device complies with Part 15 of the FCC Rul
3. 48 Select a 48 Apply Precautions zia p meia 49 Plan Bore Path 50 e Recommended Bend 51 Entry nnde nex ed oko eek n 53 e Minimum 53 Minimum 54 e Bore Path 54 CMW Prepare 44 JT520 Operator s Manual Prepare 55 Mark Bore Patli 4 eee ER ah t eR 55 Prepare Entry 55 Check Supplies and Prepare Equipment 56 Check 56 Prepare 57 Assemble Accessories 57 CMW 520 Operator s Manual Prepare 45 Gather Information Gather Information A successful job begins before the bore The first step in planning is reviewing information already available about the job and jobsite Review Job Plan Review blueprints or other plans and make sure you have taken bore enlargement during backreaming and pullback into account Check for information about existing or planned structures elevations or proposed work
4. gt bL li 00 286 readings in degrees Farenheit and degrees Centigrade CMW Controls 34 4 520 Operator s Manual 750 752 Display Item Description Notes 2 Pitch slope indicator and percentage indicator 7 ME c00ic083h eps Indicates pitch beacon percent of grade Internal shows pipe label and stored pitch External shows desired pitch 3 Roll indicator Indicates beacon roll angle c00ic084h eps 4 Target identifier Indicates approximate Only one set of arrows is active at a indicator beacon location time c00ic085h eps 5 Indicates beacon depth Internal shows job number and cO0icO86h eps Depth estimate estimate stored depth External shows desired depth CMW JT520 Operator s Manual Controls 35 750 752 Display Item Description Notes 6 Display battery status Indicates display power from If all five bars are not showing check indicator drilling unit display power connections mm 00 087 See beacon instruction sheet Indicates beacon battery 7 Beacon battery status status indicator cO0ic088h eps Indicates beacon 8 Beacon temperature temperature indicator 00 089 5 See beacon instruction sheet 8 CMW Controls 36
5. 88 e Assemble Voltage Detector 89 e Test Strike System 89 e Troubleshoot Strike System 90 e Use Electric Strike Simulator 92 Drilling Fluid 94 iere dew Re E Ru e Re VR a 94 Polymer ere Eq dod qe edu dus 94 Bentonite eco ete RN E 95 MIXIUEGS kx e 95 Basic Fluid Recipes 96 e Drilling Fluid Requirements 97 Funnel Viscosity eessen cree sb SOEUR pr e 98 Tracker Control 99 ie I EUR eR en mace 99 s Operation eigen ed us 99 CMW Systems and Equipment 86 JT520 Operator s Manual Downhole Tools 102 zA MEE E ER 102 a ROOM DLP ERE RR UD 102 jiBeacon Housings nier vei RESTE RAE BER 103 Backreamers uos n ERR PEE LEER 104 e Backream Fluid Requirements 105 Quick Wrench 107 Drill Pipe rester qute e 109 e Perform Regular Drill Pipe
6. Change Fuel Filter Initial pa B Replace filter shown after 50 hours j250m026h eps 3 CMW JT520 Operator s Manual 50 Hour Check and Adjust Fan Belt Tension Check belt tension every 50 hours Belt is properly tensioned when it moves about 1 4 3 8 7 9 mm when pushed at the long span 1 Boom Loosen two alternator bolts shown Adjust position as needed Tighten bolts Check tension Service 129 j25om024h eps CMW Service 130 JT520 Operator s Manual 100 Hour 100 Hour Location Task Notes DRILLING Change engine oil and filter DEO UNIT Lube thrust chain DEO Drilling Unit Change Engine Oil and Filter Normal Service Change engine oil and filter every 100 hours for normal service Drain oil 3 change filter 1 and add 4 2 qt 4 L of DEO at fill 2 IMPORTANT Use oil specified in temperature chart found in Recommended Lubricants Service Key on page 120 Lube Thrust Chain Lube thrust chain with DEO every 100 hours CMW j25om013h eps j250m012h eps JT520 Operator s Manual Service 131 150 Hour 150 Hour Change Fuel Filter Change filter shown every 150 hours j250m026h eps CMW Service 132 JT520 Operator s Manual 250 Hour 250 Hour Location
7. Drilling Fluid System Onboard U S Metric Maximum drilling fluid flow 0 5 gpm 0 18 9 L min Maximum drilling fluid pressure 500 psi 34 5 bar Fluid Capacities U S Metric Fuel tank 10 gal 38L Hydraulic reservoir 8 gal 30L Engine oil including filter 4 2 qt 4L Battery SAE reserve capacity rating 81 min 12V negative ground SAE cold crank rating 0 F 18 525 amps Noise Levels Operator 86 dBA sound pressure per ISO 6394 Exterior 104 dBA sound power per ISO 6393 Specifications are called out according to SAE recommended practices where indicated Specifications are general and subject to change without notice If exact measurements are required equipment should be weighed and measured Due to selected options delivered equipment may not necessarily match that shown CMW Specifications 144 JT520 Operator s Manual CMW JT520 Operator s Manual Support 145 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 w
8. Minimum Setback B1 Setback is the distance from the entry point to where pipe becomes horizontal B1 NOTICE If setback is too small B2 you will B2 exceed bend limits and damage the pipe jO7om008c eps CMW Prepare 54 JT520 Operator s Manual Plan Bore Path Minimum Depth Because you must bend pipe gradually entry pitch and Tua bend limits determine how deep the pipe will be when D1 it becomes horizontal This is called the minimum D2 depth jO7om009c eps To reduce minimum depth D1 reduce entry pitch This also decreases setback increase minimum depth D2 increase entry pitch This also increases setback Bore Path Calculator Entry pitch setback and minimum depth work together with bend limits to determine the bore path To find the setback B and entry pitch A that will take you to the desired minimum depth D use the chart below B S D 07 010 Minimum depth D Entry pitch A Setback B Depth to begin steering S 2 0 0 6 m 18 17 4 5 3 m 0 11 0 28 m 2 4 0 7 m 20 18 8 5 7 0 0 30 m 2 9 0 8 m 22 19 11 6 1 m 1 1 0 33 m 3 1 0 9 m 24 21 2 6 5 m 1 2 0 36 m 3 6 1 1 m 26 22 5 6 8 m 1 3 0 38 m 3 11 1 2 m 28 23 8 7 2 m 1 4 0 41 m 4 5 1 4 m 30 24 11 7 6 m 1 5 0 43 m IMPORTANT Numbers in table based on 70 21
9. Carriage Movement Rotation Direction forward clockwise makeup reverse counterclockwise breakout 1104 CMW JT520 Operator s Manual Assemble Drill String Assemble Drill String Prepare Beacon Housing 1 Select nozzles and bit Conduct a Bore 75 IMPORTANT A variety of nozzles and bits are available to suit your particular job conditions See Downhole Tools on page 102 for more information or contact your Ditch Witch dealer Insert nozzle 2 into beacon housing Attach bit 3 to beacon housing 1 Install beacon following beacon instructions for battery replacement e beacon positioning Install beacon housing lid See Beacon Housings on page 103 Follow beacon instructions to check beacon operation Follow tracker instructions to calibrate beacon Attach EZ Connect to Drill Head j25om045h eps Apply tool joint compound to shoulders and threads and hand tighten pin to pin adapter 4 to beacon Apply tool joint compound to shoulders and threads and hand tighten pin to EZ Connect pin adapter Option A 1 housing 1 2 Use quick wrench to fully tighten joint Hand tighten EZ Connect pin 5 to pin to pin adapter 4 Use quick wrench to fully tighten joint Option B 1 6 2 Use quick wrench to fully tighten joint CMW Conduct a Bore 76 JT520 Operator s Manual Assemble Drill String Attach Transition Sub Use either mach
10. Slow engine to low throttle and slowly back unit down trailer or ramps CMW JT520 Operator s Manual Transport 69 Tow Tow Under normal conditions drilling unit should not be towed If unit breaks down and towing is necessary e Attach chains to indicated tow points facing towing vehicle Disengage track hydraulics for short distances at less than 1 mph 1 6 km h Use maximum towing force of 1 5 times unit weight To disengage track hydraulics 1 Loosen locknut 2 2 Turn screw 1 on each counterbalance valve clockwise until it stops IMPORTANT Be sure to count number of turns 3 Repeat on other track To engage track hydraulics 1 Turn screw 1 on counterbalance valve exactly the same number of turns counterclockwise j25om008h eps Tighten locknut 2 Repeat on other track To attach chains to tow points determine which points are facing towing vehicle f back tow points are facing towing vehicle loop chains through each tow point and bring them together to a central pull point e If front tow points are facing towing vehicle loop chain through tow point and pull straight forward CMW Transport 70 JT520 Operator s Manual Tow CMW JT520 Operator s Manual Conduct a Bore 71 Conduct a Bore Chapter Contents Position Equipment 73 Connect Fluid System 73 Start Sy
11. 1 2 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 92 CMW Systems and Equipment 90 Troubleshoot Strike System JT520 Operator s Manual 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 Defective control module Check drilling unit electric system Check that harness from drilling unit to control modu
12. CMW JT520 Operator s Manual Service 139 As Needed Check Drilling Fluid Pump Check Valve Check fluid pump check valve shown o ring for wear and replace as needed j250m029h eps Check Carriage Slide Bars Check slide bars shown for wear and replace as needed j250m033h eps Replace Fuses Change fuses shown as needed Refer to decal inside panels to identify fuses j250m042h eps CMW Service 140 JT520 Operator s Manual As Needed CMW JT520 Operator s Manual Specifications 141 Specifications ij Dou 1 l S555 5522 BSSSL EN EP v 4 j250m037h eps Dimensions U S Metric L overall machine length 117 in 3m W overall machine width 35 5 in 900 mm H overall machine height 66 5 in 1 7m Operating weight w 150 45 7 m of drill pipe anchoring system
13. JT520 Operator s Manual Set Up Console Controls 21 Item Description Notes 2 Lefttrack control l T 00 147 To move forward push To move backward pull To stop move to center 3 Right track control h 00 148 To move forward push To move backward pull To stop move to center CMW Controls 22 JT520 Operator s Manual Operator s Station Operator s Station Gauges and Indicators j25om039h eps 1 Hydraulic fluid sight glass 5 Engine temperature indicator 2 Glow plug indicator 6 Drilling fluid pressure gauge 3 Hourmeter 7 Fuel gauge 4 Engine oil pressure indicator Item Description Notes 1 Hydraulic fluid sight Displays level of hydraulic Maintain level in center of glass glass fluid CMW JT520 Operator s Manual Operator s Station Controls 23 Item Description Notes 2 Glow plug indicator c00ic477h eps Lights when glow plugs are Operating Wait until light goes off before starting engine 3 Hourmeter c00ic019h eps Displays engine operating time Use engine operating times to schedule service 4 Engine oil pressure indicator c00ic119h eps Indicates engine oil pressure is too low Stop engine and check oil level 5 Engine temperature indicator
14. spindle counterclockwise until joint breaks Disengage auxiliary wrench C 5 Engage breakout wrench 6 Rotate spindle clockwise until wrench flats DP align with pipe flats La j250m010h eps CMW Conduct a Bore 84 JT520 Operator s Manual 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 injure or kill Shut off drill string power when anyone can a 2 be struck by moving or thrown tools Never use pipe wrenches on drill string Ic EN 1 Turn off drilling fluid Move drilling unit throttle control until engine is at low throttle Turn drilling unit engine off Use tracker control to verify that unit is turned off Clean pullback device D Use quick wrench to remove pullback device See Quick Wrench on page 107 CMW JT520 Operator s Manual Systems and Equipment 85 Systems and Equipment Chapter Contents S Anchor 87 s Drive Anchor RE eR Uer dedu cepas e HERE 87 Remove 87 Electric Strike System 88 FCC Statement
15. wv Indicator Check air filter service indicator 1 every 10 hours and change filter as needed See Replace Air Filter on page 132 Press evacuator 2 to expel trapped dust j25om028h eps CMW JT520 Operator s Manual 10 Hour Check Engine Oil Level While engine oil is warm move carriage to front of drill frame and check oil level at dipstick 1 every 10 hours Add DEO at fill 2 as necessary to keep oil level at highest line on dipstick Service 123 j250m014h eps CMW Service 124 JT520 Operator s Manual 10 Hour Check Hydraulic Hoses WARNING Check hydraulic hoses for leaks every 10 hours 1 1 CheckHoses eps CMW JT520 Operator s Manual Service 125 10 Hour Check Hydraulic Fluid Level Check hydraulic fluid level every 10 hours Maintain fluid level at halfway point on sight glass 2 when engine is off and fluid is cool Add THF at hydraulic fluid fill 1 as necessary und LIP Check Coolant Level bo Check coolant level every 10 hours Add coolant as needed to maintain as shown on overflow bottle E j250m031h eps Che
16. 14 9 m 7 33 1 10 1 m 8 4 2 5 19 68 1 20 8 m 53 8 16 4 m 8 37 4 11 4 m 10 9 3 3 m 20 69 1 21 1 m 58 6 17 8 m 9 41 5 12 6 m 19 7 4 1 m 21 69 8 21 2 m 63 4 19 3 m 10 45 3 13 8 m 16 7 5 1 m 22 69 11 21 3 m 68 4 20 8 m 11 48 11 14 9 m 19 11 6 1 m 23 70 0 21 4 m 70 0 21 3 m 12 52 4 15 9 23 6 7 2 m 70 21 34 j250m038h eps Pipe 13 is illustrated CMW JT520 Operator s Manual Prepare 53 Plan Bore Path Entry Pitch Entry pitch is the slope of the drill frame compared with the slope of the ground Determine entry pitch one of two ways 1 With Pitch Beacon Lay pitch beacon on the ground and read pitch Lay pitch beacon on drill frame and read pitch 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 H1 C X 100 IMPORTANT A shallow entry pitch A1 allows you 2 to reach horizontal sooner and with less bending SS Increasing entry pitch A2 makes bore path longer and deeper a coe jO7om007c eps
17. Use clean water free of salt calcium or excessive chlorine Use water with pH level between 9 and 10 Use water with hardness of less than 120 ppm Do not use bentonite containing sand e Mix bentonite thoroughly or it will settle in tank Do not mix bentonite to a funnel viscosity of over 50 For information on measuring funnel viscosity see Funnel Viscosity on page 98 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 15 100 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 16 100 gal 23 kg 380 L in rock CMW Systems and Equipment 96 Basic Fluid Recipes 4 520 Operator s Manual Drilling Fluid Soil type Mixture 100 gal 378 L of water Notes fine sand coarse sand 35 Ib 16 kg Bore Gel 35 Ib 16 kg Bore Gel 5 Ib 225 9 No Sag Add 5 Ib 225 g of Quik Trol for additional filtra
18. c00ic274h eps Indicates engine is overheating Stop engine and service unit CMW fo Controls 24 JT520 Operator s Manual Operator s Station Item Description Notes 6 Drilling fluid pressure gauge 00 157 Displays drilling fluid pressure supplied by drilling fluid pump 7 Fuel gauge 00 488 Displays fuel level IMPORTANT Use low sulfur or ultra low sulfur fuel only CMW JT520 Operator s Manual Operator s Station Con trols j25om005h eps Ignition switch Engine throttle control Auxiliary wrench handle Fluid flow control Pipe lubricator control Controls 25 o Carriage control Anchor collar rotation lock control Wrench control Anchor control 10 Auxiliary outlet Item Description Notes 1 Ignition switch cO0icO65h eps To start engine insert key and turn clockwise To stop engine turn key counterclockwise CMW Controls 26 JT520 Operator s Manual Operator s Station Item Description Notes 2 Engine throttle control gt 00 042 increase engine speed push up To decrease engine speed pull down 3 Auxiliary wrench handle 4 Fluid flow control O c00ic449h eps To engage auxiliar
19. 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 If fire cannot be extinguished leave area as quickly as possible and contact emergency personnel CMW JT520 Operator s Manual Chapter Contents Set Up Console 20 Operator s Station 22 Gauges and Indicators 22 ENERO DT 25 Engine Compartment 28 MP t 30 750 752 Display 33 Met opens 33 tet 36 Controls 19 Controls CMW 8 Controls 20 JT520 Operator s Manual Set Up Console Set Up Console j250m004h eps 1 Stabilizer and frame tilt control 3 Right track control 2 Left track control Item Description Notes 1 Stabilizer and frame tilt To raise stabilizer and control decrease frame tilt pull To lower stabilizer and increase frame tilt push Ao 00 287 CMW
20. Power output is 12V 5A CMW Controls 28 JT520 Operator s Manual Engine Compartment Engine Compartment HH i a 6 2 5 lt T gt gt mn 2 j25om040h eps 1 Battery disconnect switch 3 Air filter service indicator 2 Tracker control switch Item Description Notes 1 Battery disconnect To connect turn clockwise switch To disconnect turn counterclockwise ic0251h eps CMW JT520 Operator s Manual Engine Compartment Controls 29 Item Description Notes 2 Tracker control key To allow tracker operator to IMPORTANT Remove key and keep stop thrust and rotation move in tracker operator s possession key to enable position To override tracker control T mode move key to disable oO 9 position right c00icO63h eps 3 Air filter service Indicates when to change air indicator filter Press button to reset indicator after changing filter CMW fo Controls 30 ESID 4 520 Operator s Manual ESID 2 3 J 4 80 4 5 22 ree Ob c W 7 1 8 j070m042h eps 1 Alphanumeric display 5 Current problem indicator 2 Strike indicator 6 OK indicator 3 Alarm interrupt button 7
21. cold start driving and shutdown EN Transport 63 procedures for lifting hauling and towing Conduct a Bore 71 procedures for drilling and backreaming my Systems and Equipment 85 amp NS downhole tools and drill pipe anchor electric strike tracker control and fluid Systems Complete the Job 113 procedures for restoring the jobsite and rinsing and storing equipment e 4 Service 117 service intervals and instructions for this machine including lubrication replacement of wear items and basic maintenance a CMW Contents 8 JT520 Operator s Manual Support 145 the warranty policy for this machine and procedures for obtaining warranty consideration and training CMW JT520 Operator s Manual Chapter Contents lt 10 Safety Alert Classifications 11 Safety 12 Emergency Procedures 15 Electric Strike lt 15 If an Electric Line is Damaged 16 If a Gas Line is Damaged 17 If a Fiber Optic Cable is 18 If Machine Catches on 18 Safety 9 Safety CMW Safety 10 4 520 Operator s Manual Guidelines Guidelines Follow these guidelines before
22. 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 54 and use these measurements to help plan your bore CMW JT520 Operator s Manual Prepare 51 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 JT520 drill pipe make sure pitch A changes no more than 7 over the full length of each pipe jO7om003c eps NOTICE Bending drill pipe more sharply than recommended will damage pipe and cause failure over
23. 3 4 4 4 Glacier bit 4 4 4 3 1 2 4 Rhino bit 4 4 3 3 1 1 3 Jetting assembly 4 4 3 2 1 2 3 Rockmaster 4 4 3 2 1 1 1 Talon Rock bit 4 3 2 1 1 1 4 CMW JT520 Operator s Manual Systems and Equipment 103 Downhole Tools Soil Description sandy soil sugar sand blow sand or other soils where sand is the predominant component soft soil sandy loam medium soil loams loamy clays 4 hard soil packed clays gumbo all compacted soils rocky soil chunk rock glacial till cobble rip rap gravel soft rock soft limestone sandstone shale coral caliche hard rock granite schist marble hard limestone Installation Remove all paint from mating surfaces before attaching any bit to housing Install screws p n 107 277 and tighten bolts to 120 163 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 CMW Systems and Equipment 104 JT520 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 1 4 not recommended
24. 3 m minimum bend radius beacon housing EZ Connect connector transition sub and 1 3 of first drill pipe L totaling 5 1 5 m in the ground before steering CMW JT520 Operator s Manual Prepare 55 Prepare Jobsite Prepare Jobsite Mark Bore Path Mark your planned bore path and all located utility lines with flags or paint Prepare Entry Point For bore to be successful first pipe must be straight as it enters the ground To help ensure that the first pipe does not bend dig a small starting hole so that the first pipe is drilled into a vertical surface To prevent bending or straining pipe position drilling 07 011 unit for straight entry CMW Prepare 56 JT520 Operator s Manual Check Supplies and Prepare Equipment Check Supplies and Prepare Equipment Check Supplies e receiver transmitter or tracker with spare batteries beacons with new and spare batteries e two way radios with new and spare batteries e quick wrench see page 107 transition sub e anchoring equipment and accessories bits screens nozzles see page 102 adapters pipe beacon housings marking flags or paint e water and additional hoses e fuel Use low sulfur or ultra low sulfur fuel only drilling fluid additives see page 94 spare fuses keys backreamers swivels pulling devices see page 102 wash down hose and spray gun duct tape Spray lubric
25. Gel dry powder bentonite p n 259 804 e E Z Mud liquid polymer p n 259 805 Liqui Trol liquid polymer suspension p n 259 808 e Quik Trol M 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 CMW JT520 Operator s Manual Systems and Equipment 95 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 S e Some things to remember when mixing bentonite
26. 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 A 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 CMW Prepare 50 JT520 Operator s Manual Plan Bore Path Plan Bore Path Plan the bore path from entry to end before drilling begins The Ditch Witch Trac Management System Plus is available for planning your bore path This special software can be run in the field using a laptop computer equipped with Windows 95 or higher operating system See your Ditch Witch dealer for details If not using Trac Management System Plus mark the bore path on the ground with spray paint or flags
27. JT520 Operator s Manual 750 752 Display Controls 107 044 5 3 1 Delete button 4 Roll stop button 2 On Off button 5 Recall button 3 Channel select button 6 Store button IMPORTANT Some items operate differently depending where data is being saved Internal refers to pipe data being saved to 750 Display memory External refers to pipe data being sent to a properly connected laptop computer running a version of Trac Management System software Item Description Notes 1 Delete button To delete current pipe press Previous pipe number will appear in numeric display when data is deleted Second function To delete all jobs in internal logging memory press with Recall button 00 071 2 button To turn on press To turn off press again ERES c00ic112h eps CMW JT520 Operator s Manual 750 752 Display Controls 37 Item Description Notes 3 Channel select button CH SEL c00ic073h 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 last channel used each time unit is turned on IMPORTANT Make sure display and tracker are set to the same channel 4 Roll stop button c00ic074h eps 5 Recall button c00ic075h
28. Task Notes DRILLING Change hydraulic fluid filter UNIT Replace air filter Drilling Unit Change Hydraulic Fluid Filter Change filter shown every 250 hours Change more often if indicated by filter indicator j250m020h eps Replace Air Filter Replace filter elements every 250 hours and when indicated by air filter service indicator 1 Open air filter case 2 Remove paper element 3 and safety element 2 Wipe inside of case and wash end cup Install new elements in case Reset air filter service indicator 1 ___ j250m027h eps CMW JT520 Operator s Manual Service 133 750 Hour 750 Hour Change Drilling Fluid Pump Oil o 0 Change fluid pump oil every 750 hours Drain at plug 2 and add with EO oil at plug 1 Maintain fluid level at fill plug Capacity for pump is 1 qt 0 9 L Z AIT 1 2 j25om021h eps CMW Service 134 JT520 Operator s Manual 1000 Hour 1000 Hour Location Task Notes DRILLING Change rotation gearbox oil MPL UNIT Change hydraulic fluid and filter THF Drilling Unit Chan
29. and 2980 Ib 1352 kg anchor UFE Pipe U S Metric Length 59 1 in 1 5m Joint diameter 1 75 in 44 5 mm Tubing diameter 1 1 in 28 mm Minimum bend radius 70 ft 21 3m Weight 16 Ib 7 3 kg CMW Specifications 142 4 520 Operator s Manual Operational U S Metric Maximum spindle speed 195 rpm 195 rpm Spindle torque makeup 500 ft Ib 678 Spindle torque breakout 600 ft Ib 813 Thrust force 4500 Ib 20 kN Pullback force 5000 Ib 22 2 kN Carriage travel speed 142 fpm 43 3 m min Minimum bore diameter 2 5 in 89 mm Backream diameter soil dependent variable variable Ground travel speed forward 0 1 5 mph 0 2 5 km h reverse 0 1 5 mph 0 2 5 km h Ground bearing pressure 6 5 psi 46 kg cm2 Power U S Metric Engine Kubota D1105 T diesel Use low sulfur or ultra low sulfur fuel only Number of cylinders 3 Displacement 68 5 in 1 12L Bore 3 07 in 78 mm Stroke 3 09 in 78 4 mm Manufacturer s gross power rating per SAE J1955 32 8 hp 24 5 kW Estimated net power rating per SAE 1348 31 5 hp 23 5 kW Rated engine speed 3000 rpm 3000 rpm Maximum tilt angle fore and aft 30 30 Maximum tilt angle side to side 30 30 Exceeding these operating angles will cause engine damage This DOES NOT imply that the machine is stable to maximum angle of safe engine operation CMW JT520 Operator s Manual Specifications 143
30. hazards and classify jobsite See Classify Jobsite on page 48 6 mum CMW JT520 Operator s Manual Prepare 47 Inspect Site Select Start and End Points Select one end to use as a starting point Consider the following when selecting a starting point Slope Fluid system should be parked on a level site Consider how slope will affect drilling unit setup bending pipe and fluid flow out of hole Traffic Vehicle and pedestrian traffic must be a safe distance from drilling equipment Allow at least 10 3 m buffer zone around equipment Space Check that starting and ending points allow enough space for gradual pipe bending See Minimum Setback on page 53 Check that there is enough space to work and to set up electric strike system Comfort Consider shade wind fumes and other site features Drill downhill when possible so fluid will flow away from drilling unit CMW Prepare 48 Classify Jobsite Inspect Jobsite 4 520 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 your local One Call 811 in USA or the One Call referral number 888 258 0808 in USA and Canada to have underground utilities located before digging Also contact any utilities that do not participate in the One Call service Inspect jobsite and perimeter for evidence of underground hazards su
31. operating any jobsite equipment Complete proper training and read operator s manual before using equipment Contact your local One Call 811 in USA or the One Call referral number 888 258 0808 in USA and Canada to have underground utilities located before digging Also contact any utilities that do not participate in the One Call service Classify jobsite based on its hazards and use correct tools and machinery safety equipment and work methods for jobsite Mark jobsite clearly and keep spectators away Wear personal protective equipment Review jobsite hazards safety and emergency procedures and individual responsibilities with all personnel before work begins Safety videos are available from your Ditch Witch dealer Replace missing or damaged safety shields and safety signs Use equipment carefully Stop operation and investigate anything that does not look or feel right Do not operate unit where flammable gas may be present Contact your Ditch Witch dealer if you have any question about operation maintenance or equipment use CMW JT520 Operator s Manual Safety 11 Safety Alert Classifications Safety Alert Classifications These classifications and the icons defined on the following pages work together to alert you to situations which could be harmful to you jobsite bystanders or your equipment When you see these words and icons in the book or on the machine carefully read and follow all instructions YOUR SAFETY I
32. 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 CMW 4 520 Operator s Manual Systems and Equipment 107 Quick Wrench Quick Wrench To attach or remove downhole tools use quick wrench to join or break the joint Aa Moving tools will injure or kill Shut off drill string power when anyone can e d 2 be struck by moving or thrown tools Never use pipe wrenches on drill string Lo EN IMPORTANT Apply TJC to threads and hand tighten joint before attaching quick wrench components to tighten joint Attach quick wrench in either the join or break position QuickWrench_JoinBreak eps Join Break Place jaws 1 on wrench flats on both sides of joint Pin handles 3 to wrench jaws Be sure handles are both up Attach pivot nuts 4 to wrench handles so that screw drive handle 5 is over joint CMW Systems and Equipment 108 JT520 Operator s Manual Quick Wrench To Join 1 Scribe straight line across joint on both sides of separating line A 2 Scribe second line B on moveable side of j
33. 50m011h eps 1 Remove yellow cylinder lock from storage at rear of pipe box and place over extended cylinder rod shown with curved ends toward stabilizer shoe 2 Raise stabilizer to lower unit until load is supported by cylinder lock CMW Service 120 4 520 Operator s Manual Recommended Lubricants Service Key Recommended Lubricants Service Key Item Description 6 DEO Diesel engine oil meeting API service classification CF 4 or E1 96 and SAE viscosity recommended by engine manufacturer SAE 15W40 Engine oil SAE 10W30 Multipurpose grease meeting ASTM 0217 NLGI 5 MPL Multipurpose gear oil meeting API service classification GL 5 SAE 80W90 DEAC Diesel engine antifreeze coolant meeting 05345 prediluted 04985 concentrate 5 THF Tractor hydraulic fluid similar to Phillips 66 HG Mobilfluid 423 Chevron Tractor Hydraulic Fluid Texaco TDH Oil or equivalent TJC Tool joint compound Ditch Witch standard p n 259 858 or summer grade 256 031 b Check level of fluid or lubricant Check condition v sue Filter Co 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 Capaciti
34. Electrical power supply indicator 4 Voltage problem 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 CMW JT520 Operator s Manual ESID Controls 31 Item Description Notes 2 Strike indicator A OOOOOOC ON 00 077 Red lights come 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 limits 3 Alarm interrupt button RN b c00ic078h eps To turn off strike alarm at drilling unit press 4 Voltage problem indicator f c00ic078h eps 5 Current problem indicator c00ic080h eps Blinking red light indicates a voltage indicator problem Blinking red light indicates a current indicator problem See Troubleshoot Strike System on page 90 See Troubleshoot Strike System on page 90 CMW Controls 32 JT520 Opera
35. JT520 Operator s Manual C CMW Issue 1 1 053 1219 JT520 Operator s Manual Overview 1 Overview Chapter Contents Serial Number Location 2 Intended lt 3 Unit Components 3 Operator 4 About This 4 Bulleted 4 Numbered aout elected d gata a e datio 4 4 CMW Overview 2 JT520 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 j25om001h eps Item date of manufacture date of purchase drilling unit serial number trailer serial number engine serial number CMW JT520 Operator s Manual Overview 3 Intended Use Intended Use gt The JT520 is a self contained horizontal directional drilling unit designed to install buried cable and pipe at distances to 150 45 7 m depending on soil conditions and is intended for operation in ambient temperatures from 0 to 115 18 to 46 C Use in any other way is considered contrary to t
36. JT520 Operator s Manual Assemble Backream String Assemble Backream String DANGER 1 Select backreaming devices See Backreamers on page 104 2 Determine fluid rate requirements and install appropriate nozzles to provide sufficient flow See Backream Fluid Requirements on page 105 and Nozzles on page 102 Attach backreamer to backream beacon housing if tracking backream Install beacon following beacon instructions for battery replacement beacon positioning Install beacon housing lid See Beacon Housings on 103 Follow beacon instructions to check beacon operation Follow tracker instructions to calibrate beacon Connect EZ Connect joint or use quick wrench to attach backreamer beacon housing assembly to transition sub See Quick Wrench on page 107 9 Attach swivel and additional pullback devices or product to end of backreamer beacon housing assembly CMW JT520 Operator s Manual Conduct a Bore 83 Remove Pipe Remove Pipe 1 When pipe joint is between front wrench and pipe wiper release joystick Engage front wrench Rotate spindle clockwise until wrench flats engage into pipe flats Boom Rotate counterclockwise until upper joint breaks If joint does not break at spindle use auxiliary wrench shown Engage auxiliary wrench 1 e Rotate spindle counterclockwise until wrench flats engage into pipe flats
37. S 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 better job or make your job easier in some way CMW Safety 12 4 520 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 death Provide ventilation DANGER Moving tools will kill or injure Shut off drill string power when anyone can be struck by moving or thrown tools Never use pipe wrenches on drill string e Jobsite hazards could cause death or serious injury Use correct equipment and work methods Use and maintain proper safety 5 e
38. See Specifications on page 141 or measure and weigh equipment before lifting 1 Attach chains to four lift points two on each side of drilling unit 2 Attach each chain securely to cross members IMPORTANT Length of spreader bars should be equal to width of drilling unit 3 Bring chains together to a central pull point CMW Transport 66 JT520 Operator s Manual Haul Haul Load A WARNING 2 Start drilling unit engine Move drilling unit to rear of trailer and align with ramps Slow engine to low throttle and slowly drive unit onto trailer Lower stabilizer to trailer floor Stop engine when unit is safely positioned on trailer bed Attach tiedowns to drilling unit where indicated on page 67 CMW JT520 Operator s Manual Transport 67 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 WARNING Incorrect procedures could result in death injury or property damage Learn to use equipment correctly Loop tiedowns around rear tiedown points Use D ring or pin to trailer using hole in floor plate Make sure tiedowns are tight before transporting j25om007h eps CMW Transport 68 JT520 Operator s Manual Haul Unload WARNING 2 Lower ramps Remove tiedowns Start drilling unit engine Raise stabilizer
39. an injure or kill Many work related electrocutions result from contact with less than 440 volts Most electric strikes are not noticeable but indications of a strike include power outage smoke 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 JT520 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 e 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 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 falarm does not sound but all lights in strike indicator are on assume strike is continuing a
40. and deliberately This will help prevent thread crossing galling and shoulder swelling Torque joints fully Once the joint is connected and the shoulder faces are touching torque them to full machine torque Improperly torqued joints will damage the shoulder faces and threads and will cause joints to leak or break while drilling or backreaming Do not Overwork the Pipe Never exceed the bend radius for your pipe See Recommended Bend Limits on page 51 Do not oversteer NOTICE Bending pipe more sharply than recommended will damage pipe and cause failure CMW Systems and Equipment 112 4 520 Operator s Manual Drill Pipe CMW JT520 Operator s Manual Complete the Job 113 Complete the Job Chapter Contents Antifreeze Drilling Unit 114 Add Antifreeze 114 Reclaim Antifreeze 114 Rinse Equipment 115 Disconnect 115 Stow ToolS 115 CMW Complete the Job 114 JT520 Operator s Manual Antifreeze Drilling Unit Antifreeze Drilling Unit Your drilling unit can be left overnight in freezing conditions by circulating a polyproplyene based antifreeze p n 265 644 through optional antifreeze system before shutdown Add Antifreeze 1 Fill antifreeze tank with 1 gal 4 L of approved antifreeze 2 Move carriage to front of
41. ant tool joint compound see page 120 electrically insulating boots and gloves personal protective equipment such as hard hat and safety glasses e notepad and pencil CMW JT520 Operator s Manual Check Supplies and Prepare Equipment Prepare Equipment Fluid Levels fuel Use low sulfur or ultra low sulfur fuel only hydraulic fluid engine coolant battery charge engine oil Condition and Function filters air oil hydraulic fluid pump couplers tires and tracks pumps and motors drilling fluid mixer hoses and valves water tanks Assemble Accessories Fire Extinguisher Prepare 57 If required mount a fire extinguisher near the power unit but away from possible points of ignition The fire extinguisher should always be classified for both oil and electric fires It should meet legal and regulatory requirements CMW Prepare 58 JT520 Operator s Manual Check Supplies and Prepare Equipment CMW JT520 Operator s Manual Drive 59 Drive Chapter Contents Start Unit aca daw been dae Ree GARA A RR d 60 Steer Unit 1x xam RSE EAS AC x A ERE EUR 60 Shut Down Unit 61 CMW Drive 60 JT520 Operator s Manual Start Unit Start Unit 1 Insert key 2 Turn key clockwise See page 25 for more information 3 Run engine at low throttle for 5 minutes Steer Unit To steer drilling unit follow instructions for type of steering desired See page 20 f
42. arranty consideration Resources Publications Contact your Ditch Witch dealer for publications and videos covering safety operation service and repair bes of your equipment Ditch Witch Training For information about on site individualized training contact your Ditch Witch dealer CMW Warranty 146 JT520 Operator s Manual Warranty Ditch Witch Equipment and Replacement Parts Limited Warranty Policy Subject to the limitation and exclusions herein free replacement parts will be provided at any authorized Ditch Witch dealership for any Ditch Witch equipment or parts manufactured by The Charles Machine Works Inc CMW that fail due to a defect in material or workmanship within one 1 year of first commercial use Exception 2 years for all SK5 attachments Free labor will be provided at any authorized Ditch Witch dealership for installation of parts under this warranty during the first year following initial commercial use of the serial numbered Ditch Witch equipment on which it is installed The customer is responsible for transporting their equipment to an authorized Ditch Witch dealership for all warranty work Exclusions from Product Warranty All incidental or consequential damages All defects damages or injuries caused by misuse abuse improper installation alteration neglect or uses other than those for which products were intended defects damages or injuries caused by improper training ope
43. ation instructions to help you use and maintain your Ditch Witch equipment Read this manual before using your equipment Keep it with the equipment at all times for future reference If you sell your equipment be sure to give this manual to the new owner If you need a replacement copy contact your Ditch Witch dealer If you need assistance in locating a dealer visit our website at www ditchwitch com or write to the following address The Charles Machine Works Inc Attn Marketing Department PO Box 66 Perry OK 73077 0066 USA The descriptions and specifications in this manual are subject to change without notice The Charles Machine Works Inc reserves the right to improve equipment Some product improvements may have taken place after this manual was published For the latest information on Ditch Witch equipment see your Ditch Witch dealer Thank you for buying and using Ditch Witch equipment CMW Foreword 6 JT520 Operator s Manual JT520 Tier 4i Operator s Manual Issue number 1 1 OM 10 08 Part number 053 1219 Copyright 2008 by The Charles Machine Works Inc Ditch a Eq Witch TT Ditch Witch CMW AutoCrowd Jet Trac Roto Witch Subsite Fluid Miser Power Pipe Super Witch Pierce Airrow The Underground The Underground Authority Worldwide and Zahn are registered trademarks of The Charles Machine Works Inc 9 This product is covered by or more of the following pate
44. cause snaking This can damage pipe and will make drilling and pullback more difficult Begin to straighten out of each correction as early as possible Do not push an entire piece of drill pipe into ground without rotation This can exceed bend radius and cause pipe failure Procedure 1 Locate drill head Take readings available with your beacon and locating equipment such as depth e pitch left right information e temperature e beacon roll Compare position to bore plan Determine direction drilling should go Position drill head Push in drill pipe as needed to change direction ox 9 29 Rotate in remaining length of drill pipe CMW Conduct a Bore 80 JT520 Operator s Manual Record Bore Path Drill Head Position The drill head position is determined by reading beacon roll Roll is displayed as a clock face Ty 2 aa position __ 1 Read beacon roll 2 Slowly rotate pipe until locator displays desired beacon roll jO7om048c eps To change direction 1 Rotate pipe to clock position you intend to travel 2 Push pipe into ground To move forward without changing direction Rotate pipe into ground Record Bore Path Locate drill head every half length of pipe As the job is completed record the actual data for each drill pipe List pitch and depth of each joint and a brief description of the procedure In addition draw a simple sketch of the site and recor
45. ccess Contact your Ditch Witch dealer for information on testing water selecting additives and mixing drilling fluid e Backreaming requires more fluid than drilling Make sure enough fluid is used CMW Operation Overview 42 JT520 Operator s Manual Leaving Jobsite Leaving Jobsite 1 Remove downhole tools See page 84 Remove anchors See page 87 Rinse unit and downhole tools See page 115 Disassemble strike system and disconnect from fluid system See page 115 Stow tools See page 115 Rom Load unit onto trailer See page 66 Storing Equipment 1 For cold weather storage antifreeze drilling unit See page 114 2 Forlong term storage disconnect battery disconnect switch CMW JT520 Operator s Manual Prepare 43 Chapter Contents Gather Information 45 e Review Job 45 e Notify One Call 45 e Examine Pullback 45 e Arrange for Traffic 45 e Plan for Emergency Services 45 Inspeet SUG 46 Identify Hazards 46 e Select Start and End Points 47 Classify 48 Inspect Jobsite
46. ch 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 concrete sand or granite which is capable of producing crystalline silica quartz dust crystalline silica quartz dust within 10 3 m of any other hazard other NOTICE If you have any doubt about jobsite classification or if jobsite might contain unmarked hazards take steps outlined previously to identify hazards and classify jobsite before working CMW JT520 Operator s Manual Prepare 49 Classify Jobsite Apply Precautions Once classified precautions appropriate for jobsite must be taken Electric Jobsite Precautions In addition to using a directional drilling system with an electric strike system use one or both of these methods Expose line by careful hand digging or soft excavation Use beacon to track bore path
47. ch minute of backreaming Metric 18 L x 5 m min 9 L for each minute of backreaming IMPORTANT After you have determined how much fluid you will need see your Ditch Witch dealer for nozzle recommendations CMW Systems and Equipment 106 JT520 Operator s Manual Downhole Tools Backream Fluid Requirements Backreamer product Gal ft L m Backreamer product Gal ft L m diameter diameter 5 in 13 mm 0 01 0 13 13 5 in 343 mm 7 44 92 35 1in 25 mm 0 04 0 51 14 356 8 00 99 31 1 5 38 0 09 1 14 14 5 368 8 58 106 54 2 51 0 16 2 03 15 381 9 18 114 01 2 5 64 0 25 3 17 15 5 394 9 80 121 74 76 0 37 4 56 16 406 10 44 129 72 3 5 in 89 mm 0 5 6 21 16 5 in 419 mm 11 11 137 95 4 in 102 mm 0 65 8 11 17 432 11 79 146 44 4 5 114 0 83 10 26 17 5 445 12 49 155 18 5 127 1 02 12 67 18 457 13 22 164 17 5 5 139 1 23 15 33 18 5 470 13 96 173 42 6 152 1 47 18 24 19 483 14 73 182 92 6 5 165 1 72 21 41 19 5 495 15 51 192 68 7 178 2 00 24 83 20 in 508 mm 16 32 202 68 7 5 190 mm 2 29 28 50 20 5 in 521 mm 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
48. ck Drilling Fluid Pump Oil Level Check drilling fluid pump oil level every 10 hours Add EO as needed j250m022h eps CMW Service 126 JT520 Operator s Manual 50 Hour 50 Hour Location Task Notes DRILLING Change engine oil and filter Initial service DEO UNIT Change drilling fluid pump oil initial EO Check radiator Change hydraulic filter Initial service Check rotation gearbox oil level 2 gearboxes MPL Check battery Change fuel filter Initial service Check and adjust fan belt tension Drilling Unit Change Engine Oil and Filter Initial 56 Service Change engine oil and filter after 50 hours Drain oil 3 change filter 4 and add 4 2 qt 4 L of DEO at fill 2 IMPORTANT Use oil specified in temperature chart found in Recommended Lubricants Service Key on page 120 amp D gt lt Vi SRA S NS HM 55 j250m013h eps CMW JT520 Operator s Manual Service 127 50 Hour Change Drilling Fluid Pump Oil Initial c Service Change fluid pump oil after first 50 hours and every 750 hours thereafter Drain at plug 2 and add EO at plug 1 Maintain fluid level at fill plug j250m021h eps Check Radiator Check radiator for d
49. ck supplies and prepare equipment See page 56 Load equipment See page 66 Setting Up at Jobsite 1 Prepare jobsite See page 55 Unload drilling unit from trailer See page 68 Assemble drill string See page 75 Position drilling unit and frame See page 73 Assemble strike system See page 88 Anchor drilling unit See page 87 NOOR ODN Calibrate tracker with beacon that will be installed in beacon housing See tracker operator s manual CMW JT520 Operator s Manual Operation Overview 41 Drilling Drilling 1 Start system See page 73 Prime drilling fluid pump See page 73 Engage tracker control if desired See page 99 Drill first pipe See page 77 Record bore path See page 80 Add pipe See page 78 Drill remaining pipes in pipe box and correct direction page 79 as necessary OD Surface drill head See page 81 Backreaming 1 Assemble backream string See page 82 2 Start drilling unit and adjust throttle 3 Set drilling fluid flow Check that fluid flows through all nozzles See page 94 4 Remove pipe from bore See page 83 5 Remove pullback device See page 84 Backreaming Tips e 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 su
50. d rock sand mixture 40 50 Ib 18 23 kg 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 CMW JT520 Operator s Manual Systems and Equipment 97 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 gt 9 e 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 Ib 454 g soda ash 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 CMW Systems and Equipment 98 JT520 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 y
51. d depth and rough location of pullback The Trac Management System Plus is also available for plotting and tracking your bore path It utilizes the 750 Tracker 750 Display a tracking beacon and special software The display can store jobs in its memory or the system can be run in the field using a laptop computer equipped with the Windows 95 or higher operating system See your Ditch Witch dealer for details CMW JT520 Operator s Manual Conduct a Bore 81 Surface Drill Head Surface Drill Head e DANGER Moving tools will injure or kill Shut off drill string power when anyone can lt 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 51 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 Clean drill head especially around threads 6 Disconnect EZ Connect joint or use quick wrench to remove drill head Keep threads clean See Quick Wrench on page 107 CMW Conduct a Bore 82
52. d sharp objects Driving with sidewall edges pressed against hard walls curbs or other objects Driving on slopes e Operating on corrosive materials such as salt or fertilizer Wash immediately CMW JT520 Operator s Manual Drive 61 Shut Down Unit Shut Down Unit 1 Stop track movement 2 Lower drill frame and stabilizer to the ground IMPORTANT If frame and stabilizer cannot be lowered use cylinder locks or other suitable material to block the tracks Remove cylinder locks or chocks before driving unit Run engine at low throttle for 3 minutes to cool Turn key to STOP Remove key CMW Drive 62 JT520 Operator s Manual Shut Down Unit CMW JT520 Operator s Manual Chapter Contents Hg 64 PONS aed rated additam aede epa ie aate 64 Procedure usq et esos rue 65 Haul Rr 66 cU 66 DOWN duse se 67 MS AIO AG Axe ete vu Ui LES 68 ppl e ae 69 Transport 63 Transport CMW Transport 64 JT520 Operator s Manual Lift Lift A WARNING 2 Points Lifting points are identified by lifting decals Lifting at other points is unsafe and can damage machinery ic1319a eps CMW JT520 Operator s Manual Transport 65 Lift Procedure XS 2 j25om006h eps gi Use a crane capable of supporting the equipment s size and weight
53. d slide collar onto pin until retainer bolt hole is visible Lube retainer bolt with tool joint compound install and tighten CMW JT520 Operator s Manual Conduct a Bore 77 Drill First Pipe Drill First Pipe A DANGER m INPS Turn on drilling fluid Visually check for drilling fluid flow Turn drill bit to starting position See Prepare Entry Point on page 55 Slowly move carriage forward See Prepare Entry Point on page 55 Take care to steer to drill straight in line with drilling unit Drill in downhole tools and 1 3 of first pipe before steering Monitor gauges CMW Conduct a Bore 78 JT520 Operator s Manual Add Pipe Add Pipe m 10 11 12 13 14 15 16 17 When joint flats are aligned with front wrench release joystick Engage front wrench Rotate spindle clockwise slowly until wrench flats engage pipe flats Reverse rotation and slowly move carriage back as threads unscrew NOTICE To prevent unnecessary load on threads which can lead to thread wear slowly move carriage back while unscrewing Take next pipe from pipe box and place it inline with saver sub and last pipe Lubricate shoulders and threads Lubricate the saver sub at least every five pipes or when the thread is shiny Connect pipe to saver sub Move carriage forward until saver sub nears male pipe thread e Continue to lower carriage and rotate spindl
54. drill frame Position 1 gal 4 L bucket under spindle Install plug at quick coupler for drilling fluid pump shown 5 Open valve between antifreeze tank and head of drilling fluid pump 6 Turn drilling fluid control fully clockwise to off position 7 Start unit and set throttle to slow position 8 Slowly turn drilling fluid control counterclockwise to start fluid flow 9 Run drilling fluid pump until antifreeze comes out of spindle 10 Turn drilling fluid control fully clockwise to stop flow Reclaim Antifreeze 1 Connect remote fluid system See page 89 Turn on remote fluid system engine Start drilling unit and run at low throttle Move carriage to front of drill frame Position 1 gal 4 L bucket under spindle Turn drilling fluid pump on low speed Turn drilling fluid pump off when drilling fluid comes out of spindle Pour antifreeze into tank IMPORTANT Antifreeze can be removed from antifreeze tank and disposed of properly or it can be reused until it is too diluted with drilling fluid to protect against freezing CMW JT520 Operator s Manual Complete the Job 115 Rinse Equipment Rinse Equipment Spray water onto equipment to remove dirt and mud Some pressure might be needed to remove dried mud from wrench area NOTICE Do not spray water onto operator s console Electrical components could be damaged Wipe down instead Disconnect SS Di
55. e ________ haa 5 Tighten jam nut after adjusting j250m034h eps Replace Fan Belt Replace belt as needed 1 Loosen two alternator bolts shown Adjust position to allow belt to slip off Install new belt Adjust position to tighten belt Tighten bolts Check tension j250m025h eps CMW Service 138 JT520 Operator s Manual As Needed Replace Saver Sub Check saver sub and replace as needed See your Ditch Witch dealer for replacement parts To replace IMPORTANT Saver sub must mate up to every drill pipe Check sub for thread wear If saver sub threads are more worn than pipe threads saver sub is damaging the drill pipe 1 Remove bolt and washer 1 from both ends of shift lever pin 3 2 Remove shift lever pin 3 Remove bolt 2 that attaches back wrench collar to carriage frame 4 Remove back wrench collar and six bolts 4 that attach saver sub to carriage Replace o ring if necessary 6 Install new saver sub in reverse order and tighten six bolts to 15 0 19 j250m032h eps Replace Muffler p Replace muffler shown as needed 14 m o EX Pa j250m036h eps
56. e until pipe screws into saver sub Move carriage forward until front end of pipe is aligned with male thread of last pipe Use machine power to slowly rotate spindle and drill pipe onto male thread Tighten to full machine torque Ensure engine is at full throttle Move fluid control to desired setting to fill pipe with fluid Ensure that 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 Monitor gauges Locate drill head with tracker at least every half length of pipe CMW JT520 Operator s Manual Conduct a Bore 79 Correct Direction Correct Direction Correcting direction is a skill operators gain with experience and knowledge of equipment and soil conditions These instructions cover only basic procedures For information about specific equipment or jobsites contact your Ditch Witch dealer To track progress and make corrections one crew member locates the drill head and sends instructions to the operator Corrections are made by tracking the drill head comparing current position to bore plan and steering drill head as needed Basic Rules Steering ability depends on soil condition bit drill head and nozzle used roll of drill head and distance pushed without outer rotation All corrections should be made as gradually as possible See Recommended Bend Limits on page 51 e Over correcting will
57. elease handle and push tube 1 out Remove caps and insert new tube of TJC Watch for grease to come out of weep hole 2 Unscrew cartridge 2 3 4 Pull handle lock 5 6 Screw cartridge in 7 Release handle 8 Unscrew cartridge 2 3 turns 9 10 out of hole Screw cartridge back in when grease comes P NS E j250m017h eps NOTICE Use only genuine Ditch Witch tool joint compound to maintain warranty See Recommended Lubricants Service Key on page 120 for more information CMW JT520 Operator s Manual Service 137 As Needed Check Track Tension and Condition Check track tension and condition and adjust or replace as needed See your Ditch Witch dealer for replacement parts To adjust turn bolt 1 clockwise to tighten and counterclockwise to loosen Track tension is correct when metal piece is exactly in the middle of cut out window 2 j250m035h eps Adjust Thrust Chain Tension Adjust thrust chain tension as needed om 1 Remove all pipe from pipe box A 2 Move carriage to front of frame T 3 Loosen jam nut shown 4 adjuster bolt clockwise to tighten and 4 counterclockwise to loosen chain Chain is properly adjusted when bottom of chain is 3 8 ERA 1 2 9 13 mm above fram
58. ems and Equipment 110 JT520 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 page 138 for replacement 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 109 Rotate Pipe Order Because the lead drill pipe is in the ground longer it is subjected to higher shock loads and experiences more wear To help spread this wear evenly over all pipe move the lead pipe from the previous job out of the first position See Rotate Pipe Order on page 110 CMW JT520 Operator s Manual Systems and Equipment 111 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 107 034 Make Up and Break Out Joints Correctly up and break out joints slowly Do not ram pipes together during makeup or force them apart during breakout Carefully time rotation with carriage travel speed and always connect and disconnect joints slowly
59. eps This feature is not yet available To 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 CMW 8 Controls 38 4 520 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 appear in numeric display when data is stored IMPORTANT Pipe data cannot be stored without a valid depth estimate CMW JT520 Operator s Manual Operation Overview 39 Operation Overview Chapter Contents 40 Setting Up at Jobsite 40 41 41 Leaving 42 Storing Equipment 42 CMW Operation Overview 40 JT520 Operator s Manual Planning Planning 1 Gather information about jobsite See page 45 Inspect jobsite See page 46 Classify jobsite See page 48 Plan bore path See page 50 Che
60. es on page 143 For more information on engine lubrication and maintenance see your Kubota engine manual NOTICE Use only genuine Ditch Witch parts filters approved lubricants TJC and approved coolants to maintain warranty Use the Service Record on page 149 to record all required service to your machine CMW JT520 Operator s Manual Service 121 Recommended Lubricants Service Key Engine Oil Temperature Chart 20 30 __ 20 t100m043h eps Temperature range anticipated before next oil change Approved Coolant Any coolant is approved for use with this unit However it was filled with John Deere Cool Gard coolant before shipment from factory Add only Cool Gard p n 255 006 or any fully formulated ethylene glycol based low silicate heavy duty diesel engine coolant meeting ASTM specification D5345 prediluted or D4985 concentrate Before using any other kind of coolant completely flush radiator NOTICE Do not mix heavy duty diesel engine coolant and automotive type coolant This will lead coolant breakdown and engine damage CMW Service 122 JT520 Operator s Manual 10 Hour 10 Hour Location Task Notes DRILLING Check engine air filter service indicator UNIT Check engine oil level DEO Check hydraulic hoses Check hydraulic fluid level THF Check coolant level DEAC Check drilling fluid pump oil level Drilling Unit Check Engine Air Filter Service
61. es Operation is subject to the following two conditions 1 this device may not cause harmful interference and 2 this device must accept any interference received including interference that may cause undesired operation The Electric Strike System has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions can cause harmful interference to radio communications Operation of this equipment in a residential area could cause harmful interference which the user will be required to correct at his own expense Changes or modifications not expressly approved in writing by The Charles Machine Works Inc may void the user s authority to operate this equipment CMW JT520 Operator s Manual Systems and Equipment 89 Electric Strike System Assemble Voltage Detector 1 2 Drive voltage stake into ground at least 6 2 m away from any part of system Clip voltage limiter to voltage stake 070 021 Test Strike System If system fails any part of this test see Troubleshoot Strike System on page 90 on the following page Do not drill until test is completed successfully
62. eseuound sew JI V 931715 GALINA JHL NI 6866 0 Anad 99 Od 38 TIIM ADVLSOd AHHZd Z ON LIAH3d SSV IO 18015 TIVIN A1d3H SSANISNGA AMVSS393N 3971504 ON puy eur siu jueuudinbe yoya 10 syuey L seJejui JO sjonpoud uo uoneuuojul Se jueuudinbe 14 uo sejepdn 9AI9991 ejqeue 5141 SN opis Y uo w04 BUY eounos Aue peseuound JI OU SI Yo e peseuound sew JI 3ueudinb3 V eunjeuBis eunjeuBis diusjejeeq uoiM diusjejeeq uoiM SJOQUINN Sseuosseooy sjueuliuoenv SJOQUINN jeues Seuosseooy sjueuiuoepv SJequunN Sseuosseooy sjueuiuoepnv SJequunwN Sseuosseooy sjueuiuo epnv SJOQUNN Sseuosseooy siueuluoenv SJOQUNN Seuosseooy siueuluoenv Jequunw je
63. ge Rotation Gearbox Oil Drain oil at gearbox oil drain 3 every 1000 hours 1 IL Replace drain plug Add MPL at fill plug 1 until oil a is visible at plug 2 Replace fill plug 2 IMPORTANT Drill frame must be level for ei accurate reading LI Eu Change Hydraulic Fluid and Filter Change hydraulic fluid and filter every 1000 hours Drain hydraulic fluid 3 change filter 4 add THF at hydraulic fluid fill 1 and check level at sight glass 2 CMW j250m015h eps j250m018h eps JT520 Operator s Manual 2000 Hour 2000 Hour Change Coolant Drain 2 coolant and add DEAC at fill 1 every 2000 hours Service 135 s j250m030h eps CMW Service 136 As Needed 4 520 Operator s Manual As Needed Location Task Notes DRILLING Change pipe lubricator TJC tube TJC UNIT Check track tension and condition Check thrust chain tension Replace fan belt Replace saver sub Replace muffler Check fluid pump check valve Replace carriage slide bars Replace fuses Drilling Unit Change Lubricator TJC Tube Check pipe lubricator TJC level and change tube as needed To change tube Pull lock handle 3 back R
64. he intended use The JT520 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 j250m002h eps 1 Anchoring system 6 Tracks 2 Auxiliary wrench 7 Spindle 3 Operator s station 8 Drill frame 4 Carriage 9 Front wrench 5 Stabilizer CMW Overview 4 4 520 Operator s Manual Operator Orientation Operator Orientation IMPORTANT Top view of unit is shown 1 Front of unit Right side of unit Rear of unit Boo N Left side of unit About This Manual This manual contains information for the proper use of this machine See the beige Operation Overview pages for basic 3 operating procedures Cross references such as See page 50 will direct you to detailed procedures j210m003h eps Bulleted Lists Bulleted lists provide helpful or important information or contain procedures that do not have to be performed in a specific order Numbered Lists Numbered lists contain illustration callouts or list steps that must be performed in order Continued Indicators indicates that a procedure is continued on the next page CMW JT520 Operator s Manual Foreword 5 Foreword This manual is an important part of your equipment It provides safety information and oper
65. ilable 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 7 05 CMW 6866 0 1194 99 Od 4 5 A9 38 ADVLSOd VINOHVTMO AHHZdd 60 ON SSV IO 15414 Ad1d3H SSANISNG 931715 03110 JHL NI qaniv al AYWSS393N 3971504 ON ede uonog 5 puy eur 8141 eseeld jueuudinbe uoyAA syuey L seJejui JO sjonpoud uo uoneuuojul Se jueuudinbe 14 uo sejepdn 9AI9991 3141 SN pue opis Y uo BU 1no eseejd eounos Aue peseuound OU YoU p
66. ine torque or quick wrench to attach transition sub 2 to beacon housing 1 Machine Torque 1 Apply tool joint compound to shoulders and threads and thread transition sub onto saver sub Align drill pipe flats of EZ Connect box with front wrench of drill frame Start drilling unit engine Use machine power to slowly rotate spindle and transition sub onto EZ Connect box a OI Tighten to full machine torque Quick Wrench 1 Lube joints with TJC 2 Attach quick wrench to the joint in the join position and tighten joint See Quick Wrench on page 107 Connect Drill Pipe Start drilling unit engine Align transition sub in front wrench Load pipe Lubricate shoulders and threads Move carriage forward until saver sub nears male pipe thread Slowly rotate spindle clockwise Carriage will move forward as threads screw together Slowly move carriage forward until pipe end touches end of transition sub To thread pipes together and fully torque joint slowly rotate drill pipe until spindle stops turning o ON DN Open front wrench and move carriage back 10 Turn off engine Engage EZ Connect 1 Apply tool joint compound to shoulders and threads and align hole in EZ Connect collar with tapped hole in EZ Connect box Slide collar onto octagonal barrel and push toward wrench flats Thread tool head EZ Connect pin into EZ Connect box until shoulders are touching Back tool head off one flat an
67. irt grass and other foreign matter every 50 hours Check more often if operating in dusty or grassy conditions Clean fins with compressed air or spray wash IMPORTANT Be careful not to damage fins with high pressure air or water j25om041h eps Change Hydraulic Filter Initial Service 4 1 Change hydraulic filter shown after first 50 hours H 8 e j250m020h eps CMW Service 128 JT520 Operator s Manual 50 Hour Check Rotation Gearbox Oil Level Check rotation gearbox oil level every 50 hours Oil 1 should be visible at plug 2 Add MPL at plug 1 as needed Ei 2 IMPORTANT Drill frame must be level for ET accurate reading L 1 m j25om016h eps Check Battery Keep batteries clean and free of corrosion Apply coat of grease to cable clamps after cleaning In cold weather battery loses some starting ability Closely watch voltmeter for signs of battery discharge If battery will not hold charge see your Ditch Witch dealer for replacement battery IMPORTANT Use battery disconnect switch shown when servicing welding and during long term storage j250m023h eps
68. le is connected Check that cable from drilling unit carries more than 10V 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 Information on screen is visible during self test but not after test is complete LCD contrast is not set properly Contact your Ditch Witch dealer to adjust contrast OK indicator is on but electrical power supply indicator is off Strike system is not getting adequate power from drilling unit Check drilling unit electric system Check that harness from drilling unit to control module is connected Check that harness from drilling unit carries more than 10V Defective control module Have control module checked or replaced Electrical power supply indicator is on but OK indicator is off CMW Problem detected during test Check for error code and have control module checked or replaced Defective control module Have control module checked or replaced JT520 Operator s Manual Electric Strike System Systems and Equipment 91 Problem Possible cause Possible solution Strobe light on drilling unit does not work d
69. n carriage will go off Thrust and rotation will function 5 Remove tracker control key shown Keep in tracker operator s possession 6 Drill and track bore CMW eps oth qe ii 7 CEP hes O mh asl CEN _ j250m044h eps JT520 Operator s Manual Tracker Control Disable Thrust and Rotation 2 3 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 carriage will come on Hydraulic power to thrust and rotation will be disabled IMPORTANT Tracker operator cannot disable thrust and rotation from tracker if tracker control key shown is installed in drilling unit and turned to the disable position See Tracker control key on page 29 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 carriage will go off and thrust and rotation will function If you are not tracking backreamer s path install tracker c
70. nd 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 e 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 JT520 Operator s Manual Safety 17 Emergency Procedures If a Gas Line is Damaged XS A WARNING S A WARNING If you suspect a gas line has been damaged take the following actions The order and degree of action will depend on the situation Immediately shut off engine s if this can be done safely and quickly Remove any ignition source s if this can be done safely and quickly Warn others that a gas line has been cut and that they should leave the area Leave jobsite as quickly as possible Immediately call your local emergency phone number and utility company f jobsite is along street stop traffic from driving near jobsite Do not return to jobsite until given permission by emergency personnel and utility company CMW Safety 18 JT520 Operator s Manual Emergency Procedures If a Fiber Optic Cable is Damaged
71. nts U S B1 4 858 704 4 953 638 5 148 880 5 242 026 5 341 887 5 490 569 5 684 466 5 713 423 5 794 719 5 880 680 5 941 322 6 085 852 6 109 371 6 179 065 6 216 803 6 250 403 6 250 404 6 290 606 6 311 790 6 411 094 6 543 551 6 550 547 6 672 409 6 739 413 6 761 231 6 776 246 6 808 210 6 827 158 6 848 506 6 871 712 RE37 450 RE37 923 RE37 975 RE38 418 AU 689 533 706 544 718 034 755 862 CA 2 156 398 2 217 899 DE 694 17 019 695 29 634 297 01 406 EP 0683845 0674093 0817901 0846841 0927892 FR 674 093 GB 2 309 239 2 312 006 EP674 093 EP846 841 JP 3 458 247 other U S and foreign patents pending CMW JT520 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 39 an overview for completing a job with this machine planning setting up installing product and restoring the jobsite with cross references to detailed procedures Prepare 43 procedures for inspecting and classifying the jobsite planning the installation path and preparing the jobsite for work Drive 59 procedures for startup
72. oint in the opposite direction of tightening action 25 6 mm away from first line Turn handle until second line B meets first A Turn handle opposite direction two turns to relieve pressure 5 Remove quick wrench components j070m071h eps To Break 1 Turn handle until joint is broken 2 Turn handle opposite direction two turns to relieve pressure 3 Remove quick wrench components CMW JT520 Operator s Manual Systems and Equipment 109 Drill Pipe Drill Pipe Perform Regular Drill Pipe Care S e Precondition New Pipe Repeat this procedure three times for each piece of pipe before it is used the first time 1 Hand lubricate entire surface of threads and shoulders of both ends of pipe with copper base tool joint compound See page 120 for correct lubricant Join pipe and tighten joint Break joint Move pipe back to box NOTICE Failure to follow this procedure could result in fused joints Pipe will be damaged or destroyed Lubricate Joints Before Each Use Lubricate threads and shoulders of male joints with copper base tool joint compound This prevents rust and reduces wear on shoulders and threads See page 120 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 CMW Syst
73. ontrol key shown on drilling unit Green tracker control light on drilling unit carriage will go off and thrust and rotation will function Systems and Equipment 101 j250m043h eps j250m044h eps CMW Systems and Equipment 102 JT520 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 1 4 not 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
74. or more information To steer while moving forward move one control slightly more than the other to turn in the desired direction Drilling unit will gradually turn to left or right To steer while moving backward move one control slightly more than the other to turn in the desired direction Drilling unit will gradually turn to left or right For tight steering at low speed one control to reverse and one control to forward to turn in the desired direction Tracks will counter rotate and turn drilling unit in a tight circle Tips to Reduce Track Wear Rubber tracks are best suited at soil based job sites with minimal rock and debris Sharp objects such as gravel steel shards and broken concrete will damage rubber tracks and undercarriage components Excessive operation on concrete or asphalt will shorten track life When storing your machine keep tracks away from rain and direct sunlight Wash tracks daily to remove foreign objects and abrasive soil from sprockets and idler rollers Drive slowly and make wide turns when possible Regularly check undercarriage components sprocket rollers idler for wear and damage Maintain proper track tension See Check Track Tension and Condition on page 137 To prevent premature wear avoid the following e Spinning tracks under heavy load Turning on sharp objects such as stones stumps and debris e Quick turns or spin turns on asphalt or concrete Driving over curbs ledges an
75. ou have a stopwatch available for timing the viscosity 1 Using wash hose and a clean container take a fresh sample of drilling fluid The sample must be at least 1 5 gt 1 4 L 2 With finger over bottom of funnel fill with fluid from the container through the screen until fluid reaches the bottom of the screen 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 CMW JT520 Operator s Manual Systems and Equipment 99 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 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 d
76. quipment 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 CMW JT520 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 A WARNING 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 vehicles wear high visibility clothing post appropriate warning signs CMW Safely 14 Pd ji CMW JT520 Operator s Manual Safety Alerts A WARNING Hot pressurized cooling system fluid could cause serious b
77. ration or servicing of products in a manner inconsistent with manufacturer s recommendations All engines and engine accessories these are covered by original manufacturer s warranty Tires belts and other parts which may be subject to another manufacturer s warranty such warranty will be available to purchaser ALL IMPLIED WARRANTIES NOT EXPRESSLY STATED HEREIN INCLUDING ANY WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY IF THE PRODUCTS ARE PURCHASED FOR COMMERCIAL PURPOSES AS DEFINED BY THE UNIFORM COMMERCIAL CODE THEN THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE FACE HEREOF AND THERE ARE NO IMPLIED WARRANTIES OF ANY KIND WHICH EXTEND TO A COMMERCIAL BUYER ALL OTHER PROVISIONS OF THIS LIMITED WARRANTY APPLY INCLUDING THE DUTIES IMPOSED Ditch Witch products have been tested to deliver acceptable performance in most conditions This does not imply they will deliver acceptable performance in all conditions Therefore to assure suitability products should be operated under anticipated working conditions prior to purchase Defects will be determined by an inspection within thirty 30 days of the date of failure of the product or part by CMW or its authorized dealer CMW will provide the location of its inspection facilities or its nearest authorized dealer upon inquiry CMW reserves the right to supply remanufactured replacements parts under this warranty as it deems appropriate Extended warranties are ava
78. rilling unit 2 Turn off 750 Display 3 Press and hold DOWNLOAD 1 while turning on 750 Display until a four digit code 2 appears Von ee 107 023 CMW Systems and Equipment 100 4 Turn on 750 Tracker and check four digit code If codes on tracker and display match thrust and rotation hydraulics on the drilling unit are enabled If codes on tracker and display do not match adjust tracker code Press and hold fore aft left right button while making the following adjustments Use ON OFF to advance first two digits 1 Use DEPTH to lower first two digits Use up arrow to advance last two digits 2 Use down arrow to lower last two digits Press and hold each button to advance or lower value quickly start sending code from the tracker to the JT520 Operator s Manual Tracker Control 107 024 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 e Check whether the green tracker control light located on carriage is on If it is communication has probably stopped between tracker and display or tracker is set to incorrect code f communication cannot be restored install tracker control key shown in drilling unit Green tracker control light located o
79. rm up IMPORTANT Ensure that mixture of drilling fluid matches drilling conditions Enable tracker control mode if desired See Tracker Control on page 99 Move drilling unit throttle control until engine is at full throttle Move fluid control to desired setting to fill pipe with fluid Prime Drilling Fluid Pump Incorrect procedures could result in death injury or property damage Learn to use equipment correctly NOTICE Failure to prime the drilling fluid pump will cause flow fluctuations which will make it difficult to control the washwand Pressurized fluid or air could pierce skin and cause injury or death Stay away Prime drilling fluid pump each time tank is changed To prime the pump Boo m Fill drilling fluid hose and connect hose to unit Operate mixing transfer pump at full speed for 1 3 minutes to discharge air from system Return mixing transfer pump to normal operating speed and continue the bore If drilling fluid pressure surges are observed repeat step 2 CMW Conduct a Bore 74 JT520 Operator s Manual Operate Carriage Control Operate Carriage Control The thrust rotation control has eight positions which allow the four basic XC functions to be combined The chart below summarizes functions that occur when control is put at a combined position Operator must be in seat for EN control to function 00 452
80. s Manual Electric Strike System To test for current at strike levels 1 2 Put two or three loops through current transformer 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 Voltage Test 1 Systems and Equipment 93 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 to frame Clip other lead to one voltage limiter mount Move simulator switch to voltage and press test button Watch screen and lights above display on strike system All lights should turn on Alarm and strobe should turn on Voltage V should show 90 110 It is normal for simulator voltage levels to drift below strike level When this happens light in triangle should go off and alarm and strobe should stop working If the level drifts above strike level again light alarm and strobe should be turned on again CMW Systems and Equipment 94 JT520 Operator s Manual Drilling Fluid Drilling Fluid For productive drilling and equipment protection use these recommended Baroid products available from your Ditch Witch dealer e Soda ash e Quik
81. sconnect and store the following hoses and cables if used electric strike system voltage stake fluid hose Stow Tools Make sure all quick wrenches bits pullback devices and other tools are loaded on trailer CMW Complete the Job 116 JT520 Operator s Manual Stow Tools CMW JT520 Operator s Manual Chapter Contents Service lt 118 Recommended Lubricants Service Key 120 10 BOUF ERR Rb RI EE E Em E bs 122 DU auus sues Mud 126 100 Hour 130 150 Hour 131 200 HOUN 132 5 133 1000 Hour 134 2000 Hour 136 Needed 136 Service 117 Service CMW Service 118 JT520 Operator s Manual Service Precautions Service Precautions AWARNING Welding Precaution Washing Precaution JT520 Operator s Manual Service 119 Service Precautions Working Under Drilling Unit Crushing weight could cause death or serious injury Use proper procedures and equipment or stay away Before working under area of drilling unit supported by a stabilizer make sure drilling unit is parked on hard surface j2
82. stem 73 Prime Drilling Fluid Pump 73 Operate Carriage Control 74 Assemble Drill String 75 Prepare Beacon Housing 75 Attach EZ Connect to Drill Head 75 Attach Transition Sub 76 Connect Drill Pipe 76 Engage 2 Drill First 77 AGG PIDG e 78 Correct Direction 79 Basic Rules iiu ones kee x aee e x ace eem Pon x aha IEKSA 79 TM 79 Drill Head Position 80 CMW Conduct a Bore 72 JT520 Operator s Manual Record Bore 80 Surface Drill Head 81 Assemble Backream String 82 Remove Pipe 83 Remove Pullback Device 84 CMW JT520 Operator s Manual Conduct a Bore 73 Position Equipment Position Equipment 1 2 Review bore plan and select drilling unit position and fluid unit position See Select Start and End Points on page 47 Move equipment into selected positions Start System 1 Start drilling unit and remote fluid unit Allow both engines to wa
83. te control fine sand below water table 40 Ib 18 kg Bore Gel 75 Ib 340 9 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 9 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 9 Quik Trol of returns 75 Ib 340 No Sag cobble 50 Ib 23 kg Bore Gel Add 5 Ib 225 g of Barolift to reduce loss 75 Ib 340 9 Quik Trol 75 10 340 g 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 9 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 Mu
84. that may be taking place at the same time Notify One Call Services Contact your local One Call 811 in USA or the One Call referral number 888 258 0808 in USA and Canada to have underground utilities located before digging Also contact any utilities that do not participate in the One Call service Examine Pullback Material Ask for a sample of the material you will be pulling back Check its weight and stiffness Contact the manufacturer for bend radius information Check that you have appropriate pullback devices Arrange for Traffic Control If working near a road or other traffic area contact local authorities about safety procedures and regulations Plan for Emergency Services Have the telephone numbers for local emergency and medical facilities on hand Check that you will have access to a telephone CMW Prepare 46 JT520 Operator s Manual Inspect Site Inspect Site Inspect jobsite before transporting equipment Check for the following overall grade or slope changes in elevation such as hills or open trenches obstacles such as buildings railroad crossings or streams Signs of utilities See Inspect Jobsite on page 48 e traffic access Soil type and condition e water supply Sources of locator interference rebar railroad tracks etc Take soil samples from several locations along bore path to determine best bit and backreamer combinations Identify Hazards Identify safety
85. time Changes in pitch must be equally distributed over the length of a pipe Maximum changes in pitch within 1 2 300 600 mm of pipe create sharp bends that will damage pipe Monitor the pitch of each pipe with the 750 752 Display on the operator s console See page 49 Bend Radius JT520 drill pipes have a tested minimum bend radius of 70 21 3 m This means that a 90 degree bend in the bore path has a radius A of 70 21 3 m A requires approximately 110 33 5 m of drill pipe NOTICE Bending drill pipe more sharply than recommended will damage the pipe and cause failure over time Mec B f bend radius is reduced drill pipe life is reduced jO7om078h eps f bend radius is increased drill pipe life is increased IMPORTANT Use the charts on the next page to keep bends within safe limits CMW Prepare 52 JT520 Operator s Manual Plan Bore Path Pipe By Pipe Bend Limits Pipe Forward B Deflection A Pipe Forward B Deflection A C C 1 4 11 1 5 m 0 2 05 m 13 55 5 16 9 m 27 3 8 3 m 2 9 10 3 0 m 0 8 2 m 14 58 4 17 8 m 31 3 9 5 m 3 14 8 4 5 m 177 5 15 60 11 18 6 m 35 5 10 8 m 4 19 5 5 9 m 2 9 8 m 16 632 19 3 m 39 8 12 1 m 5 24 1 7 4 m 4 3 1 8 m 17 65 1 19 9 m 44 4 13 5 m 6 28 8 8 7 m 6 2 1 9 m 18 66 9 20 4 m 48 11
86. tor s Manual ESID Item Description Notes 6 OKindicator cO0icO56h eps Green light means system self test detected no problems Strike system is ready to operate 7 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 NOTICE See If an Electric Line is Damaged on page 16 CMW JT520 Operator s Manual 750 752 Display 750 752 Display Indicators Controls 33 jO70m043h eps 1 Beacon temperature display 2 Pitch slope indicator and percentage indicator 3 Roll indicator 4 Target indentifier indicator ouod Depth estimate Display battery status indicator Beacon battery status 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 connected laptop computer running a version of Trac Management System software Item Description Notes Shows beacon temperature 1 Beacon temperature display
87. trol module Have control module checked or replaced EV1 code displays and voltage problem indicator is on Improper connection of voltage limiter to ground stake Check voltage limiter connection to ground stake and verify that ground stake is driven into the ground Defective voltage limiter Defective control module Have voltage limiter checked or replaced Have control module checked or replaced CMW Systems and Equipment 92 4 520 Operator s Manual Electric Strike System Problem Possible cause Possible solution EV2 code displays and Improper connections with Check cable connection on control voltage problem indicator is control module module on Defective voltage limiter Have voltage limiter checked or replaced Defective control module Have control module checked or replaced Use Electric Strike Simulator Use the Electric Strike Simulator p n 259 506 to test voltage and current sensors on ESID If readings are less than indicated here replace 9V battery in simulator and retest Current Test To test for current at normal levels 1 Thread one lead wire through current transformer Clip ends of lead wires together to make one loop Move simulator switch to current and press test button gt m Watch screen and lights above display on strike system Three or four lights should turn on Current A should show 30 50 in display CMW JT520 Operator
88. ues IPPON Jequunw jeues IPPON JequinN 9po2 JequinN diz ejes diz Ayunog MO Aunog MO xog sseJppy 1 4 xog O d JO sseJppy 1 4 uonuenv uonuenv Auedwos 5 5 uoneuJ0Ju ed j uoneuoJu ed j u231M u231M JT520 Operator s Manual Service Record 149 Service Record Service Performed Date Hours CMW Service Record 150 JT520 Operator s Manual Service Performed Date Hours CMW
89. uring 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 Defective control module 1 Disconnect strobe and connect to external 12V power source 2 If strobe does not work replace it Have control module checked or replaced Strobe light and alarm on drilling unit do not work during total test Improper connections with control module Check connections and wiring harness Defective control module Have control module checked or replaced EC2 code displays and current problem indicator is on Improper connections with control module Check cable connections on control module and current transformer Defective current transformer 1 Disconnect current transformer 2 Check 20 40 ohms from pin 1 to pin 4 20 40 ohms from pin 1 to pin 2 and less than 1 ohm from pin 2 to pin 4 Defective current transformer cable 1 Disconnect cable from transformer and control module 2 Check continuity of cable 3 If continuity is zero or cable is damaged replace Defective con
90. urns 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 JT520 Operator s Manual Safety 15 Emergency Procedures Emergency Procedures e AA WARNING Jobsite hazards could cause death or serious injury Use 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 electric lines will cause death or serious injury Know location of lines and stay away When working near electric cables remember the following Electricity follows all paths to ground not just path of least resistance Pipes hoses and cables will conduct electricity back to all equipment Low voltage current c
91. y wrench lower over wrench flats To disengage raise To increase flow turn counterclockwise To decrease flow turn clockwise To stop flow turn all the way clockwise 5 Pipe lubricator control To apply joint compound a front wrench press pedal IMPORTANT Manually apply joint compound at carriage 6 Carriage control vo PP CA VEA 00 452 To move carriage forward push To move carriage backward pull To rotate spindle counterclockwise breakout move right To rotate spindle clockwise makeup move left 7 Anchor collar rotation lock control To allow anchor collar to rotate freely press pedal To prevent anchor collar rotation release pedal Collar will rotate until pin engages in hole CMW JT520 Operator s Manual Operator s Station Controls 27 Item Description Notes 8 Wrench control i NX c00ic454h eps To clamp front wrench and shut off drilling fluid move toward pipebox To unclamp front wrench move away from pipebox To clamp and rotate rear rotating wrench move toward engine compartment To unclamp rear rotating wrench move toward seat 9 Anchor control c00ic478h eps 10 Auxiliary outlet c00ic448h eps To drive anchor push To remove anchor pull Provides power for other equipment

Ditch Witch JT520 Operators Manual

Contents

Download Pdf Manuals

Related Search

Related Contents