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JT520 Operator’s Manual

Systems and Equipment - 85

CMW

Systems and Equipment

Chapter Contents

Anchor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

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Drive Anchor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

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Remove Anchor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

Electric Strike System . . . . . . . . . . . . . . . . . . . . . . 88

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FCC Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

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Assemble Voltage Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

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Test Strike System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

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Troubleshoot Strike System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

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Use Electric Strike Simulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

Drilling Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

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Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

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Polymer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

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Bentonite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

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Mixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

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Basic Fluid Recipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

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Drilling Fluid Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

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Funnel Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

Tracker Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

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Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

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Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

Summary of Contents for JT520

Page 1: ...JT520 Issue 1 1 Operator s Manual CMW 053 1219...

Page 2: ...tor s Manual Overview 1 CMW Overview Chapter Contents Serial Number Location 2 Intended Use 3 Unit Components 3 Operator Orientation 4 About This Manual 4 Bulleted Lists 4 Numbered Lists 4 Continued I...

Page 3: ...ion CMW Serial Number Location Record serial numbers and date of purchase in spaces provided Drilling unit serial number is located as shown Item date of manufacture date of purchase drilling unit ser...

Page 4: ...om 0 to 115 F 18 to 46 C Use in any other way is considered contrary to the intended use The JT520 can be used with Ditch Witch drilling fluid units and Ditch Witch locating equipment It should be ope...

Page 5: ...es for basic operating procedures Cross references such as See page 50 will direct you to detailed procedures Bulleted Lists Bulleted lists provide helpful or important information or contain procedur...

Page 6: ...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...

Page 7: ...or more of the following patents U S B1 4 858 704 4 953 638 5 148 880 5 242 026 5 341 887 5 490 569 5 684 466 5 713 423 5 794 719 5 880 680 5 941 322 6 085 852 6 109 371 6 179 065 6 216 803 6 250 403...

Page 8: ...ling product and restoring the jobsite with cross references to detailed procedures 39 Prepare procedures for inspecting and classifying the jobsite planning the installation path and preparing the jo...

Page 9: ...cifications including weights measurements power ratings and fluid capacities 141 Support the warranty policy for this machine and procedures for obtaining warranty consideration and training 145 Serv...

Page 10: ...ntents Guidelines 10 Safety Alert Classifications 11 Safety Alerts 12 Emergency Procedures 15 Electric Strike Description 15 If an Electric Line is Damaged 16 If a Gas Line is Damaged 17 If a Fiber Op...

Page 11: ...rds 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...

Page 12: ...levels DANGER WARNING and CAUTION Learn what each level means indicates an imminently hazardous situation which if not avoided will result in death or serious injury indicates a potentially hazardous...

Page 13: ...will cause sickness or death Provide ventilation Moving tools will kill or injure Shut off drill string power when anyone can be struck by moving or thrown tools Never use pipe wrenches on drill strin...

Page 14: ...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 cabl...

Page 15: ...glasses Hot parts may cause burns Do not touch until cool Exposure to high noise levels may cause hearing loss Wear hearing protection Fall possible Slips or trips may result in injury Keep area clea...

Page 16: ...any work related electrocutions result from contact with less than 440 volts Most electric strikes are not noticeable but indications of a strike include power outage smoke explosion popping noises ar...

Page 17: ...ication 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...

Page 18: ...and quickly Warn others that a gas line has been cut and that they should leave the area Leave jobsite as quickly as possible Immediately call your local emergency phone number and utility company If...

Page 19: ...s 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...

Page 20: ...rator s Manual Controls 19 CMW Controls Chapter Contents Set Up Console 20 Operator s Station 22 Gauges and Indicators 22 Controls 25 Engine Compartment 28 ESID 30 750 752 Display 33 Indicators 33 Con...

Page 21: ...W Set Up Console 1 Stabilizer and frame tilt control 2 Left track control 3 Right track control Item Description Notes 1 Stabilizer and frame tilt control To raise stabilizer and decrease frame tilt p...

Page 22: ...Up Console CMW 2 Left track control To move forward push To move backward pull To stop move to center 3 Right track control To move forward push To move backward pull To stop move to center Item Descr...

Page 23: ...ors 1 Hydraulic fluid sight glass 2 Glow plug indicator 3 Hourmeter 4 Engine oil pressure indicator 5 Engine temperature indicator 6 Drilling fluid pressure gauge 7 Fuel gauge Item Description Notes 1...

Page 24: ...s off before starting engine 3 Hourmeter Displays engine operating time Use engine operating times to schedule service 4 Engine oil pressure indicator Indicates engine oil pressure is too low Stop eng...

Page 25: ...ator s Station CMW 6 Drilling fluid pressure gauge Displays drilling fluid pressure supplied by drilling fluid pump 7 Fuel gauge Displays fuel level IMPORTANT Use low sulfur or ultra low sulfur fuel o...

Page 26: ...3 Auxiliary wrench handle 4 Fluid flow control 5 Pipe lubricator control 6 Carriage control 7 Anchor collar rotation lock control 8 Wrench control 9 Anchor control 10 Auxiliary outlet Item Description...

Page 27: ...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 To move carriage fo...

Page 28: ...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 To dri...

Page 29: ...ngine Compartment CMW Engine Compartment 1 Battery disconnect switch 2 Tracker control switch 3 Air filter service indicator Item Description Notes 1 Battery disconnect switch To connect turn clockwis...

Page 30: ...t and rotation move key to enable position up To override tracker control mode move key to disable position right IMPORTANT Remove key and keep in tracker operator s possession 3 Air filter service in...

Page 31: ...urrent problem indicator 6 OK indicator 7 Electrical power supply indicator 8 Self test button Item Description Notes 1 Alphanumeric display Display amount of current and voltage being detected as a p...

Page 32: ...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 To turn off st...

Page 33: ...supply indicator 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 To start manual self test...

Page 34: ...eacon battery status indicator 8 Beacon temperature indicator IMPORTANT Some items operate differently depending where data is being saved Internal refers to pipe data being saved to 750 Display memor...

Page 35: ...s pipe label and stored pitch External shows desired pitch 3 Roll indicator Indicates beacon roll angle 4 Target identifier indicator Indicates approximate beacon location Only one set of arrows is ac...

Page 36: ...splay power from drilling unit If all five bars are not showing check display power connections 7 Beacon battery status indicator Indicates beacon battery status See beacon instruction sheet 8 Beacon...

Page 37: ...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 Not...

Page 38: ...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 This feature is not yet a...

Page 39: ...store current pipe data press Second function To download all jobs stored in internal logging memory Press with Recall button Connect display to PC running Trac Management System software Pipe number...

Page 40: ...JT520 Operator s Manual Operation Overview 39 CMW Operation Overview Chapter Contents Planning 40 Setting Up at Jobsite 40 Drilling 41 Backreaming 41 Leaving Jobsite 42 Storing Equipment 42...

Page 41: ...and prepare equipment See page 56 6 Load equipment See page 66 Setting Up at Jobsite 1 Prepare jobsite See page 55 2 Unload drilling unit from trailer See page 68 3 Assemble drill string See page 75...

Page 42: ...nit 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 Plan...

Page 43: ...ee page 87 3 Rinse unit and downhole tools See page 115 4 Disassemble strike system and disconnect from fluid system See page 115 5 Stow tools See page 115 6 Load unit onto trailer See page 66 Storing...

Page 44: ...Material 45 Arrange for Traffic Control 45 Plan for Emergency Services 45 Inspect Site 46 Identify Hazards 46 Select Start and End Points 47 Classify Jobsite 48 Inspect Jobsite 48 Select a Classifica...

Page 45: ...repare 44 JT520 Operator s Manual CMW Prepare Jobsite 55 Mark Bore Path 55 Prepare Entry Point 55 Check Supplies and Prepare Equipment 56 Check Supplies 56 Prepare Equipment 57 Assemble Accessories 57...

Page 46: ...al 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...

Page 47: ...backreamer combinations Identify Hazards Identify safety hazards and classify jobsite See Classify Jobsite on page 48 Jobsite hazards could cause death or serious injury Use correct equipment and work...

Page 48: ...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 endi...

Page 49: ...t 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...

Page 50: ...lling system and positioning equipment upwind from gas lines use one or both of these methods Expose lines by careful hand digging or soft excavation Use beacon to track bore path Have gas shut off wh...

Page 51: ...int or flags or record it on paper for operator reference For complicated bores consult an engineer Have the jobsite surveyed and bore path calculated Be sure the engineer knows minimum entry pitch be...

Page 52: ...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 requires approximately 110 33 5 m of drill pipe B IMPORTA...

Page 53: ...5 5 10 8 m 4 19 5 5 9 m 2 9 8 m 16 63 2 19 3 m 39 8 12 1 m 5 24 1 7 4 m 4 3 1 3 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 14 9 m 7 33 1 10 1 m 8 4 2 5 m 19 68 1 20 8 m 5...

Page 54: ...om the ground to front end of drill frame H1 Measure from the ground to back end of frame H2 Subtract H1 from H2 Record this number Measure the distance between front and back points C Divide H2 H1 by...

Page 55: ...bend limits to determine the bore path To find the setback B and entry pitch A that will take you to the desired minimum depth D use the chart below Minimum depth D Entry pitch A Setback B Depth to b...

Page 56: ...surface To prevent bending or straining pipe position drilling unit for straight entry Jobsite hazards could cause death or serious injury Use correct equipment and work methods Use and maintain prope...

Page 57: ...ng equipment and accessories bits screens nozzles see page 102 adapters pipe beacon housings marking flags or paint water and additional hoses fuel Use low sulfur or ultra low sulfur fuel only drillin...

Page 58: ...ition and Function filters air oil hydraulic fluid pump couplers tires and tracks pumps and motors drilling fluid mixer hoses and valves water tanks Assemble Accessories Fire Extinguisher If required...

Page 59: ...Prepare 58 JT520 Operator s Manual Check Supplies and Prepare Equipment CMW...

Page 60: ...JT520 Operator s Manual Drive 59 CMW Drive Chapter Contents Start Unit 60 Steer Unit 60 Shut Down Unit 61...

Page 61: ...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 operati...

Page 62: ...r drill frame and stabilizer to the ground 3 Run engine at low throttle for 3 minutes to cool 4 Turn key to STOP 5 Remove key IMPORTANT If frame and stabilizer cannot be lowered use cylinder locks or...

Page 63: ...Drive 62 JT520 Operator s Manual Shut Down Unit CMW...

Page 64: ...JT520 Operator s Manual Transport 63 CMW Transport Chapter Contents Lift 64 Points 64 Procedure 65 Haul 66 Load 66 Tie Down 67 Unload 68 Tow 69...

Page 65: ...t CMW Lift Points Lifting points are identified by lifting decals Lifting at other points is unsafe and can damage machinery Crushing weight If load falls or moves it could kill or crush you Use prope...

Page 66: ...ht 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 3 Br...

Page 67: ...on trailer bed 6 Attach tiedowns to drilling unit where indicated on page 67 Crushing weight If load falls or moves it could kill or crush you Use proper procedures and equipment or stay away NOTICE L...

Page 68: ...to trailer at other points is unsafe and can damage machinery Procedure Loop tiedowns around rear tiedown points Use D ring or pin to trailer using hole in floor plate Make sure tiedowns are tight bef...

Page 69: ...izer 5 Slow engine to low throttle and slowly back unit down trailer or ramps Crushing weight If load falls or moves it could kill or crush you Use proper procedures and equipment or stay away NOTICE...

Page 70: ...crew 1 on each counterbalance valve clockwise until it stops 3 Repeat on other track To engage track hydraulics 1 Turn screw 1 on counterbalance valve exactly the same number of turns counterclockwise...

Page 71: ...Transport 70 JT520 Operator s Manual Tow CMW...

Page 72: ...art System 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...

Page 73: ...Conduct a Bore 72 JT520 Operator s Manual CMW Record Bore Path 80 Surface Drill Head 81 Assemble Backream String 82 Remove Pipe 83 Remove Pullback Device 84...

Page 74: ...g Fluid Pump Prime drilling fluid pump each time tank is changed To prime the pump 1 Fill drilling fluid hose and connect hose to unit 2 Operate mixing transfer pump at full speed for 1 3 minutes to d...

Page 75: ...control has eight positions which allow the four basic functions to be combined The chart below summarizes functions that occur when control is put at a combined position Operator must be in seat for...

Page 76: ...to calibrate beacon Attach EZ Connect to Drill Head Option A 1 Apply tool joint compound to shoulders and threads and hand tighten pin to pin adapter 4 to beacon housing 1 2 Use quick wrench to fully...

Page 77: ...tion sub in front wrench 3 Load pipe 4 Lubricate shoulders and threads 5 Move carriage forward until saver sub nears male pipe thread 6 Slowly rotate spindle clockwise Carriage will move forward as th...

Page 78: ...e 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 5 Monitor gauges Turning shaft can kill you or crush arm or leg Stay...

Page 79: ...ead Continue to lower carriage and rotate spindle until pipe screws into saver sub Move carriage forward until front end of pipe is aligned with male thread of last pipe 9 Use machine power to slowly...

Page 80: ...rill 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 Over correcting w...

Page 81: ...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...

Page 82: ...ator 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...

Page 83: ...eck beacon operation 7 Follow tracker instructions to calibrate beacon 8 Connect EZ Connect joint or use quick wrench to attach backreamer beacon housing assembly to transition sub See Quick Wrench on...

Page 84: ...lats engage into pipe flats 4 Rotate counterclockwise until upper joint breaks If joint does not break at spindle use auxiliary wrench shown Engage auxiliary wrench Rotate spindle counterclockwise unt...

Page 85: ...n pulled back and removed 1 Turn off drilling fluid 2 Move drilling unit throttle control until engine is at low throttle 3 Turn drilling unit engine off 4 Use tracker control to verify that unit is t...

Page 86: ...Electric Strike System 88 FCC Statement 88 Assemble Voltage Detector 89 Test Strike System 89 Troubleshoot Strike System 90 Use Electric Strike Simulator 92 Drilling Fluid 94 Guidelines 94 Polymer 94...

Page 87: ...0 Operator s Manual CMW Downhole Tools 102 Nozzles 102 Bits 102 Beacon Housings 103 Backreamers 104 Backream Fluid Requirements 105 Quick Wrench 107 Drill Pipe 109 Perform Regular Drill Pipe Care 109...

Page 88: ...t or stay away NOTICE Drive anchor properly before drilling Wear high top protective boots with legs of pants completely tucked inside Wear protective gloves If you are not driving anchor to full dept...

Page 89: ...rference 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 limit...

Page 90: ...ully 1 Turn on drilling unit 2 ESID control module will perform internal tests which check everything but alarms and strobe 3 If green OK indicator and electrical power supply indicator lights remain...

Page 91: ...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...

Page 92: ...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 connectio...

Page 93: ...ent transformer 2 Clip ends of lead wires together to make one loop 3 Move simulator switch to current and press test button 4 Watch screen and lights above display on strike system Three or four ligh...

Page 94: ...1 Place voltage limiter on something insulated from ground and drilling unit such as dry board or tire but near frame of drilling unit 2 Clip one lead to frame 3 Clip other lead to one voltage limite...

Page 95: ...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 Poly...

Page 96: ...ormation 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 oth...

Page 97: ...e loss of returns sand gravel clay or shale 35 40 lb 16 18 kg Bore Gel 5 pt 235 mL EZ Mud 5 gal 2 L Con Det Vary mixture according to percentage of sand and clay clay 5 lb 225 g Poly Bore 5 gal 2 L Co...

Page 98: ...bility Drilling fluid Water supply If more water than can be carried with the unit will be needed arrange to transport additional water Bentonite and or polymer 3 Check water quality Use meter or pH t...

Page 99: ...a fresh sample of drilling fluid The sample must be at least 1 5 qt 1 4 L 2 With finger over bottom of funnel fill with fluid from the container through the screen until fluid reaches the bottom of t...

Page 100: ...een 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 drilli...

Page 101: ...each button to advance or lower value quickly To start sending code from the tracker to the display press and hold fore aft left right button and press MODE Thrust and rotation hydraulics on the drill...

Page 102: ...er 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 control key shown on d...

Page 103: ...y 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...

Page 104: ...beacon is installed correctly in rock housing place battery end of beacon away from bit end of housing Soil Description sandy soil sugar sand blow sand or other soils where sand is the predominant co...

Page 105: ...lector at www ditchwitch com 1 best 2 good 3 fair 4 not recommended Backreamer Sandy Soil Soft Soil Medium Soil Hard Soil Rocky Soil Soft Rock Hard Rock Beavertail 3 1 1 1 3 4 4 Three Wing 4 3 3 2 1 1...

Page 106: ...nstructions 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 lea...

Page 107: ...57 mm 13 22 164 17 5 5 in 139 mm 1 23 15 33 18 5 in 470 mm 13 96 173 42 6 in 152 mm 1 47 18 24 19 in 483 mm 14 73 182 92 6 5 in 165 mm 1 72 21 41 19 5 in 495 mm 15 51 192 68 7 in 178 mm 2 00 24 83 20...

Page 108: ...ats 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 Moving tools will injure or kill Sh...

Page 109: ...int in the opposite direction of tightening action 25 6 mm away from first line 3 Turn handle until second line B meets first A 4 Turn handle opposite direction two turns to relieve pressure 5 Remove...

Page 110: ...oint 3 Break joint 4 Move pipe back to box 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 s...

Page 111: ...er sub regularly for wear Replace it when it is worn or it will damage your drill pipe See page 138 for replacement procedure Precondition a new saver sub the same way you do new pipe See Precondition...

Page 112: ...on with carriage travel speed and always connect and disconnect joints slowly and deliberately This will help prevent thread crossing galling and shoulder swelling Torque joints fully Once the joint i...

Page 113: ...Systems and Equipment 112 JT520 Operator s Manual Drill Pipe CMW...

Page 114: ...520 Operator s Manual Complete the Job 113 CMW Complete the Job Chapter Contents Antifreeze Drilling Unit 114 Add Antifreeze 114 Reclaim Antifreeze 114 Rinse Equipment 115 Disconnect 115 Stow Tools 11...

Page 115: ...ise 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 spi...

Page 116: ...o remove dried mud from wrench area Disconnect Disconnect and store the following hoses and cables if used electric strike system voltage stake fluid hose Stow Tools Make sure all quick wrenches bits...

Page 117: ...Complete the Job 116 JT520 Operator s Manual Stow Tools CMW...

Page 118: ...Service 117 CMW Service Chapter Contents Service Precautions 118 Recommended Lubricants Service Key 120 10 Hour 122 50 Hour 126 100 Hour 130 150 Hour 131 250 Hour 132 750 Hour 133 1000 Hour 134 2000...

Page 119: ...er to engine manufacturer s manual for engine maintenance instructions NOTICE Welding can damage electronics Disconnect battery to prevent damage to battery Do not turn off battery disconnect switch w...

Page 120: ...re drilling unit is parked on hard surface 1 Remove yellow cylinder lock from storage at rear of pipe box and place over extended cylinder rod shown with curved ends toward stabilizer shoe 2 Raise sta...

Page 121: ...ecommended by engine manufacturer SAE 15W40 EO Engine oil SAE 10W30 MPG Multipurpose grease meeting ASTM D217 and NLGI 5 MPL Multipurpose gear oil meeting API service classification GL 5 SAE 80W90 DEA...

Page 122: ...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 Bef...

Page 123: ...ator 1 every 10 hours and change filter as needed See Replace Air Filter on page 132 Press evacuator 2 to expel trapped dust Location Task Notes DRILLING UNIT Check engine air filter service indicator...

Page 124: ...e 123 10 Hour CMW 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 leve...

Page 125: ...relieve pressure Lower block or support any raised component with a hoist Cover connection with heavy cloth and loosen connector nut slightly to relieve residual pressure Catch all fluid in a contain...

Page 126: ...at halfway point on sight glass 2 when engine is off and fluid is cool Add THF at hydraulic fluid fill 1 as necessary Check Coolant Level Check coolant level every 10 hours Add coolant as needed to m...

Page 127: ...2 Location Task Notes DRILLING UNIT Change engine oil and filter Initial service DEO Change drilling fluid pump oil initial EO Check radiator Change hydraulic filter Initial service Check rotation ge...

Page 128: ...at plug 1 Maintain fluid level at fill plug Check Radiator Check radiator for dirt grass and other foreign matter every 50 hours Check more often if operating in dusty or grassy conditions Clean fins...

Page 129: ...oat 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 W...

Page 130: ...ck 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 Loosen two alternator bolts shown 2 Adjust...

Page 131: ...y 100 hours for normal service Drain oil 3 change filter 1 and add 4 2 qt 4 L of DEO at fill 2 Lube Thrust Chain Lube thrust chain with DEO every 100 hours Location Task Notes DRILLING UNIT Change eng...

Page 132: ...JT520 Operator s Manual Service 131 150 Hour CMW 150 Hour Change Fuel Filter Change filter shown every 150 hours...

Page 133: ...ndicator 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 3 Wipe insid...

Page 134: ...nual Service 133 750 Hour CMW 750 Hour Change Drilling Fluid Pump Oil 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...

Page 135: ...l oil is visible at plug 2 Replace fill plug 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 fil...

Page 136: ...JT520 Operator s Manual Service 135 2000 Hour CMW 2000 Hour Change Coolant Drain 2 coolant and add DEAC at fill 1 every 2000 hours...

Page 137: ...ease handle 8 Unscrew cartridge 2 3 turns 9 Watch for grease to come out of weep hole 10 Screw cartridge back in when grease comes out of hole Location Task Notes DRILLING UNIT Change pipe lubricator...

Page 138: ...ow 2 Adjust Thrust Chain Tension Adjust thrust chain tension as needed 1 Remove all pipe from pipe box 2 Move carriage to front of frame 3 Loosen jam nut shown 4 Turn adjuster bolt clockwise to tighte...

Page 139: ...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 5 Replace o ring if necessary 6 Install new saver sub in reverse...

Page 140: ...Fluid Pump Check Valve Check fluid pump check valve shown o ring for wear and replace as needed Check Carriage Slide Bars Check slide bars shown for wear and replace as needed Replace Fuses Change fus...

Page 141: ...Service 140 JT520 Operator s Manual As Needed CMW...

Page 142: ...W overall machine width 35 5 in 900 mm H overall machine height 66 5 in 1 7 m Operating weight w 150 45 7 m of drill pipe anchoring system and anchor 2980 lb 1352 kg UFE Pipe U S Metric Length 59 1 in...

Page 143: ...se 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 in3...

Page 144: ...quipment may not necessarily match that shown 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 Capacitie...

Page 145: ...Specifications 144 JT520 Operator s Manual CMW...

Page 146: ...chase 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 U...

Page 147: ...S 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...

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Page 150: ...JT520 Operator s Manual Service Record 149 CMW Service Record Service Performed Date Hours...

Page 151: ...CMW Service Record 150 JT520 Operator s Manual Service Performed Date Hours...

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