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JT920/JT920L - MAINTENANCE

131

GENERAL COMPONENTS

JT920/JT920L - MAINTENANCE

131

GENERAL COMPONENTS

Battery

IMPORTANT:

Use battery disconnect switch when servicing, and

during long-term storage.

Keep battery 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.

Alternator Belt

Check tension of alternator belt every
50 hours. Belt is properly tensioned
when long span moves about 0.6”
(15 mm) when pushed. If needed,
loosen idler pulley bolts and adjust
idler pulley. Tighten bolts and torque
to 27-30 lb•ft (36-40 N•m).

om1629.eps

Battery

IMPORTANT:

Use battery disconnect switch when servicing, and

during long-term storage.

Keep battery 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.

Alternator Belt

Check tension of alternator belt every
50 hours. Belt is properly tensioned
when long span moves about 0.6”
(15 mm) when pushed. If needed,
loosen idler pulley bolts and adjust
idler pulley. Tighten bolts and torque
to 27-30 lb•ft (36-40 N•m).

om1629.eps

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Summary of Contents for JT920

Page 1: ...and date of purchase of your equipment in the spaces below Date of Manufacture Date of Purchase Drilling Unit Serial Number om0115c eps SERVICE SERIAL NUMBER Record the serial numbers and date of pur...

Page 2: ...d repair of your equipment Ditch Witch Training Center For information about on site individualized training contact your Ditch Witch dealer SUPPORT PROCEDURE Notify your dealer immediately of any mal...

Page 3: ...atest information on Ditch Witch equipment see your Ditch Witch dealer Thank you for buying and using Ditch Witch equipment FOREWORD This manual is an important part of your equipment It provides safe...

Page 4: ...ia 684 595 689 533 718 034 706 544 755 862 UK 2 309 239 2 312 006 EP683 845 EP674 093 other U S and foreign patents pending Operator s Manual JT920 JT920L Issue No 6 0 OP 4 11 Part Number 054 509 Copy...

Page 5: ...0 Underground Hazards 40 Emergency Procedures 41 Jobsite Classification 44 Safety Alert Classifications 48 Safety Alerts 49 CONTENTS SERVICE 1 Serial Number 1 Support Procedure 2 Resources 2 FOREWORD...

Page 6: ...Lift 69 Tiedown 71 Haul 72 Tow 74 SETUP 77 Unload 77 Assemble Electric Strike System 78 Anchor 80 Assemble Drill String 81 PREPARATION 55 Gather Information 55 Inspect Site 56 Plan Bore Path 59 Check...

Page 7: ...ove Anchors 117 Rinse Equipment 118 Disconnect 118 Stow Tools 118 LUBRICATION 119 Drilling Unit 120 Drilling Fluid Pump 127 OPERATION 87 Start System 87 Operate Thrust rotation Control 88 Drill First...

Page 8: ...148 APPENDIX 151 A Bend Limits 151 B Entry Pitch Setback and Depth 158 C Drilling Fluid Requirements 156 D Nozzle Flow 161 MAINTENANCE 129 Overview 129 General Components 130 Filters 134 Power Compon...

Page 9: ...x 5 Set up drive controls 11 Front wrench 6 Drilling fluid pump 12 Stake mount plate 1 2 3 4 5 6 7 8 9 10 11 12 om2098a eps OVERVIEW The JT920 directional drilling unit can be connected to a fluid uni...

Page 10: ...12 Anchoring system 6 Drilling fluid pump 13 Anchoring controls 7 Rear stabilizer 1 3 4 5 6 7 8 9 10 11 12 13 2 om0109c eps The JT920L directional drilling unit is a self contained unit that can be c...

Page 11: ...control 4 Frame tilt control 5 Left track control 6 Right track control 7 Autobore select switch 8 Ignition switch 9 Cold start switch om2094a eps CONTROLS SETUP CONSOLE OVERVIEW 1 Throttle switch 2...

Page 12: ...l to move left track in Stabilizer Lift Control This lever controls rear stabilizer Push to lower Pull to raise ic0136h eps ic1064x eps ic0054c eps SETUP CONSOLE DESCRIPTIONS Throttle Switch This swit...

Page 13: ...r controls speed and direction of right track Push to move forward Pull to move backward Move to center to stop ic0056c eps ic0143h eps ic0142h eps Frame Tilt Control This lever raises or lowers drill...

Page 14: ...position Cold Start Switch This optional switch helps start cold engine Turn key to on position Press top of switch for 10 20 seconds Start engine Autobore Select Switch This switch selects between a...

Page 15: ...3 Fluid flow control 14 ESID 15 Remote display mounting bracket called out later in chapter 1 3 2 4 5 6 7 8 10 9 11 12 13 14 15 om0111c eps DRILL OVERVIEW 1 Fluid pump switch 2 Spindle control 3 Pipe...

Page 16: ...ove forward Move to right or left to control rotation Move right to rotate counterclockwise breakout Move left to rotate makeup ic0059c eps DRILL DESCRIPTIONS Fluid Pump Switch This switch controls fl...

Page 17: ...load function Press top when drilling Press center to use manual pipe loader controls Press bottom when backreaming ic1280a eps ic1328a eps Pipe Lift Switch JT920L only This switch raises and lowers a...

Page 18: ...Push switch Release when engine starts This button only works when ignition switch on fluid unit is on ic1327a eps ic0048c eps ic1272a eps Auxiliary Wrench Switch This switch controls auxiliary back...

Page 19: ...ts Move lever to right or left to control front wrench Move right to lock onto pipe flats Move left to release pipe ic0050c eps ic1057c eps Throttle Switch This switch controls remote fluid unit engin...

Page 20: ...ress red button on operator s station to stop engine s Use ignition or remote restart switch es to restart engine s ic0136h eps ic1273a eps Remote Throttle Switch This switch controls engine speed dur...

Page 21: ...ise to decrease flow Fluid Pressure Gauge This gauge displays drilling fluid system pressure 2 3 4 1 0 0 BAR PSI X 100 10 20 30 ic0061c eps Fluid Flow Control This knob adjusts drilling fluid flow fro...

Page 22: ...ss 6 Hourmeter 7 Hydraulic oil filter service indicator 8 Hydraulic oil temperature indicator 9 Engine oil pressure indicator 1 2 3 4 5 6 7 8 9 om2095a eps GAUGES AND INDICATORS OVERVIEW 1 Air filter...

Page 23: ...25 L Voltmeter This gauge measures voltage in electric system Reading should be 13 volts with engine running If not stop engine and investigate ic1309a eps GAUGES AND INDICATORS DESCRIPTIONS Air Filte...

Page 24: ...ly visible in glass when oil is cool Hourmeter This gauge records engine operating time Use these times to schedule lubrication and maintenance om1675c eps Engine Temperature Gauge This gauge displays...

Page 25: ...sounds and engine shuts down if oil pressure is too low If indicator lights and sounds turn unit off check engine oil level and check for leaks ic0111h eps Hydraulic Oil Filter Service Indicator This...

Page 26: ...STEM CONSOLE OVERVIEW 1 Left rotation control 2 Left thrust control 3 Right rotation control 4 Right thrust control 5 Anchor slide locks 1 2 3 4 5 om0127c eps ANCHORING SYSTEM CONSOLE OVERVIEW 1 Left...

Page 27: ...f left anchor Push to move down Pull to move up Right Rotation Control This lever controls rotation of right anchor Push to drive anchor Pull to remove anchor ANCHORING SYSTEM CONSOLE DESCRIPTIONS Lef...

Page 28: ...ck and unlock anchor driver into hole in center of anchor frame Turn handle parallel to frame to lock Turn handle perpendicular to frame to unlock om2165a eps Right Thrust Control This lever controls...

Page 29: ...rrupt button 4 Voltage problem indicator 5 Current problem indicator 6 OK indicator 7 Electrical power supply indicator 8 Self test button ESID OVERVIEW 1 Alphanumeric display 2 Strike indicator 3 Ala...

Page 30: ...at drilling unit during a strike Voltage Problem Indicator Red light indicates a voltage problem See Troubleshoot Strike System in MAINTENANCE ESID DESCRIPTIONS Alphanumeric Display This area shows ho...

Page 31: ...indicator is also on Self Test Button Press this button to start manual self test which checks all systems and circuits except voltage limiter Current Problem Indicator Red light indicates a current p...

Page 32: ...ff button 9 Channel select button 10 Roll stop button 11 Recall button 12 Store button 13 Beacon battery status indicator 14 Beacon temperature indicator SUBSITE 750 DISPLAY OVERVIEW 1 Left right indi...

Page 33: ...ows beacon s roll angle Target Identifier These arrows indicate approximate beacon location Only one set of arrows fore aft or left right is active at a time SUBSITE 750 DISPLAY DESCRIPTIONS Left Righ...

Page 34: ...beacon s battery status see beacon s instruction sheet Beacon Temperature Indicator This indicator shows beacon s temperature see beacon s instruction sheet Depth Estimate Pipe Number TMS Option Disp...

Page 35: ...h Recall button to delete all jobs in internal logging memory On Off Button This button turns display unit on or off Press to turn on Press again to turn off Delete Button This button deletes last sto...

Page 36: ...function Press with Recall button to select job to open Init and job number will be displayed Roll Stop Button This feature is not yet available si1069a eps Channel Select Button This button selects...

Page 37: ...th Recall button to download all jobs stored in internal logging memory Connect display to PC running Trac Management System software si1066a eps si1064a eps Recall Button This button allows operator...

Page 38: ...38 JT920 JT920L CONTROLS SUBSITE 750 DISPLAY DESCRIPTIONS 38 JT920 JT920L CONTROLS SUBSITE 750 DISPLAY DESCRIPTIONS...

Page 39: ...mable gas is present Contact your Ditch Witch dealer if you have any question about operation maintenance or equipment use SAFETY Follow these guidelines before operating any jobsite equipment Complet...

Page 40: ...ctric lines Natural gas lines Fiber optic cables Water lines Sewer lines Pipes carrying other chemicals liquids or gases Storage tanks ACCESSORIES Fire Extinguisher If required a fire extinguisher sho...

Page 41: ...e explosion popping noises arcing electricity If any of these occur or if strike alarm sounds or flashes assume an electric strike has occurred EMERGENCY PROCEDURES Before operating any equipment revi...

Page 42: ...u are wearing electric insulating boots If you leave do not return to area or allow anyone into area until given permission by electric company If an Electric Line is Damaged On Drilling Unit or Bonde...

Page 43: ...uisher is available attempt to extinguish fire If fire cannot be extinguished leave area as quickly as possible and contact emergency personnel If a Gas Line is Damaged If you suspect a gas line has b...

Page 44: ...each side of bore path Verify previously marked line and cable locations Mark location of all buried utilities and obstructions Classify jobsite JOBSITE CLASSIFICATION Inspecting Jobsite Follow U S D...

Page 45: ...e or concrete which is capable of producing crystalline silica quartz dust crystalline silica quartz dust within 10 3 m of any other hazard other Selecting a Classification Jobsites are classified acc...

Page 46: ...excavation Use beacon to track bore path Have gas shut off while work is in progress Have gas company test lines before returning them to service Applying Precautions Once classified precautions appro...

Page 47: ...rds Talk with those knowledgeable about hazards present at each site to determine which precautions should be taken or if job should be attempted Crystalline Silica Quartz Dust Precautions Follow OSHA...

Page 48: ...machine or someone s property It can also alert you against unsafe practices IMPORTANT can help you do a better job or make your job easier in some way SAFETY ALERT CLASSIFICATIONS These classificatio...

Page 49: ...l kill or injure Shut off drill string power when anyone can be struck by thrown or moving tools Never use pipe wrenches on drill string SAFETY ALERTS Turning shaft will kill you or crush arm or leg S...

Page 50: ...t could cause death or serious injury Use proper procedures and equipment or stay away Moving parts could cut off hand or foot Stay away Jobsite hazards could cause death or serious injury Use correct...

Page 51: ...o not look into ends of fiber optic or unidentified cable Pressurized fluid or air could pierce skin and cause injury or death Stay away Explosion possible Serious injury or equipment damage could occ...

Page 52: ...rol function could cause death or serious injury If control does not work as described in instructions stop machine and have it serviced Fire or explosion possible Fumes could ignite and cause burns N...

Page 53: ...use of chemicals may result in illness injury or equipment damage Follow instructions on labels and in material safety data sheets MSDS Flying objects may cause injury Wear hard hat and safety glasse...

Page 54: ...54 JT920 JT920L SAFETY SAFETY ALERTS 54 JT920 JT920L SAFETY SAFETY ALERTS...

Page 55: ...ns Emergency Services Have the telephone numbers for local emergency and medical facilities on hand Check that you will have access to a telephone PREPARATION GATHER INFORMATION A successful job begin...

Page 56: ...ference rebar railroad tracks etc Take soil samples from several locations along bore path to determine best bit and backreamer combinations INSPECT SITE Inspect jobsite before transporting equipment...

Page 57: ...rground hazards Mark jobsite clearly and keep spectators away Remember jobsite is classified by hazards in place not by line being installed Identify Hazards Identify safety hazards and classify jobsi...

Page 58: ...ike system Comfort Consider shade wind fumes and other site features Drill downhill when possible so fluid will flow away from drilling unit Select Start and End Points Select one end to use as a star...

Page 59: ...end limits entry pitch minimum setback and minimum depth Recommended bend limits must be considered during any bend not just during bore entry PLAN BORE PATH The bore path from entry to end must be pl...

Page 60: ...tch changes no more than 9 per pipe NOTICE Bending pipe more sharply than recommended will damage pipe and cause failure over time om2258a eps Recommended Bend Limit Though Ditch Witch pipes are desig...

Page 61: ...w entry pitch allows you to reach horizontal sooner and with less bending Increasing entry pitch makes bore path longer and deeper B A x 100 C Entry Pitch Entry pitch is drilling unit slope compared t...

Page 62: ...ur required depth use chart in APPENDIX section B Find entry pitch you will be using then minimum setback A Proper setback B Setback too small Minimum Setback Setback is the distance from entry to hor...

Page 63: ...nd entry pitch that will take you to desired depth locate depth on chart in APPENDIX section B Then find corresponding setback and entry pitch Minimum Depth Because pipe must be bent gradually entry p...

Page 64: ...eamers swivels pulling devices Washdown hose and spray gun Duct tape Spray lubricant Tool joint compound Electrically insulating boots and gloves Notepad and pencil CHECK SUPPLIES AND PREPARE EQUIPMEN...

Page 65: ...function Drive chains Filters air oil hydraulic Fluid pump Couplers Tires and tracks Relief valve Centrifugal pump Drilling fluid mixer Hoses and valves Water tanks Prepare Equipment Check levels Fuel...

Page 66: ...hole so first pipe is drilled into a vertical surface To prevent bending or straining pipe position drilling unit for straight entry om1431 pcx PREPARE JOBSITE Jobsite hazards could cause death or ser...

Page 67: ...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 RECORD BORE PATH As the job is completed record the act...

Page 68: ...68 JT920 JT920L PREPARATION 68 JT920 JT920L PREPARATION...

Page 69: ...lifted load machine into a container or onto a platform appropriate for lifting For weight of machine see specifications in this manual TRANSPORTATION LIFT This machine is not configured for lifting I...

Page 70: ...nd can damage machinery Procedure Loop tiedowns around unit at tiedown points Make sure tiedowns are tight before transporting om2101a eps TIEDOWN Points Tiedown points are identified by tiedown decal...

Page 71: ...r floor 6 Stop engine when unit is safely positioned on trailer bed 7 Attach tiedowns to drilling unit where tiedown decals are located HAUL Crushing weight If load falls or moves it could kill or cru...

Page 72: ...er trailer or ramps 2 Start engine 3 Remove tiedowns 4 Raise stabilizers 5 Use track controls to slowly back unit down trailer or ramps Unloading from Trailer 1 Lower trailer or ramps 2 Start engine 3...

Page 73: ...se maximum towing force of 1 5 times unit weight Disengage power to tracks IMPORTANT When hydraulics are disengaged unit has no brakes TOW Under normal conditions drilling unit should not be towed If...

Page 74: ...urn screw A on counterbalance exactly same number of turns counterclockwise 2 Tighten locknut B 3 Repeat on other track A B om1803 eps To disengage track hydraulics 1 Loosen locknut B 2 Turn screw A o...

Page 75: ...JT920 JT920L TRANSPORTATION 75 TOW JT920 JT920L TRANSPORTATION 75 TOW...

Page 76: ...76 JT920 JT920L TRANSPORTATION TOW 76 JT920 JT920L TRANSPORTATION TOW...

Page 77: ...ed entry pitch 3 Lower stabilizers until stabilizers begin to put pressure on ground 4 Continue lowering to increase entry pitch SETUP UNLOAD 1 Drive drilling unit off trailer following directions in...

Page 78: ...pense Changes or modifications not expressly approved in writing by The Charles Machine Works Inc may void the user s authority to operate this equipment ASSEMBLE ELECTRIC STRIKE SYSTEM Anytime drilli...

Page 79: ...mbers Alarms and strobes on both units should sound 4 If this test is successful OK indicator and electrical power supply indicator lights will remain on Assemble Voltage Detector 1 Drive voltage stak...

Page 80: ...lide lock 7 Rotate anchor while retracting cylinder until collar rests firmly on centering cap 8 Repeat process for other anchor ANCHOR Crushing weight If load falls or moves it could kill or crush yo...

Page 81: ...in the opposite direction of tightening action 3 8 in 9 5 mm away from first line 4 Turn handle to tighten joint until second line meets first ASSEMBLE DRILL STRING Select Nozzle and Bit 1 Select noz...

Page 82: ...dles 2 to wrench jaws Be sure handles are both up Attach pivoting nut heads 3 so that screw 4 is over joint Turn screw to pull handles together Attach EZ Connect Option A 1 Apply tool joint compound t...

Page 83: ...sing scribe line technique to achieve proper preload 4 Turn screw opposite way two turns to relieve pressure and remove quick wrench components 3 Tighten joint 4 Turn screw opposite way two turns to r...

Page 84: ...Start drilling unit engine 4 Use machine power to slowly rotate spindle and transition sub onto EZ Connect box 5 Tighten to full machine torque Attach Transition Sub 1 Apply tool joint compound to thr...

Page 85: ...o transition sub male thread 6 Tighten to full machine torque 7 Disengage front wrench and move carriage back to top of frame 8 Turn off engine Connect Drill Pipe 1 Start drilling unit engine 2 Align...

Page 86: ...tool head off one flat and slide collar onto pin until retainer bolt hole is visible 5 Install retainer bolt and tighten Engage EZ Connect 1 Apply tool joint compound to threads and align hole in EZ...

Page 87: ...E Anchor drilling unit properly before drilling EMERGENCY SHUTDOWN Push remote engine stop button or turn ignition switch to stop position OPERATION START SYSTEM This section covers basic operation Fo...

Page 88: ...d Rotates pipe counterclockwise breakout Moves carriage backward Rotates pipe counterclockwise breakout Moves carriage backward Rotates pipe clockwise makeup OPERATE THRUST ROTATION CONTROL The thrust...

Page 89: ...p switch until pipe fills and fluid pressure begins to rise Adjust fluid flow control to set pressure to appropriate level Do not exceed maximum pump setting 1 Start drilling unit and remote fluid uni...

Page 90: ...maintain proper safety equipment 1 Rotate spindle clockwise full speed 2 Move carriage forward slowly Drill first pipe as straight as possible DRILL FIRST PIPE Turning shaft can kill you or crush arm...

Page 91: ...MPORTANT Move carriage back only after threads have unscrewed completely to protect threads 5 Stop rotation and move carriage to back of frame Break Joint at Saver Sub 1 When joint flats are aligned w...

Page 92: ...until spindle stops turning Lift pipe Use loader shuttle switch to move shuttle under selected row Lower pipe into shuttle JT920L only ADD PIPE Turning shaft can kill you or crush arm or leg Stay away...

Page 93: ...slowly Adjust rotation speed control according to bit size and soil conditions 8 Locate drill head at least every half length of pipe 4 Press top of drilling unit throttle switch until engine is at f...

Page 94: ...crews together Rotate joint slowly until spindle stops turning 7 Open front wrench Shuttles will retract and pipe lift arms will lower Option B Use Autoload Function JT920L only 1 Position carriage be...

Page 95: ...slowly Adjust rotation speed control according to bit size and soil conditions 12 Locate drill head at least every half length of pipe 8 Press top of drilling unit throttle switch until engine is at f...

Page 96: ...a pipe box with pipes in it raise pipes with pipe lifter install storage pin 5 on each end of pipe box and lower pipes before beginning procedure REMOVE ADD PIPE BOX Crushing weight If load falls or m...

Page 97: ...tles 6 Disconnect lifting device from lift plate assembly 1 7 Remove lift plate assembly from pipe box 8 Replace pipe box pins and lynch pins 2 3 Remove 1 Remove lynch pins and pipe box pins 2 3 2 Pos...

Page 98: ...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 CORRECT DIRECTION Correcting direction is a skill operat...

Page 99: ...sition you intend to travel 2 Push pipe into ground To move forward without changing direction 1 Rotate pipe 2 Push pipe into ground om1477 pcx 1 Locate drill head Take readings available with your be...

Page 100: ...ogether 6 Loosen joint 7 Turn screw opposite way two turns to relieve pressure and remove quick wrench components 8 Remove drill head om2053a eps SURFACE DRILL HEAD 1 Guide drill head to target pit or...

Page 101: ...serious injury Use correct equipment and work methods Use and maintain proper safety equipment NOTICE Continue to use strike system during backreaming ASSEMBLE BACKREAM STRING When the bore is comple...

Page 102: ...g unit throttle switch until engine is at full throttle 5 Set drilling fluid flow 6 Check that fluid flows through all nozzles 7 Pull pipe through bore 1 Select backreaming devices 2 Determine fluid r...

Page 103: ...back material and drilling fluid affect backreamer choice To determine which combination will work best at your jobsite contact your Ditch Witch dealer Backreaming Tips Plan backreaming job before dri...

Page 104: ...t of fluid per minute needed for the flow and pressure you will be using A combination of nozzles that will supply more fluid per minute is recommended Determine Fluid Requirements Backreaming is only...

Page 105: ...Pin handles 2 to wrench jaws Be sure handles are both up Attach pivoting nut heads 3 so that screw 4 is over joint Turn screw to pull handles together Attach EZ Connect to Backreamer Option A 1 Apply...

Page 106: ...joint using scribe line technique to achieve proper preload 8 Turn screw opposite way two turns to relieve pressure and remove quick wrench components 3 Tighten joint using scribe line technique to a...

Page 107: ...joint using scribe line technique to achieve proper preload 4 Turn screw opposite way two turns to relieve pressure and remove quick wrench components Option B 1 Apply tool joint compound to threads...

Page 108: ...oulders are touching 10 Back backreamer off one flat and slide collar onto pin until retainer bolt hole is visible 11 Install retainer bolt and tighten Attach Pullback Device Pullback devices are avai...

Page 109: ...iliary wrench 5 Engage breakout wrench 6 Rotate spindle clockwise until wrench flats align with pipe flats 7 Move shuttles out JT920L only REMOVE PIPE Option A Use Manual Pipeloader Controls 1 When pi...

Page 110: ...nough to allow pipe to screw into saver sub Joint should only be tight enough to prevent leaking 14 Disengage front wrench to release pipe 8 Rotate pipe counterclockwise to unscrew bottom joint 9 Dise...

Page 111: ...ngage front wrench Shuttles will extend and pipe lift arms will lower 6 Rotate spindle clockwise until wrench flats engage into pipe flats Option B Use Autoload Function JT920L only 1 Position carriag...

Page 112: ...joystick 14 Rotate spindle counterclockwise and move carriage back slightly to unscrew pipe from saver sub 15 Move spindle away from pipe 7 Rotate counterclockwise until upper joint breaks If joint d...

Page 113: ...ow pipe to screw into saver sub Joint should only be tight enough to prevent leaking 18 Disengage front wrench to release pipe om0134c eps 16 Move carriage to back of drill frame Pipe will automatical...

Page 114: ...re path has been reached Remaining pipe is then pulled back and removed Reverse steps outlined in Attaching Pullback Device to remove pullback device REMOVE PULLBACK DEVICE The pullback device can be...

Page 115: ...ectric eyes or tape so that pipe OK light B is on Press pipe shuttle switch to manually extend shuttles This will restart automation cycle om0134c eps TROUBLESHOOT AUTOMATION Drill Mode The most commo...

Page 116: ...n is interrupted at any other point in the cycle refer to Troubleshooting section of Repair Guide or contact your local Ditch Witch dealer om0134c eps Backream Mode The most common reason for pipeload...

Page 117: ...r frame 4 Engage anchor slide lock 5 Continue to rotate anchor out of ground while fully extending cylinder 6 Repeat process for other anchor BREAKDOWN REMOVE ANCHORS Crushing weight If load falls or...

Page 118: ...ic strike system ground stake fluid hose if used STOW TOOLS Make sure all wrenches bits pullback devices and other tools are loaded on trailer RINSE EQUIPMENT Spray water onto equipment to remove dirt...

Page 119: ...pment or stay away NOTICE Unless otherwise instructed all service in this chapter should be performed with the engine s shut off LUBRICATION Fluid under pressure can pierce skin and cause injury or de...

Page 120: ...HF 1 11 12 Change rotation gearbox oil MPL 1 as needed Lube pipe loader shuttle slide MPG 1 Change pipe auto lubricator tube TJC 1 om0122c eps DRILLING UNIT Reference Hours Description Lubricant Point...

Page 121: ...llips 66 HG Fluid Mobilfluid 423 Chevron Tractor Hydraulic Fluid Texaco TDH Oil or equivalent TJC Tool joint compound standard or summer grade Lubricant chart MPG Multipurpose grease DEO Diesel engine...

Page 122: ...ll 3 Change Change oil after first 50 hours After that change oil every 100 hours Open drain 4 change filter 1 and refill with DEO om2104a eps Engine Oil Check Check oil every 10 hours at dipstick 2 I...

Page 123: ...ry 1000 hours Change oil and filter every 500 hours if jobsite temperature exceeds 100 F 38 C more than 50 of the time om2105a eps om2106a eps Hydraulic Oil Check Check oil every 10 hours Maintain flu...

Page 124: ...one stroke of molybdenum based MPG every four hours Using more than one stroke of grease gun can lead to seal failure om2109a eps om2110a eps Frame and Carriage Rotation Gearbox Check gearbox every 5...

Page 125: ...arings Lube flange bearings 9 with MPG every 250 hours Pipe Loader Shuttle Slide Lube shuttle slide as needed with MPG om2108a eps om2107a eps Thrust Chain Lube thrust chain 10 with DEO or chain lubri...

Page 126: ...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 Pipe Auto Lubricator IMPORTANT Use only Ditch Witch TJC I...

Page 127: ...engine oil Drain 14 and refill crankcase every 750 hours Pump holds 1 qt 9 L See pump manufacturer s handbook for additional information om2099a eps DRILLING FLUID PUMP Check oil level 15 in crankcase...

Page 128: ...128 JT920 JT920L LUBRICATION DRILLING FLUID PUMP 128 JT920 JT920L LUBRICATION DRILLING FLUID PUMP...

Page 129: ...heck pipe loader shuttle inserts 132 change air filter 134 clean pipe 140 repair pipe threads 140 troubleshoot Electric Strike System 141 MAINTENANCE NOTICE Unless otherwise instructed all service in...

Page 130: ...s Ref Task Hours n a inspect hoses 10 5 check battery 50 3 check alternator belt 50 1 2 clean radiator 50 4 replace saver sub as needed om2111a eps GENERAL COMPONENTS NOTICE Before disconnecting any h...

Page 131: ...bout 0 6 15 mm when pushed If needed loosen idler pulley bolts and adjust idler pulley Tighten bolts and torque to 27 30 lb ft 36 40 N m om1629 eps Battery IMPORTANT Use battery disconnect switch when...

Page 132: ...le inserts A and pipe loader shuttle inserts B for wear Replace as needed See your Ditch Witch dealer for replacement parts om2089a eps om0287h eps Saver Sub Remove saver sub as needed To remove smoot...

Page 133: ...not use water or automotive type coolant This will lead to engine damage or premature engine failure and void John Deere engine warranty om1691 eps Radiator Check radiator for dirt grass and other for...

Page 134: ...service indicator Ref Task Hours 3 change fuel filter 1000 1 check muffler as needed 2 change air filter as needed om2112 eps om1637 eps FILTERS Air Filter Change air filter when yellow band on air fi...

Page 135: ...move bolt at bottom of filter 2 Remove cup and paper element 3 Place new element into cup 4 Position cup and bolt into place om2113a eps Muffler Change muffler as needed Fuel Filter Replace fuel filte...

Page 136: ...is 15 15 5 380 390 mm Ref Task Hours 1 check thrust chain tension as needed 2 check track tension and condition as needed om2114a eps om2100a eps POWER COMPONENTS Track Check track tension as needed T...

Page 137: ...ve frame when pulled with approximately 20 lb 9 kg of force 4 Tighten jam nut against other nut after adjusting 6mm 25 in om0113c eps om0112c eps Thrust Chain Adjust thrust chain tension as needed To...

Page 138: ...on position Do not start engine 2 Place metal object in front of each switch 3 If light on back of switch comes on switch is functioning om00135c eps PIPELOADER AUTOMATION Proximity Switches Check si...

Page 139: ...it is in the LO position Row Select Pin Check that row select pin 3 is installed properly Pin should be pushed completely in and up against snap ring Photoelectric Eyes Clean photoelectric eyes 8 and...

Page 140: ...mmended bend limit Cleaning Threads Clean threads as needed with high pressure water and soap Do not use gasoline or similar solvents PIPE Before pipe is used first time Hand lubricate threads and sho...

Page 141: ...ntrol module is connected Check that harness from drilling unit carries more than 10 volts Defective control module Have control module checked or replaced TROUBLESHOOT STRIKE SYSTEM When strike syste...

Page 142: ...ction on control module Defective voltage limiter Have voltage limiter checked or replaced Defective control module Have control module checked or replaced Battery power light is on but system OK ligh...

Page 143: ...h 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 USE ELECTRIC STRIKE SIMULATOR The Electri...

Page 144: ...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 Voltage Test 1 Place voltage limiter on s...

Page 145: ...pipe U S Metric Length 78 75 in 2 m Joint diameter 2 in 50 8 mm Tubing diameter 1 35 in 34 3 mm Min bend radius 85 ft 25 9 m om2097a eps SPECIFICATIONS JT920 Dimensions U S Metric Length 200 in 5 1 m...

Page 146: ...1 in 79 mm Gross power 3000 rpm 55 4 hp 41 3 kW Maximum governed speed no load 3000 rpm 3000 r min Operating power 2750 rpm 45 hp 33 6 kW Operational U S Metric Spindle Speed 0 182 rpm 0 182 r min Tor...

Page 147: ...Fluid pressure 750 psi 52 bar Flow rate variable 0 9 gpm 0 34 L min Battery SAE reserve capacity 120 min SAE cold crank 0 F 18 C 800 amps Noise Level Operator 89 dBA sound pressure per ISO 6394 Operat...

Page 148: ...pipe U S Metric Length 120 in 3 m Joint diameter 2 in 50 8 mm Tubing diameter 1 625 in 41 mm Min bend radius 100 ft 30 m H W L om0110c eps JT920L Dimensions U S Metric Length 200 in 5 1 m Height 87 in...

Page 149: ...1 in 79 mm Gross power 3000 rpm 55 4 hp 41 3 kW Maximum governed speed no load 3000 rpm 3000 r min Operating power 2750 rpm 45 hp 33 6 kW Operational U S Metric Spindle Speed 0 182 rpm 0 182 r min To...

Page 150: ...fluid system on board U S Metric Flow rate variable 13 gpm 49 L min Battery SAE reserve capacity 120 min SAE cold crank 0 F 18 C 800 amps Noise Level Operator 89 dBA sound pressure per ISO 6394 Opera...

Page 151: ...ally distributed over the length of a pipe Maximum percent changes in pitch in 1 2 30 60 cm of pipe create sharp bends and will damage pipe APPENDIX A BEND LIMITS JT920 Power Pipe Drill Pipe Turns in...

Page 152: ...is damage adds up and can lead to sudden pipe failure Use the following charts to keep bends within safe limits JT920 Power Pipe Drill Pipe Bending pipe beyond recommended limits will overstress pipe...

Page 153: ...m 27 74 m 24 104 ft 9 in 97 ft 7 in 31 92 m 29 73 m 25 104 ft 11 in 104 ft 1 in 31 98 m 31 73 m 26 105 ft 0 in 105 ft 0 in 32 00 m 32 00 m JT920 Power Pipe Drill Pipe Dimensions given at minimum bend...

Page 154: ...154 JT920 JT920L APPENDIX A BEND LIMITS 154 JT920 JT920L APPENDIX A BEND LIMITS JT920L Power Pipe Drill Pipe JT920L Power Pipe Drill Pipe...

Page 155: ...29 20 m 21 73 m 14 98 ft 2 in 80 ft 10 in 29 92 m 24 64 m 15 99 ft 7 in 90 ft 7 in 30 34 m 27 61 m 16 100 ft 0 in 100 ft 0 in 30 5 m 30 5 m JT920L Power Pipe Drill Pipe Dimensions given at minimum ben...

Page 156: ...105 32 m minimum bend radius 2 L beacon housing EZ Connect and transition sub and 1 3 of first drill pipe totalling 6 t 3 1 9 m in the ground before steering B ENTRY PITCH SETBACK AND DEPTH Entry pitc...

Page 157: ...00 30 5 m minimum bend radius 2 L beacon housing EZ Connect and transition sub and 1 3 of first drill pipe totalling 7 5 2 26 m in the ground before steering JT920L Power Pipe Drill Pipe EA SB d D 18...

Page 158: ...page can be used to determine the minimum amount of fluid needed in perfect conditions Use more than amount indicated or bore might be dry and unsuccessful C DRILLING FLUID REQUIREMENTS Backreaming is...

Page 159: ...9 8 121 74 16 in 40 64 cm 10 44 129 72 16 5 in 41 91 cm 11 11 137 95 17 in 43 18 cm 11 79 146 44 17 5 in 44 45 cm 12 49 155 18 18 in 45 72 cm 13 22 164 17 Backreamer product diameter Gallons per foot...

Page 160: ...m 22 53 279 83 24 in 60 96 cm 23 5 291 86 24 5 in 62 23 cm 24 49 304 15 25 in 63 5 cm 25 5 316 69 25 5 in 64 77 cm 26 53 329 49 26 in 66 04 cm 27 58 342 53 Backreamer product diameter Gallons per foot...

Page 161: ...supply more fluid per minute is recommended U S Nozzle Flow A Flow per nozzle gallons minute B Nozzle pressure psi C Nozzle size om1529 pcx D NOZZLE FLOW Select nozzles that will supply at least the a...

Page 162: ...W 162 JT920 JT920L APPENDIX D NOZZLE FLOW Metric Nozzle Flow A Flow per nozzle liters minute B Nozzle pressure bar C Nozzle size om1528 pcx Metric Nozzle Flow A Flow per nozzle liters minute B Nozzle...

Page 163: ...nt owners in countries other than U S Canada Mexico and Puerto Rico should refer to Ditch Witch International Warranty Policy WARRANTY Ditch Witch Equipment and Replacement Parts North American Limite...

Page 164: ...rest authorized dealer upon inquiry CMW reserves the right to supply remanufactured replacement parts as it deems appropriate Product Limited Warranty Products are warranted for 90 days from date of d...

Page 165: ...is limited warranty gives owner specific legal rights and the owner may also have other rights which vary from state to state Exclusions from Major Component and Product Limited Warranty Specifically...

Page 166: ...rt department P O Box 66 Perry OK 73077 0066 or contact your local Ditch Witch dealer First version 1 91 Latest revision 4 99 For information regarding this limited warranty contact CMW s Product Supp...

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Page 169: ...JT920 JT920L 169 JT920 JT920L 169...

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