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Ditch Witch JT520 Operator's Manual

Ditch Witch JT520 Operator's Manual

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JT520
Operator's
Manual
®
Issue 1.1
053-1219
CMW

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Summary of Contents for Ditch Witch JT520

  • Page 1 JT520 Operator’s Manual ® Issue 1.1 053-1219...

  • Page 2: Overview

    JT520 Operator’s Manual Overview - 1 Overview Chapter Contents Serial Number Location ..... . 2 Intended Use ....... 3 Unit Components .
  • Page 3 JT520 Operator’s Manual Overview - 2 Serial Number Location Serial Number Location Record serial numbers and date of purchase in spaces provided. Drilling unit serial number is located as shown. Item date of manufacture date of purchase drilling unit serial number...
  • Page 4 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 operated, serviced, and repaired only by persons familiar with its particular characteristics and acquainted with the relevant safety procedures.
  • Page 5 JT520 Operator’s Manual Overview - 4 Operator Orientation Operator Orientation IMPORTANT: Top view of unit is shown. 1. Front of unit 2. Right side of unit 3. Rear of unit 4. Left side of unit About This Manual This manual contains information for the proper use of this machine.

  • Page 6: Foreword

    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.
  • Page 7 Copyright 2008 by The Charles Machine Works, Inc. , 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.

  • Page 8: Table Of Contents

    JT520 Operator’s Manual Contents - 7 Contents Overview 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 part number, revision level, and publication date of this manual, and factory contact...
  • Page 9 JT520 Operator’s Manual Contents - 8 Specifications machine specifications including weights, measurements, power ratings, and fluid capacities Support the warranty policy for this machine, and procedures for obtaining warranty consideration and training Service Record a record of major service performed on the machine...

  • Page 10: Safety

    JT520 Operator’s Manual Safety - 9 Safety Chapter Contents Guidelines ....... . 10 Safety Alert Classifications .

  • Page 11: Guidelines

    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.

  • Page 12: Safety Alert Classifications

    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.

  • Page 13: Safety Alerts

    JT520 Operator’s Manual Safety - 12 Safety Alerts Safety Alerts Turning shaft will kill you or crush arm or leg. Stay away. Electric shock. Contacting electric lines will cause death or serious injury. Know location of lines and stay away.
  • Page 14 JT520 Operator’s Manual Safety - 13 Safety Alerts Explosion possible. Serious injury or equipment damage could occur. Follow directions carefully. Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly. Improper control function could cause death or serious injury. If control does not work as described in instructions, stop machine and have it serviced.
  • Page 15 JT520 Operator’s Manual Safety - 14 Safety Alerts Hot pressurized cooling system fluid could cause serious burns. Allow to cool before servicing. Flying objects may cause injury. Wear hard hat and safety glasses. Hot parts may cause burns. Do not touch until cool.

  • Page 16: Emergency Procedures

    JT520 Operator’s Manual Safety - 15 Emergency Procedures Emergency Procedures Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. Before operating any equipment, review emergency procedures and check that all safety precautions have been taken.

  • Page 17: If An Electric Line Is Damaged

    JT520 Operator’s Manual Safety - 16 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.

  • Page 18: If A Gas Line Is Damaged

    JT520 Operator’s Manual Safety - 17 Emergency Procedures If a Gas Line is Damaged Fire or explosion possible. Fumes could ignite and cause burns. No smoking, no flame, no spark. Explosion possible. Serious injury or equipment damage could occur. Follow directions carefully.

  • Page 19: If A Fiber Optic Cable Is Damaged

    JT520 Operator’s Manual Safety - 18 Emergency Procedures If a Fiber Optic Cable is Damaged Do not look into cut ends of fiber optic or unidentified cable. Vision damage can occur. If Machine Catches on Fire Perform emergency shutdown procedure and then take the following actions. The order and degree of action will depend on the situation.

  • Page 20: Controls

    JT520 Operator’s Manual Controls - 19 Controls Chapter Contents Set-Up Console ......20 Operator’s Station ......22 •...

  • Page 21: Set-Up Console

    JT520 Operator’s Manual Controls - 20 Set-Up Console Set-Up Console 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.
  • Page 22 JT520 Operator’s Manual Controls - 21 Set-Up Console Item Description Notes 2. Left track control To move forward, push. To move backward, pull. To stop, move to center. c00ic147h.eps 3. Right track control To move forward, push. To move backward, pull.

  • Page 23: Operator's Station

    JT520 Operator’s Manual Controls - 22 Operator’s Station Operator’s Station Gauges and Indicators 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...
  • Page 24 JT520 Operator’s Manual Controls - 23 Operator’s Station Item Description Notes 2. Glow plug indicator Lights when glow plugs are operating. Wait until light goes off before starting engine. 3. Hourmeter Displays engine operating Use engine operating times to time.
  • Page 25 JT520 Operator’s Manual Controls - 24 Operator’s Station Item Description Notes 6. Drilling fluid pressure Displays drilling fluid pressure gauge supplied by drilling fluid pump. c00ic157h.eps 7. Fuel gauge Displays fuel level. IMPORTANT: Use low sulfur or ultra low sulfur fuel only.

  • Page 26: Controls

    JT520 Operator’s Manual Controls - 25 Operator’s Station Controls 1. Ignition switch 6. Carriage control 2. Engine throttle control 7. Anchor collar rotation lock control 3. Auxiliary wrench handle 8. Wrench control 4. Fluid flow control 9. Anchor control 5. Pipe lubricator control 10.
  • Page 27 JT520 Operator’s Manual Controls - 26 Operator’s Station Item Description Notes 2. Engine throttle control To increase engine speed, push up. To decrease engine speed, pull down. 3. Auxiliary wrench To engage auxiliary wrench, handle lower over wrench flats. To disengage, raise.
  • Page 28 JT520 Operator’s Manual Controls - 27 Operator’s Station Item Description Notes 8. Wrench control 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.

  • Page 29: Engine Compartment

    JT520 Operator’s Manual Controls - 28 Engine Compartment Engine Compartment 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.
  • Page 30 JT520 Operator’s Manual Controls - 29 Engine Compartment 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 (up). To override tracker control mode, move key to disable position (right).

  • Page 31: Esid

    JT520 Operator’s Manual Controls - 30 ESID ESID j07om042h.eps 1. Alphanumeric display 5. Current problem indicator 2. Strike indicator 6. OK indicator 3. Alarm interrupt button 7. Electrical power supply indicator 4. Voltage problem indicator 8. Self test button Item...
  • Page 32 JT520 Operator’s Manual Controls - 31 ESID Item Description Notes 2. Strike indicator Red lights come on as values NOTICE: The ESID does not indicate in display increase. proximity to electric lines. System will activate only when voltage and/or Light in triangle represents...
  • Page 33 JT520 Operator’s Manual Controls - 32 ESID Item Description Notes 6. OK indicator Green light means system self test detected no problems. Strike system is ready to operate. 7. Electrical power supply Green light means control indicator box has sufficient electrical power for operation.

  • Page 34: 750/752 Display

    JT520 Operator’s Manual Controls - 33 750/752 Display 750/752 Display Indicators 1. Beacon temperature display 5. Depth estimate 2. Pitch/slope indicator and percentage indicator 6. Display battery status indicator 3. Roll indicator 7. Beacon battery status indicator 4. Target indentifier indicator 8.
  • Page 35 JT520 Operator’s Manual Controls - 34 750/752 Display Item Description Notes 2. Pitch/slope indicator Indicates pitch beacon Internal: shows pipe label and stored and percentage percent of grade. pitch. indicator External: shows desired pitch. 3. Roll indicator Indicates beacon roll angle.
  • Page 36 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. 7. Beacon battery status Indicates beacon battery See beacon instruction sheet.

  • Page 37: Controls

    JT520 Operator’s Manual Controls - 36 750/752 Display Controls 1. Delete button 4. Roll stop button 2. On/Off button 5. Recall button 3. Channel select button 6. Store button IMPORTANT: Some items operate differently depending where data is being saved. Internal refers to pipe data being saved to 750 Display memory.
  • Page 38 JT520 Operator’s Manual Controls - 37 750/752 Display Item Description Notes 3. Channel select button To display current channel, Unit defaults to last channel used press and release. each time unit is turned on. To switch channels, press IMPORTANT: Make sure display and and hold.
  • Page 39 JT520 Operator’s Manual Controls - 38 750/752 Display Item Description Notes 6. Store button To display serial number, Pipe number will appear in numeric press and hold while pressing display when data is stored. on/off button. To store current pipe data, IMPORTANT: Pipe data cannot be press.

  • Page 40: Operation Overview

    JT520 Operator’s Manual Operation Overview - 39 Operation Overview Chapter Contents Planning........40 Setting Up at Jobsite .

  • Page 41: Planning

    JT520 Operator’s Manual Operation Overview - 40 Planning Planning 1. Gather information about jobsite. See page 45. 2. Inspect jobsite. See page 46. 3. Classify jobsite. See page 48. 4. Plan bore path. See page 50. 5. Check supplies and prepare equipment. See page 56.

  • Page 42: Drilling

    • Keep all bends as gradual as possible. • Drilling fluid quality is a key factor in backreaming success. Contact your Ditch Witch dealer for information on testing water, selecting additives, and mixing drilling fluid. • Backreaming requires more fluid than drilling. Make sure enough fluid is used.

  • Page 43: Leaving Jobsite

    JT520 Operator’s Manual Operation Overview - 42 Leaving Jobsite Leaving Jobsite 1. Remove downhole tools. See page 84. 2. Remove anchors. See page 87. 3. Rinse unit and downhole tools. See page 115. 4. Disassemble strike system and disconnect from fluid system. See page 115.

  • Page 44: Prepare

    JT520 Operator’s Manual Prepare - 43 Prepare Chapter Contents Gather Information ......45 • Review Job Plan ......... . .45 •...

  • Page 45: Prepare

    JT520 Operator’s Manual Prepare - 44 Prepare Jobsite ......55 • Mark Bore Path ..........55 •...

  • Page 46: Gather Information

    JT520 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.

  • Page 47: Inspect Site

    JT520 Operator’s Manual Prepare - 46 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 •...

  • Page 48: Select Start And End Points

    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.

  • Page 49: Classify Jobsite

    JT520 Operator’s Manual Prepare - 48 Classify Jobsite Classify Jobsite Inspect Jobsite • Follow U.S. Department of Labor regulations on excavating and trenching (Part 1926, Subpart P) and other similar regulations. • Contact your local One-Call (811 in USA) or the One-Call referral number (888-258-0808 in USA and Canada) to have underground utilities located before digging.

  • Page 50: Apply Precautions

    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.

  • Page 51: 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 ®...

  • Page 52: Recommended Bend Limits

    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.
  • Page 53 JT520 Operator’s Manual Prepare - 52 Plan Bore Path Pipe-By-Pipe Bend Limits Pipe Forward (B) Deflection (A) Pipe Forward (B) Deflection (A) 4’ 11" (1.5 m) 0’ 2" (.05 m) 55’ 5" (16.9 m) 27’ 3" (8.3 m) 9’ 10" (3.0 m) 0’...

  • Page 54: Entry Pitch

    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.

  • Page 55: Minimum Depth

    JT520 Operator’s Manual Prepare - 54 Plan Bore Path Minimum Depth Because you must bend pipe gradually, entry pitch and bend limits determine how deep the pipe will be when it becomes horizontal. This is called the minimum depth. •...

  • Page 56: Prepare Jobsite

    JT520 Operator’s Manual Prepare - 55 Prepare Jobsite Prepare Jobsite Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. NOTICE: • If jobsite classification is in question or if the possibility of unmarked electric utilities exists, classify jobsite as electric.

  • Page 57: Check Supplies And Prepare Equipment

    JT520 Operator’s Manual Prepare - 56 Check Supplies and Prepare Equipment Check Supplies and Prepare Equipment Check Supplies • receiver/transmitter or tracker with spare batteries • beacons with new and spare batteries • two-way radios with new and spare batteries •...

  • Page 58: Prepare Equipment

    JT520 Operator’s Manual Prepare - 57 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 •...
  • Page 59 JT520 Operator’s Manual Prepare - 58 Check Supplies and Prepare Equipment...

  • Page 60: Drive

    JT520 Operator’s Manual Drive - 59 Drive Chapter Contents Start Unit ....... . . 60 Steer Unit .
  • Page 61 JT520 Operator’s Manual Drive - 60 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 for more information.
  • Page 62 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.
  • Page 63 JT520 Operator’s Manual Drive - 62 Shut Down Unit...

  • Page 64: Transport

    JT520 Operator’s Manual Transport - 63 Transport Chapter Contents Lift ........64 •...

  • Page 65: Lift

    JT520 Operator’s Manual Transport - 64 Lift Lift Crushing weight. If load falls or moves it could kill or crush you. Use proper procedures and equipment or stay away. Points Lifting points are identified by lifting decals. Lifting at other points is unsafe...

  • Page 66: Procedure

    JT520 Operator’s Manual Transport - 65 Lift Procedure Use a crane capable of supporting the equipment's size and weight. 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).

  • Page 67: Haul

    JT520 Operator’s Manual Transport - 66 Haul Haul Load Crushing weight. If load falls or moves it could kill or crush you. Use proper procedures and equipment or stay away. NOTICE: • Load and unload trailer on level ground. •...

  • Page 68: Tie Down

    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. Procedure Incorrect procedures could result in death, injury, or property damage.

  • Page 69: Unload

    JT520 Operator’s Manual Transport - 68 Haul Unload Crushing weight. If load falls or moves it could kill or crush you. Use proper procedures and equipment or stay away. NOTICE: • Load and unload trailer on level ground. • Ensure trailer wheels are blocked.

  • Page 70: Tow

    JT520 Operator’s Manual Transport - 69 Under normal conditions, drilling unit should not be towed. If unit breaks down and towing is necessary: • Attach chains to indicated tow points facing towing vehicle. • Disengage track hydraulics. • Tow for short distances at less than 1 mph (1.6 km/h).
  • Page 71 JT520 Operator’s Manual Transport - 70...

  • Page 72: Conduct A Bore

    JT520 Operator’s Manual Conduct a Bore - 71 Conduct a Bore Chapter Contents Position Equipment ......73 Connect Fluid System .
  • Page 73 JT520 Operator’s Manual Conduct a Bore - 72 Record Bore Path ......80 Surface Drill Head ......81 Assemble Backream String .

  • Page 74: Position Equipment

    JT520 Operator’s Manual Conduct a Bore - 73 Position Equipment Position Equipment 1. Review bore plan and select drilling unit position and fluid unit position. See “Select Start and End Points” on page 47. 2. Move equipment into selected positions.

  • Page 75: Operate Carriage Control

    JT520 Operator’s Manual Conduct a Bore - 74 Operate Carriage Control Operate Carriage Control The thrust/rotation control has eight positions which allow the four basic functions to be combined. The chart below summarizes functions that occur when control is put at a combined position. Operator must be in seat for control to function.

  • Page 76: Assemble Drill String

    1. Select nozzles and bit. 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. 2. Insert nozzle (2) into beacon housing.

  • Page 77: Attach Transition Sub

    JT520 Operator’s Manual Conduct a Bore - 76 Assemble Drill String Attach Transition Sub Use either machine 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.

  • Page 78: Drill First Pipe

    JT520 Operator’s Manual Conduct a Bore - 77 Drill First Pipe Drill First Pipe Turning shaft can kill you or crush arm or leg. Stay away. NOTICE: • Keep everyone at least 10’ (3 m) away from turning drill string.

  • Page 79: Add Pipe

    JT520 Operator’s Manual Conduct a Bore - 78 Add Pipe Add Pipe 1. When joint flats are aligned with front wrench, release joystick. 2. Engage front wrench. 3. Rotate spindle clockwise slowly until wrench flats engage pipe flats. 4. Reverse rotation and slowly move carriage back as threads unscrew.

  • Page 80: 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.

  • Page 81: Drill Head Position

    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.

  • Page 82: Surface Drill Head

    JT520 Operator’s Manual Conduct a Bore - 81 Surface Drill Head Surface Drill Head Moving tools will injure or kill. Shut off drill string power when anyone can be struck by moving or thrown tools. Never use pipe wrenches on drill string.

  • Page 83: Assemble Backream String

    JT520 Operator’s Manual Conduct a Bore - 82 Assemble Backream String Assemble Backream String Turning shaft will kill you or crush arm or leg. Stay away. NOTICE: Keep everyone away from material being installed. Moving tools will injure or kill. Shut off drill string power when anyone can be struck by moving or thrown tools.

  • Page 84: Remove Pipe

    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. 2. Engage front wrench. 3. Rotate spindle clockwise until wrench flats engage into pipe flats.

  • Page 85: Remove Pullback Device

    JT520 Operator’s Manual Conduct a Bore - 84 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.

  • Page 86: Systems And Equipment

    JT520 Operator’s Manual Systems and Equipment - 85 Systems and Equipment Chapter Contents Anchor System ......87 •...
  • Page 87 JT520 Operator’s Manual Systems and Equipment - 86 Downhole Tools ......102 • Nozzles ..........102 •...

  • Page 88: Anchor System

    JT520 Operator’s Manual Systems and Equipment - 87 Anchor System Anchor System Crushing weight. If load falls or moves, it could kill or crush you. Use proper procedures and equipment or stay away. NOTICE: • Drive anchor properly before drilling.

  • Page 89: Electric Strike System

    JT520 Operator’s Manual Systems and Equipment - 88 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: •...

  • Page 90: Assemble Voltage Detector

    JT520 Operator’s Manual Systems and Equipment - 89 Electric Strike System Assemble Voltage Detector 1. Drive voltage stake into ground at least 6’ (2 m) away from any part of system. 2. Clip voltage limiter to voltage stake. Test Strike System If system fails any part of this test, see “Troubleshoot Strike System”...

  • Page 91: Troubleshoot Strike System

    Defective control module Have control module checked or replaced Information on screen is LCD contrast is not set properly Contact your Ditch Witch dealer to visible during self test but adjust contrast not after test is complete OK indicator is on, but...
  • Page 92 JT520 Operator’s Manual Systems and Equipment - 91 Electric Strike System Problem Possible cause Possible solution Strobe light on drilling unit Improper connections with Check connections and wiring does not work during total control module harness test Defective strobe light 1.

  • Page 93: Use Electric Strike Simulator

    JT520 Operator’s Manual Systems and Equipment - 92 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 Defective voltage limiter Have voltage limiter checked or...
  • Page 94 JT520 Operator’s Manual Systems and Equipment - 93 Electric Strike System To test for current at strike levels: 1. Put two or three loops through current transformer. 2. Follow steps above to test. 3. Display should show the following: •...

  • Page 95: Drilling Fluid

    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.

  • Page 96: Bentonite

    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.

  • Page 97: Basic Fluid Recipes

    JT520 Operator’s Manual Systems and Equipment - 96 Drilling Fluid Basic Fluid Recipes Soil type Mixture/100 gal (378 L) of water Notes fine sand 35 lb (16 kg) Bore-Gel coarse sand 35 lb (16 kg) Bore-Gel Add .5 lb (225 g) of Quik-Trol for .5 lb (225 g) No-Sag...

  • Page 98: Drilling Fluid Requirements

    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 • Water supply. If more water than can be carried with the unit will be needed, arrange to transport additional water.

  • Page 99: Funnel Viscosity

    JT520 Operator’s Manual Systems and Equipment - 98 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.

  • Page 100: Tracker Control

    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.
  • Page 101 JT520 Operator’s Manual Systems and Equipment - 100 Tracker Control 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: •...
  • Page 102 JT520 Operator’s Manual Systems and Equipment - 101 Tracker Control Disable Thrust and Rotation 1. When drill head enters target pit or exits the ground, turn off tracker. After 8-16 seconds, green tracker control light (shown), located on drilling unit carriage, will come on.

  • Page 103: Nozzles

    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.

  • Page 104: Beacon Housings

    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 hard soil packed clays, gumbo, all compacted soils...

  • Page 105: 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.

  • Page 106: Backream Fluid Requirements

    Metric 18 L x .5 m/min = 9 L for each minute of each minute of backreaming. backreaming IMPORTANT: After you have determined how much fluid you will need, see your Ditch Witch dealer for nozzle recommendations.
  • Page 107 JT520 Operator’s Manual Systems and Equipment - 106 Downhole Tools Backream Fluid Requirements Backreamer/product Gal/ft Backreamer/product Gal/ft diameter diameter .5 in 13 mm 0.01 0.13 13.5 in 343 mm 7.44 92.35 1 in 25 mm 0.04 0.51 14 in 356 mm 8.00...

  • Page 108: Quick Wrench

    JT520 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. Moving tools will injure or kill. Shut off drill string power when anyone can be struck by moving or thrown tools.
  • Page 109 JT520 Operator’s Manual Systems and Equipment - 108 Quick Wrench To Join 1. Scribe straight line across joint on both sides of separating line (A). 2. Scribe second line (B) on moveable side of joint in the opposite direction of tightening action .25” (6 mm) away from first line.

  • Page 110: Drill Pipe

    JT520 Operator’s Manual Systems and Equipment - 109 Drill Pipe Drill Pipe Perform Regular Drill Pipe Care Precondition New Pipe Repeat this procedure three times for each piece of pipe before it is used the first time: 1. Hand-lubricate entire surface of threads and shoulders of both ends of pipe with copper base tool joint compound.
  • Page 111 JT520 Operator’s Manual Systems and Equipment - 110 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. Replace Worn Saver Sub Because each pipe comes in contact with the saver sub, check saver sub regularly for wear.

  • Page 112: Use Drill Pipe Correctly

    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.
  • Page 113 JT520 Operator’s Manual Systems and Equipment - 112 Drill Pipe...

  • Page 114: Complete The Job

    JT520 Operator’s Manual Complete the Job - 113 Complete the Job Chapter Contents Antifreeze Drilling Unit ....114 • Add Antifreeze ......... . .114 •...

  • Page 115: Antifreeze Drilling Unit

    JT520 Operator’s Manual Complete the Job - 114 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.

  • Page 116: Rinse Equipment

    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.
  • Page 117 JT520 Operator’s Manual Complete the Job - 116 Stow Tools...

  • Page 118: Service

    JT520 Operator’s Manual Service - 117 Service Chapter Contents Service Precautions ..... . . 118 Recommended Lubricants/Service Key ..120 10 Hour .
  • Page 119 JT520 Operator’s Manual Service - 118 Service Precautions Service Precautions Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly. NOTICES: • Unless otherwise instructed, all service should be performed with engine off. • Refer to engine manufacturer’s manual for engine maintenance instructions.
  • Page 120 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.
  • Page 121 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.
  • Page 122 JT520 Operator’s Manual Service - 121 Recommended Lubricants/Service Key Engine Oil Temperature Chart 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.
  • Page 123 JT520 Operator’s Manual Service - 122 10 Hour 10 Hour Location Task Notes DRILLING Check engine air filter service indicator UNIT Check engine oil level Check hydraulic hoses Check hydraulic fluid level Check coolant level DEAC Check drilling fluid pump oil level...
  • Page 124 JT520 Operator’s Manual Service - 123 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...
  • Page 125 JT520 Operator’s Manual Service - 124 10 Hour Check Hydraulic Hoses Pressurized fluid or air could pierce skin and cause injury or death. Stay away. NOTICE: Escaping pressurized fluid can cause injury or pierce skin and poison. • Before disconnecting a hydraulic line, turn engine off and operate all controls to relieve pressure.
  • Page 126 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.
  • Page 127 JT520 Operator’s Manual Service - 126 50 Hour 50 Hour Location Task Notes DRILLING Change engine oil and filter Initial service, DEO UNIT Change drilling fluid pump oil (initial) Check radiator Change hydraulic filter Initial service Check rotation gearbox oil level...
  • Page 128 JT520 Operator’s Manual Service - 127 50 Hour Change Drilling Fluid Pump Oil (Initial 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.
  • Page 129 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.
  • Page 130 JT520 Operator’s Manual Service - 129 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. Loosen two alternator bolts (shown).
  • Page 131 JT520 Operator’s Manual Service - 130 100 Hour 100 Hour Location Task Notes DRILLING Change engine oil and filter UNIT Lube thrust chain Drilling Unit Change Engine Oil and Filter (Normal Service) Change engine oil and filter every 100 hours for normal service.
  • Page 132 JT520 Operator’s Manual Service - 131 150 Hour 150 Hour Change Fuel Filter Change filter (shown) every 150 hours.
  • Page 133 JT520 Operator’s Manual Service - 132 250 Hour 250 Hour Location 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.
  • Page 134 JT520 Operator’s Manual Service - 133 750 Hour 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 pump is 1 qt (0.9...
  • Page 135 JT520 Operator’s Manual Service - 134 1000 Hour 1000 Hour Location Task Notes DRILLING Change rotation gearbox oil UNIT Change hydraulic fluid and filter Drilling Unit Change Rotation Gearbox Oil Drain oil at gearbox oil drain (3) every 1000 hours.
  • Page 136 JT520 Operator’s Manual Service - 135 2000 Hour 2000 Hour Change Coolant Drain (2) coolant and add DEAC at fill (1) every 2000 hours.
  • Page 137 9. Watch for grease to come out of weep hole. 10. Screw cartridge back in when grease comes out of hole.. NOTICE: Use only genuine Ditch Witch tool joint compound to maintain warranty. See “Recommended Lubricants/Service Key” on page 120 for more information.
  • Page 138 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).
  • Page 139 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.
  • Page 140 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. Check Carriage Slide Bars Check slide bars (shown) for wear and replace as needed.
  • Page 141 JT520 Operator’s Manual Service - 140 As Needed...
  • Page 142 JT520 Operator’s Manual Specifications - 141 Specifications Dimensions U.S. Metric L, overall machine length 117 in 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...
  • Page 143 JT520 Operator’s Manual Specifications - 142 Operational U.S. Metric Maximum spindle speed 195 rpm 195 rpm Spindle torque, makeup 500 ft•lb 678 N•m Spindle torque, breakout 600 ft•lb 813 N•m Thrust force 4500 lb 20 kN Pullback force 5000 lb 22.2 kN...
  • Page 144 JT520 Operator’s Manual Specifications - 143 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 38 L Hydraulic reservoir...
  • Page 145 JT520 Operator’s Manual Specifications - 144...
  • Page 146 Return damaged parts to dealer for inspection and warranty consideration if in warranty time frame. Order genuine Ditch Witch replacement or repair parts from your authorized Ditch Witch dealer. Use of another manufacturer's parts may void warranty consideration.
  • Page 147 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).
  • Page 150 JT520 Operator’s Manual Service Record - 149 Service Record Service Performed Date Hours...
  • Page 151 JT520 Operator’s Manual Service Record - 150 Service Performed Date Hours...

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