053-1361 JT2020T3 - 3-0

JT2020 Mach 1
Tier 3
Operator’s
Manual
CMW®
Issue 3.0 053-1361
Original Instruction
JT2020 Mach 1 Operator’s Manual Overview - 1
Overview
Chapter Contents
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . 2
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Equipment Modification . . . . . . . . . . . . . . . . . . . . . . 3
Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operator Orientation. . . . . . . . . . . . . . . . . . . . . . . . . 5
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 5

• Bulleted Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
• Numbered Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
• “Continued” Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CMW
Overview - 2 JT2020 Mach 1 Operator’s Manual
Serial Number Location
Serial Number Location

Record serial numbers and date of purchase in spaces provided. Drilling unit serial number is located as
shown.
Item
date of manufacture
date of purchase
drilling unit serial number
engine serial number
trailer serial number
CMW
Intended Use
Intended Use
The JT2020 Mach 1 is a self-contained horizontal directional drilling unit designed to install buried cable
and pipe at distances to 400’ (122 m) depending on soil conditions.
The unit is designed for operation in temperatures typically experienced in earth moving and construction
work environments. Provisions may be required to operate in extreme temperatures. Contact your Ditch
Witch dealer. Use in any other way is considered contrary to the intended use.
The JT2020 Mach 1 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.
Equipment Modification
This equipment was designed and built in accordance with applicable standards and regulations.
Modification of equipment could mean that it will no longer meet regulations and may not function properly
or in accordance with the operating instructions. Modification of equipment should only be made by
competent personnel possessing knowledge of applicable standards, regulations, equipment design
functionality/requirements and any required specialized testing.
CMW
Unit Components
Unit Components
1
2
6 6
8 7 5
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1. Operator’s station 6. Pipeloader

2. Spindle 7. Tracks
3. Carriage 8. Vise wrenches
4. Drill frame 9. Anchoring system
5. Stabilizer
CMW
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. See the beige Operation Overview
pages for basic operating procedures. Cross references such as “See page 50” will direct you to detailed
procedures.
Bulleted Lists
Bulleted lists provide helpful or important information or contain procedures that do not have to be
performed in a specific order.
Numbered Lists
Numbered lists contain illustration callouts or list steps that must be performed in order.
“Continued” Indicators
indicates that a procedure is continued on the next page.
CMW
About This Manual
CMW
JT2020 Mach 1 Operator’s Manual Foreword - 7
Foreword
This manual is an important part of your equipment. It provides safety information and operation
instructions to help you use and maintain your Ditch Witch equipment.
Read this manual before using your equipment. Keep it with the equipment at all times for future reference.
If you sell your equipment, be sure to give this manual to the new owner.
If you need a replacement copy, contact your Ditch Witch dealer. If you need assistance in locating a
dealer, visit our website at www.ditchwitch.com or write to the following address:
The Charles Machine Works, Inc.

Attn: Marketing Department
PO Box 66
Perry, OK 73077-0066
USA
The descriptions and specifications in this manual are subject to change without notice. The Charles
Machine Works, Inc. reserves the right to improve equipment. Some product improvements may have
taken place after this manual was published. For the latest information on Ditch Witch equipment, see your
Ditch Witch dealer.
Thank you for buying and using Ditch Witch equipment.
CMW
Foreword - 8 JT2020 Mach 1 Operator’s Manual
JT2020 Mach 1 (Tier 3)

Operator’s Manual
Issue number 3.0/OM-4/11

Part number 053-1361
Copyright 2009, 2010, 2011

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.
This product is covered by one or more of the following patents:

U.S. B1 4,858,704; 4,953,638; 5,148,880; 5,242,026; 5,341,887; 5,490,569; 5,684,466; 5,713,423; 5,794,719; 5,880,680; 5,941,322;
6,085,852; 6,109,371; 6,179,065; 6,216,803; 6,250,403; 6,250,404; 6,290,606; 6,311,790; 6,411,094; 6,543,551; 6,550,547;
6,672,409; 6,739,413; 6,761,231; 6,776,246; 6,808,210; 6,827,158; 6,848,506; 6,871,712; RE37,450; RE37,923; RE37,975;
RE38,418; AU 689,533; 706,544; 718,034; 755,862; CA 2,156,398; 2,217,899; DE 694 17 019; 695 29 634; 297 01 406;
EP 0683845; 0674093; 0817901; 0846841; 0927892; FR 674,093; GB 2,309,239; 2,312,006; EP674,093; EP846,841; JP 3,458,247;
other U.S. and foreign patents pending.
CMW
JT2020 Mach 1 Operator’s Manual Contents - 9
Contents
Overview 1
machine serial number, information about the type of work this machine is designed
to perform, basic machine components, and how to use this manual
Foreword 7
part number, revision level, and publication date of this manual, and factory contact
information
Safety 11
machine safety alerts and emergency procedures
Controls 21
machine controls, gauges, and indicators and how to use them
Operation Overview 59
an overview for completing a job with this machine: planning, setting up, installing
product, and restoring the jobsite; with cross references to detailed procedures
Prepare 63
procedures for inspecting and classifying the jobsite, planning the installation path,
and preparing the jobsite for work
Drive 79
procedures for startup, cold start, driving, and shutdown
Transport 83
procedures for lifting, hauling, and towing
Conduct a Bore 91
procedures for drilling and backreaming
Systems and Equipment 113

downhole tools and drill pipe, anchor, electric strike, tracker control, and fluid
systems
Complete the Job 153

procedures for restoring the jobsite and rinsing and storing equipment
Service 159
service intervals and instructions for this machine including lubrication, replacement
of wear items, and basic maintenance
CMW
Contents - 10 JT2020 Mach 1 Operator’s Manual
Specifications 193
machine specifications including weights, measurements, power ratings, and fluid
capacities
Support 153
the warranty policy for this machine, and procedures for obtaining warranty
consideration and training
Service Record 201

a record of major service performed on the machine
CMW
JT2020 Mach 1 Operator’s Manual Safety - 11
Safety
Chapter Contents
Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Safety Alert Classifications . . . . . . . . . . . . . . . . . . 13
Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Emergency Procedures . . . . . . . . . . . . . . . . . . . . . 17
• Electric Strike Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
• If an Electric Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
• If a Gas Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
• If a Fiber Optic Cable is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
• If Machine Catches on Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CMW
Safety - 12 JT2020 Mach 1 Operator’s Manual
Guidelines
Guidelines
Follow these guidelines before operating any jobsite equipment:
• Complete proper training and read operator’s manual before using equipment.
• Contact your local One-Call (811 in USA) or the One-Call referral number (888-258-0808 in USA and
Canada) to have underground utilities located before digging. Also contact any utilities that do not
participate in the One-Call service.
• Classify jobsite based on its hazards and use correct tools and machinery, safety equipment, and work
methods for jobsite.
• Mark jobsite clearly and keep spectators away.
• Wear personal protective equipment.
• Review jobsite hazards, safety and emergency procedures, and individual responsibilities with all
personnel before work begins. Safety videos are available from your Ditch Witch dealer.
• Replace missing or damaged safety shields and safety signs.
• Use equipment carefully. Stop operation and investigate anything that does not look or feel right.
• Do not operate unit where flammable gas may be present.
• Contact your Ditch Witch dealer if you have any question about operation, maintenance, or equipment
use.
CMW
Safety Alert Classifications
Safety Alert Classifications

These classifications and the icons defined on the following pages work together to alert you to situations
which could be harmful to you, jobsite bystanders or your equipment. When you see these words and
icons in the book or on the machine, carefully read and follow all instructions. YOUR SAFETY IS AT
STAKE.
Watch for the three safety alert 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 situation which, if not avoided, could result in death or
serious injury.
indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
Watch for two other words: NOTICE and IMPORTANT.
NOTICE can keep you from doing something that might damage the machine or someone's property. It
can also alert you against unsafe practices.
IMPORTANT can help you do a better job or make your job easier in some way.
CMW
Safety 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.
Deadly gases. Lack of oxygen or presence of gas 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 string.
Jobsite hazards could cause death or serious injury. Use

correct equipment and work methods. Use and maintain proper safety
equipment.
Crushing weight could cause death or serious injury. Use

proper procedures and equipment or stay away.
Moving parts could cut off hand or foot. Stay away.
CMW
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.
Looking into fiber optic cable could result in permanent vision damage. Do
not look into ends of fiber optic or unidentified cable.
Pressurized fluid or air could pierce skin and cause injury or

death. Stay away.
Fire or explosion possible. Fumes could ignite and cause burns. No

smoking, no flame, no spark.
Moving traffic - hazardous situation. Death or serious injury could result.

Avoid moving vehicles, wear high visibility clothing, post appropriate warning signs.
CMW
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.
Exposure to high noise levels may cause hearing loss. Wear hearing
protection.
Fall possible. Slips or trips may result in injury. Keep area clean.
Battery acid may cause burns. Avoid contact.
Improper handling or use of chemicals may result in illness, injury, or

equipment damage. Follow instructions on labels and in material safety data sheets
(MSDS).
CMW
Emergency Procedures

equipment.
Before operating any equipment, review emergency procedures and check that all safety precautions have
been taken.
EMERGENCY SHUTDOWN - Turn ignition switch to stop position or push remote engine stop button (if
equipped).
Electric Strike Description
When working near electric cables, remember the following:
• Electricity follows all paths to ground, not just path of least resistance.
• Pipes, hoses, and cables will conduct electricity back to all equipment.
• Low voltage current can injure or kill. Many work-related electrocutions result from contact with less
than 440 volts.
Most electric strikes are not noticeable, but indications of a strike include:
• power outage
• smoke
• explosion
• popping noises
• arcing electricity
If any of these occur, or if strike alarm sounds or flashes, assume an electric strike has occurred.
CMW
If an Electric Line is Damaged

If you suspect an electric line has been damaged and you are on drilling unit or bonded equipment, DO
NOT MOVE. Remain on drilling machine or mats and take the following actions. The order and degree of
action will depend on the situation.
• Warn people nearby that an electric strike has occurred.

• Have someone contact electric company.
• Reverse drilling direction and try to break contact. Do not touch drill pipe with hands or hand-held
tools.
• Press electric strike system status button.
• If alarm sounds again, stay where you are and wait for electric company to shut off power.
• If alarm does not sound and there is no other indication of a strike, wait at least one full minute
before moving away from equipment. Utility might use automatic reclosers which will restart
current flow. If alarm sounds again while waiting, stay where you are until electric company shuts
off power.
• If alarm does not sound but all lights in strike indicator are on, assume strike is continuing and stay
where you are until electric company shuts off power.
• Do not resume drilling or allow anyone into area until given permission by electric company.
If you suspect an electric line has been damaged and you are off drilling unit or bonded equipment, DO
NOT TOUCH ANY EQUIPMENT connected to drilling unit. Take the following actions. The order and
degree of action will depend on the situation.
• Stay where you are unless you are wearing electric insulating boots. If you leave, do not return to area
or allow anyone into area until given permission by electric company.
CMW
If a Gas Line is Damaged


If you suspect a gas line has been damaged, take the following actions. The order and degree of action will
depend on the situation.
• Immediately shut off engine(s), if this can be done safely and quickly.
• Remove any ignition source(s), if this can be done safely and quickly.
• Warn others that a gas line has been cut and that they should leave the area.
• Leave jobsite as quickly as possible.
• Immediately call your local emergency phone number and utility company.
• If jobsite is along street, stop traffic from driving near jobsite.
• Do not return to jobsite until given permission by emergency personnel and utility company.
CMW
If a Fiber Optic Cable is Damaged

Do not look into cut ends of fiber optic or unidentified cable. Vision damage can occur.
If Machine Catches on Fire

Perform emergency shutdown procedure and then take the following actions. The order and degree of
action will depend on the situation.
• Immediately move battery disconnect switch (if equipped) to disconnect position.

• If fire is small and fire extinguisher is available, attempt to extinguish fire.
• If fire cannot be extinguished, leave area as quickly as possible and contact emergency personnel.
CMW
JT2020 Mach 1 Operator’s Manual Controls - 21
Controls
Chapter Contents
Set-Up Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Tethered Ground Drive Controller . . . . . . . . . . . . 25
Left Control Console . . . . . . . . . . . . . . . . . . . . . . . 27

• Pipeloading controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
• Drilling/Operation controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Gauge Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
• Unit status indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
• Pipeloading status indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
• Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Right Control Console . . . . . . . . . . . . . . . . . . . . . . 42
Anchoring System Console . . . . . . . . . . . . . . . . . 44
Seat/Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
ESID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Ditch Witch Electronics 750/752 Display . . . . . . . 53
• Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
• Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
CMW
Controls - 22 JT2020 Mach 1 Operator’s Manual
Set-Up Console
Set-Up Console
1. Tracker control key 5. Right track switch

2. Cold start wait indicator 6. Right stabilizer control
3. Ignition switch 7. Frame tilt control
4. Left track switch 8. Left stabilizer control
Item Description Notes
1. 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).
CMW
Set-Up Console

2. Cold start wait indicator Lights when intake air pre-
heater is operating.
Wait until light goes off before

starting engine.
3. Ignition switch To start engine, insert key and IMPORTANT:

turn clockwise.
• Restart engine with ignition switch
To stop engine, turn key after it has been turned off with
counterclockwise. remote engine stop switch.
• If wrenches are engaged when
engine is stopped with ignition
switch, wrenches will release and
then engage when unit is started.
4. Left track switch To move forward, press top. IMPORTANT: Use track switches only
if tethered control is inoperable.
To move backward, press
bottom.
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5. Right track switch To move forward, press top. IMPORTANT: Use track switches only
if tethered control is inoperable.
To move backward, press
bottom.
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6. Right stabilizer control To raise, pull up. IMPORTANT: Lower left and right
stabilizers to the ground to stabilize
To lower, push down. unit and then adjust for side-to-side
stability. After unit is level, adjust for
entry angle.
NOTICE: Stand clear of stabilizer to

avoid crushing your foot.
CMW
Set-Up Console

7. Frame tilt control To raise front end of drill
frame, pull up.
To lower front end of drill

frame, push down.
8. Left stabilizer control To raise, pull up. IMPORTANT: Lower left and right
stabilizers to the ground to stabilize
To lower, push down. unit and then adjust for side-to-side
stability. After unit is level, adjust for
entry angle.
NOTICE: Stand clear of stabilizer to

avoid crushing your foot.
CMW
Tethered Ground Drive Controller
1
5
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1. Speed/direction control 4. Operator presence switch

2. Power mode switch 5. Throttle switch
3. Remote engine stop
1. Speed/direction control To move forward, push. IMPORTANT:
To move backward, pull. • Operator presence switch must

be pressed and operator seat
To steer, move left or right. must be empty for control to work.
• See “Steer Unit” on page 80 for
more information.
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CMW

2. Power mode switch To select normal driving mode
(high), push.
To select loading and

unloading mode (low), pull.
To disable controller, return to

center.
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3. Remote engine stop To stop engine, press red IMPORTANT: To restart engine, turn
button. ignition switch off and then back on.
4. Operator presence To operate ground drive with

switch tethered controller, press.
To disable controller, release.
5. Throttle switch To increase engine speed, IMPORTANT: Throttle switch at

push. operator’s station must be in center
position for this switch to control
To decrease engine speed, speed.
pull.
CMW
Left Control Console

Pipeloading Controls
1. Add pipe/manual/remove pipe switch 6. Pipe lift switch

2. Set/Resume switch 7. Pipe shuttle switch
3. Pipe box switch 8. Two-speed rotation switch
4. Resume switch 9. Pipe gripper switch
5. Wrench control 10. Pipe lubricator switch
IMPORTANT: Switch 1 will not function unless unit is equipped with pipeloader automation option.
CMW
1. Add pipe/manual/ To select “add pipe” See “Add Pipe” on page 102.
remove pipe switch automated pipeloader
function, press top.
To use manual pipeloader

controls, move to center.
To select “remove pipe” See “Remove Pipe” on page 109.

automated pipeloader
function, press bottom.
2. Set/Resume switch To resume operation or See “Cruise Control” on page 146.

increase operation levels,
RESUME / press top.
To set operating conditions or

reduce operation levels,
press bottom.
SET /
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3. Pipe box switch To shift pipe box toward IMPORTANT: See “Shift Pipe Box” on
operator, press left side. page 141.
To shift pipe box away from

operator, press right side.
4. Resume switch To resume operation, press. See “Add Pipe” on page 102.
CMW

5. Wrench control To clamp front wrench, move
to right.
To unclamp front wrench,

move to left.
To clamp and rotate rear

(rotating) wrench, push.
To unclamp rear (rotating)

wrench, pull.
6. Pipe lift switch To raise, press top.
To lower, press bottom.
7. Pipe shuttle switch To move toward pipe box,

press top.
To move toward spindle,

press bottom.
8. Two-speed rotation To rotate at low speed, high

switch torque, press right.
To rotate at high speed, low

torque, press left.
CMW

9. Pipe gripper switch To close, press top.
To open, press bottom.
10. Pipe lubricator switch To fill applicator at back of

pipeloader, press top.
To apply joint compound to

threads at wrenches, press
bottom.
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CMW
Drilling/Operation Controls
1. Engine throttle switch 6. Console/Work light switch

2. Drilling fluid pressure gauge 7. Fluid pump speed switch
3. Thrust pressure gauge 8. Fluid pump indicator
4. Rotation pressure gauge 9. Fluid flow control
5. Remote engine start switch
1. Engine throttle switch To increase speed, press top. Autothrottle mode slows the engine to
Return switch to center when low throttle after 15 seconds of
desired speed is reached. inactivity involving thrust, rotation,
drilling fluid flow, or pipeloader
To enable autothrottle mode, functions. To return to high speed,
press top and leave switch in activate thrust, rotation, drilling fluid,
top position. or an add/remove cycle.
To decrease speed, press

bottom.
To disable autothrottle mode,

return switch to center after
desired speed is reached.
CMW

2. Drilling fluid pressure Displays drilling fluid pressure
gauge supplied by drilling fluid
pump.
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3. Thrust pressure gauge Displays hydraulic fluid

pressure to thrust motor
during thrust and pullback.
Estimates thrust and pullback

force on lines outside gauge.
4. Rotation pressure Displays hydraulic fluid

gauge pressure to rotation motor
when spindle is turned
clockwise.
Estimates rotational torque on

lines outside gauge.
5. Remote engine start To start engine from IMPORTANT: This button works only
switch operator’s station, push when key on set-up console is on,
button. operator is in seat, and battery
disconnect switch is closed.
Release when engine starts.
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CMW

6. Console/Work light To turn on, press top.
switch
To turn off, press bottom.
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7. Fluid pump speed For high speed, press top. High speed delivers more flow at
switch lower pressure.
For low speed, press bottom. Low speed delivers less flow at higher
pressure.
8. Fluid pump indicator If fluid pump is on, light

should be on.
If fluid pump is off, light

should be off.
9. Fluid flow control To increase flow, turn

clockwise.
To decrease flow, turn

counterclockwise.
To stop flow, turn all the way

counterclockwise.
CMW
Gauge Cluster
Gauge Cluster
Unit Status Indicators
1. Diagnostic light (red) 5. Operator presence indicator

2. Hydraulic fluid temperature indicator 6. Cold start wait indicator
3. Hydraulic filter service indicator 7. Water in fuel indicator
4. Fluid pump status indicator 8. Battery charging indicator
CMW
Gauge Cluster
1. Diagnostic light (red) If system is OK, light should

be off.
If system may not be getting

power, light should be on.
If a non-essential diagnostic See “Interpret Diagnostic Codes” on

code is recorded, light should page 147.
flash on and off for 10
seconds.
If an essential diagnostic
code is recorded, light should
flash on for three seconds
and off for half a second.
2. Hydraulic fluid Indicates hydraulic fluid is • Check hydraulic fluid level.

temperature indicator overheating.
• Check cooler for debris. See
page 174.
3. Hydraulic filter service Indicates hydraulic fluid filter Change filter when indicator lights
indicator needs replacing. continuously and as indicated on
page 174.
4. Fluid pump status If fluid pump is on, light NOTICE: Do not run fluid pump
indicator should be on. without fluid.
If fluid pump is off, light

should be off.
CMW
Gauge Cluster

5. Operator presence Indicates operator is seated Thrust and rotation will not operate
indicator in operator’s station. unless light is on.
6. Cold start wait indicator Lights when intake air pre-

heater is operating.
Wait until light goes off before

starting engine.
7. Water in fuel indicator Indicates the presence of Drain water from fuel filter. See
water in the fuel. page 165.
8. Battery charging Indicates battery is not

indicator charging.
CMW
Gauge Cluster
Pipeloading Status Indicators
1. Control cycle light (green) 5. Rear stop status indicator

2. Front wrench status indicator 6. Pipe lift status indicator
3. Shuttle home status indicator 7. Front pipe box status indicator
4. Carriage home status indicator 8. Rear pipe box status indicator
1. Control cycle light If nothing is being controlled,

(green) light should be off.
If system is waiting for an

action before starting cycle,
light should flash on and off.
If something is being
controlled, light should be on.
If control cycle is interrupted,

light should flash twice
quickly.
CMW
Gauge Cluster

2. Front wrench status If front wrench is closed, light
indicator should be on.
If front wrench is open, light

should be off.
3. Shuttle home status If shuttle is retracted, light

indicator should be on.
If shuttle is not completely

retracted, light should be off.
4. Carriage home status If carriage is in the home

indicator zone at either end of drill
frame, light should be on.
If carriage is out of the home

zone at either end of drill
frame, light should be off.
5. Rear stop status If carriage is at very back of

indicator drill frame, light should be on.
If carriage is away from very

back of drill frame, light
should be off.
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Gauge Cluster

6. Pipe lift status indicator If pipe lifter is lifted fully and
lift pressure switch is
engaged, light should be on.
If pipe lift pressure switch is

not engaged, light should be
off.
7. Front pipe box status If active pipe column contains IMPORTANT:

indicator pipe, light should be on.
• Check pipe box status lights to
If active pipe column does not see when active column of pipe
contain pipe, light should be box is empty. See “Shift Pipe Box”
off. on page 141.
• One light on and one light off
indicates a jammed pipe. See
“Correct Misaligned or Jammed
Pipe” on page 142.
8. Rear pipe box status If active pipe column contains IMPORTANT:

indicator pipe, light should be on.
• Check pipe box status lights to
If active pipe column does not see when active column of pipe
contain pipe, light should be box is empty. See “Shift Pipe Box”
off. on page 141.
• One light on and one light off
indicates a jammed pipe. See
“Correct Misaligned or Jammed
Pipe” on page 142..
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Gauge Cluster
Gauges
1. Voltmeter 4. Engine oil pressure gauge

2. Tachometer/Hourmeter 5. Fuel gauge
3. Engine coolant temperature gauge
1. Voltmeter Displays system voltage. Should show 13-14V with engine

running.
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Gauge Cluster

2. Tachometer/Hourmeter Displays engine rpm. Full load reading should be 2600 rpm.
Displays engine operating Use these times to schedule service.

time.
3. Engine coolant Displays engine coolant Normal coolant temperature is

temperature gauge temperature. 160°-212° F (71°-100° C).
4. Engine oil pressure Displays engine oil pressure. Full load reading should be 35-65 psi
gauge (2.4-4.5 bar).
At idle, reading should not drop below

12 psi (0.8 bar).
5. Fuel gauge Displays fuel level in tank. Use only #2 diesel fuel.
Refer to engine operator’s manual for

cold weather fuel recommendations.
Tank holds 30 gal (114 L).
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Right Control Console
1. Drilling fluid pump switch 4. Drilling fluid quick fill switch

2. Dual speed carriage control 5. Remote engine stop switch
3. Carriage control
1. Drilling fluid pump To turn on, press once.

switch
To turn off, press once.
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2. Dual speed carriage To engage high carriage Use during bore or pullback when no
control travel speed, push and hold. pipe is in spindle to save time.
To return to normal carriage IMPORTANT: Overriding assisted

speed, release. makeup mode puts pipe threads in
jeopardy. If frequent overriding is
To override assisted makeup necessary, see your Ditch Witch
mode, push and hold. dealer for pipeloader adjustment.
3. Carriage control To move carriage forward, IMPORTANT: See “Operate Carriage

push. Control” on page 95 for more
information.
To move carriage backward,
pull.
To rotate spindle
counterclockwise (breakout),
move right.
To rotate spindle clockwise

(makeup), move left.
4. Drilling fluid quick fill To override fluid control

switch setting for full pump flow,
press and hold.
To return fluid flow to flow

control setting, release.
5. Remote engine stop To stop engine, press. IMPORTANT:

switch
To restart engine, turn ignition • If this switch is used to stop
off and then back to start. drilling unit, be sure to turn
ignition switch off if machine will
be left unattended for long
periods of time. Battery discharge
can occur.
• If wrenches are engaged when
remote stop is pressed, wrenches
will remain engaged but could
gradually open.
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Anchoring System Console
j10om015h.eps
1. Left rotation control 3. Right rotation control

2. Left thrust control 4. Right thrust control
1. Left rotation control To drive anchor, push down. IMPORTANT: Stand on platform when
operating anchor controls.
To remove anchor, pull up.
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2. Left thrust control To move anchor down, push IMPORTANT: Stand on platform when
down. operating anchor controls.
To move anchor up, pull up.
3. Right rotation control To drive anchor, push down. IMPORTANT: Stand on platform when
operating anchor controls.
To remove anchor, pull up.
4. Right thrust control To move anchor down, push IMPORTANT: Stand on platform when
down. operating anchor controls.
To move anchor up, pull up.
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Seat/Armrest
Seat/Armrest
1. Armrest adjustment 3. Seat slide control

2. Seat recline control
1. Armrest adjustment To adjust armrest position,

unscrew knob, move armrest
to new position, and screw
knob in.
2. Seat recline control To recline or raise seatback,

lift.
To lock seatback in position,

release.
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Seat/Armrest

3. Seat slide control To slide forward or backward,
move left.
To lock seat in position, move

right.
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Battery
Battery
1. Battery disconnect switch
1. Battery disconnect To connect, move clockwise.

switch
To disconnect, move
counterclockwise.
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Engine Compartment Controls
Engine Compartment Controls
1. High/auto fan speed switch
1. High/auto fan speed For high speed, press top. IMPORTANT: If switch is on high
switch speed, fan will run at full speed all the
For automatic speed, press time. If switch is on auto speed, fan
bottom. speed will vary in relation to engine
temperature.
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ESID
ESID
2 3
1
4
6
7
8
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
1. Alphanumeric display Displays amount of current

and voltage being detected
as a percentage of strike
condition.
The line with the “V” shows

voltage reading and the line
with the “A” shows current
reading.
2. Strike indicator Red lights come on as values If system is activated, assume a strike
in display increase. has occurred.
Light in triangle represents NOTICE: The ESID does not indicate

strike warning condition and proximity to electric lines. System will
will trigger alarm(s) and activate only when voltage and/or
strobe(s). amperage detected at the drilling unit
are above threshold minimum limits.
IMPORTANT: System can go
from one or two lights to an
electric strike immediately.
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ESID

3. Alarm interrupt button To turn off strike alarm at
drilling unit, press.
4. Voltage problem Blinking red light indicates a See “Troubleshoot Strike System” on
indicator voltage indicator problem. page 118.
5. Current problem Blinking red light indicates a See “Troubleshoot Strike System” on
indicator current indicator problem. page 118.
6. OK indicator Green light means system

self test detected no
problems.
Strike system is ready to

operate.
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ESID

7. Electrical power supply Green light means control
indicator 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, Checks all systems and circuits.
press.
To reset system after a strike NOTICE: See “If an Electric Line is

has been detected, press. Damaged” on page 18.
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Ditch Witch Electronics 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. Beacon temperature indicator
IMPORTANT: Some items operate differently depending where data is being saved. Internal refers to
pipe data being saved to 750 Display memory. External refers to pipe data being sent to a properly
connected laptop computer running a version of Trac Management System software.
1. Beacon temperature Indicates beacon temperature

display in degrees Centigrade and
degrees Fahrenheit.
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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.
4. Target identifier Indicates approximate Only one set of arrows is active at a

indicator beacon location. time.
5. Depth estimate Indicates beacon depth Internal: shows job number and
estimate. stored depth.
External: shows desired depth.
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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.
indicator status.
8. Beacon temperature Indicates beacon See beacon instruction sheet.

indicator temperature.
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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. External refers to pipe data being sent to a properly
connected laptop computer running a version of Trac Management System software.
1. Delete button To delete current pipe, press. Previous pipe number will appear in
numeric display when data is deleted.
Second function:
To delete all jobs in internal

logging memory, press with
Recall button.
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2. On/Off button To turn on, press.
To turn off, press again.
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. tracker are set to the same channel.
Second function:
To start a new job, press with

Recall button.
“Init” and job number will be

displayed.
4. Roll stop button This feature is not yet

available.
5. Recall button To see data about pipe, press Internal: shows data about previous
and release. pipe.
Second function: External: shows data about next pipe.
To access second functions,

press with other buttons.
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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. stored without a valid depth estimate.
Second function:
To download all jobs stored in

internal logging memory:
• Press with Recall button

• Connect display to PC
running Trac
Management System
software.
CMW
JT2020 Mach 1 Operator’s Manual Operation Overview - 59
Operation Overview
Chapter Contents
Planning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Setting Up at Jobsite . . . . . . . . . . . . . . . . . . . . . . . 60
Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Backreaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Leaving Jobsite. . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Storing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 62
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Operation Overview - 60 JT2020 Mach 1 Operator’s Manual
Planning
Planning
1. Gather information about jobsite. See page 65.
2. Inspect jobsite. See page 66.
3. Classify jobsite. See page 68.
4. Plan bore path. See page 71.
5. Check supplies and prepare equipment. See page 76.
6. Load equipment. See page 85.
Setting Up at Jobsite
1. Prepare jobsite. See page 76.
2. Unload drilling unit from trailer. See page 88.
3. Assemble drill string. See page 97.
4. Position drilling unit and drill frame. See page 93.
5. Assemble strike system. See page 116.
6. Anchor drilling unit. See page 115.
7. Connect fluid system. See page 93.
8. Calibrate tracker with beacon that will be installed in beacon housing. See tracker operator’s manual.
CMW
JT2020 Mach 1 Operator’s Manual Operation Overview - 61
Drilling
Drilling
1. Start system. See page 93.
2. Engage tracker control if desired. See page 127.
3. Drill first pipe. See page 100.
4. Record bore path. See page 105.
5. Enable automated pipeloader system. See page 105.
6. Add pipe. See page 102.
7. Drill remaining pipes in pipe box.
• Correct direction. See page 104.
• Engage cruise control. See page 146.
• Shift pipe box. See page 141.
8. Add up to a single column of drill pipe to empty box (see page 141) to complete bore.
9. Surface drill head. See page 106.
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Operation Overview - 62 JT2020 Mach 1 Operator’s Manual
Backreaming
Backreaming
1. Assemble backream string. See page 107.
2. Start drilling unit and adjust throttle.
3. Set drilling fluid flow. Check that fluid flows through all nozzles. See page 122.
4. Remove pipe from bore. See page 109.
5. Remove up to a single column of drill pipe from full box (see page 137) to complete backream.
6. Remove pullback device. See page 111.
Backreaming Tips
• Plan backreaming job before drilling. Plan bore path as straight as possible. Check bend limits of
pullback material. Check that appropriate pullback devices are on hand.
• Keep all bends as gradual as possible.
• Drilling fluid quality is a key factor in backreaming success. Contact your Ditch Witch dealer for
information on testing water, selecting additives, and mixing drilling fluid.
• Backreaming requires more fluid than drilling. Make sure enough fluid is used.
Leaving Jobsite
1. Remove downhole tools. See page 111.
2. Remove anchors. See page 115.
3. Rinse unit and downhole tools. See page 156.
4. Disassemble strike system and disconnect from fluid system. See page 157.
5. Stow tools. See page 157.
6. Load unit onto trailer. See page 85.
Storing Equipment
1. For cold weather storage, antifreeze drilling unit. See page 154.
2. For long-term storage, disconnect battery disconnect switch.
CMW
JT2020 Mach 1 Operator’s Manual Prepare - 63
Prepare
Chapter Contents
Gather Information . . . . . . . . . . . . . . . . . . . . . . . . . 65
• Review Job Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
• Notify One-Call Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
• Examine Pullback Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
• Arrange for Traffic Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
• Plan for Emergency Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Inspect Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
• Identify Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
• Select Start and End Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Classify Jobsite. . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
• Inspect Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
• Select a Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
• Apply Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Plan Bore Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

• Recommended Bend Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
• Entry Pitch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
• Minimum Setback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
• Minimum Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
• Bore Path Calculator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
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Prepare - 64 JT2020 Mach 1 Operator’s Manual
Prepare Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
• Mark Bore Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
• Prepare Entry Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Check Supplies and Prepare Equipment . . . . . . . 77

• Check Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
• Prepare Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
• Assemble Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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Gather Information
Gather Information
A successful job begins before the bore. The first step in planning is reviewing information already
available about the job and jobsite.
Review Job Plan

Review blueprints or other plans and make sure you have taken bore enlargement during backreaming
and pullback into account. Check for information about existing or planned structures, elevations, or
proposed work that may be taking place at the same time.
Notify One-Call Services

Contact your local One-Call (811 in USA) or the One-Call referral number (888-258-0808 in USA and
Examine Pullback Material

Ask for a sample of the material you will be pulling back. Check its weight and stiffness. Contact the
manufacturer for bend radius information. Check that you have appropriate pullback devices.
Arrange for Traffic Control

If working near a road or other traffic area, contact local authorities about safety procedures and
regulations.
Plan for Emergency Services

Have the telephone numbers for local emergency and medical facilities on hand. Check that you will have
access to a telephone.
CMW
Inspect Site
Inspect Site
Inspect jobsite before transporting equipment. Check for the following:
• overall grade or slope

• changes in elevation such as hills or open trenches
• obstacles such as buildings, railroad crossings, or streams
• signs of utilities (See “Inspect Jobsite” on page 68.)
• traffic
• access
• soil type and condition
• water supply
• sources of locator interference (rebar, railroad tracks, etc.)
Take soil samples from several locations along bore path to determine best bit and backreamer
combinations.
Identify Hazards
Identify safety hazards and classify jobsite. See “Classify Jobsite” on page 68.

equipment.
NOTICE:
• Wear personal protective equipment including hard hat, safety eye wear, and hearing protection.
• Do not wear jewelry or loose clothing.
• Notify One-Call and companies which do not subscribe to One-Call.
• Comply with all utility notification regulations before digging or drilling.
• Verify location of previously marked underground hazards.
• Mark jobsite clearly and keep spectators away.
Remember, jobsite is classified by hazards in place -- not by line being installed.
CMW
Inspect Site
Select Start and End Points

Select one end to use as a starting point. Consider the following when selecting a starting point:
Slope
Fluid system should be parked on a level site. Consider how slope will affect drilling unit setup, bending
pipe, and fluid flow out of hole.
Traffic
Vehicle and pedestrian traffic must be a safe distance from drilling equipment. Allow at least 10’ (3 m)
buffer zone around equipment.
Space
Check that starting and ending points allow enough space for gradual pipe bending. See “Minimum
Setback” on page 74.
Check that there is enough space to work and to set up electric strike system.
Comfort
Consider shade, wind, fumes, and other site features.
Drill downhill when possible so fluid will flow away from drilling unit.
CMW
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
• Inspect jobsite and perimeter for evidence of underground hazards, such as:
– “buried utility” notices
– utility facilities without overhead lines
– gas or water meters
– junction boxes
– drop boxes
– light poles
– manhole covers
– sunken ground
• Have an experienced locating equipment operator sweep area within 20’ (6 m) to each side of bore
path. Verify previously marked line and cable locations.
• Mark location of all buried utilities and obstructions.
• Classify jobsite.
Select a Classification
Jobsites are classified according to underground hazards present.
If working... then classify jobsite as...
within 10’ (3 m) of a buried electric line electric
within 10’ (3 m) of a natural gas line natural gas
in concrete, sand, or granite which is capable of producing crystalline silica (quartz) dust
crystalline silica (quartz) dust
within 10’ (3 m) of any other hazard other
NOTICE: If you have any doubt about jobsite classification, or if jobsite might contain unmarked
hazards, take steps outlined previously to identify hazards and classify jobsite before working.
CMW
Classify Jobsite
Apply Precautions
Once classified, precautions appropriate for jobsite must be taken.
Electric Jobsite Precautions
In addition to using a directional drilling system with an electric strike system, use one or both of these
methods.
• Expose line by careful hand digging or soft excavation. Use beacon to track bore path. Have someone
observe clearance between drill head and backreamer when crossing a line.
• Have service shut down while work is in progress. Have electric company test lines before returning
them to service.
Natural Gas Jobsite Precautions


In addition to using a directional drilling system and positioning equipment upwind from gas lines, use one
or both of these methods.
• Expose lines by careful hand digging or soft excavation. Use beacon to track bore path. Have
someone observe clearance between drill head and backreamer when crossing a line.
• Have gas shut off while work is in progress. Have gas company test lines before returning them to
service.
CMW
Classify Jobsite
Crystalline Silica (Quartz) Dust Precautions
Jobsite hazards could cause death or serious injury. Use correct

equipment and work methods. Use and maintain proper safety equipment.
NOTICE: Cutting, drilling or working materials such as, concrete, sand or rock containing quartz may
result in exposure to silica dust. Use water spray or other means to control dust. If workers are exposed
to dust they must wear appropriate breathing protection. Silica dust may cause lung disease and is
known to the State of California to cause cancer.
Follow OSHA or other guidelines for exposure to crystalline silica when trenching, sawing or drilling
through material that might produce dust containing crystalline silica (quartz).
Other Jobsite Precautions
You may need to use different methods to safely avoid other underground hazards. Talk with those
knowledgeable about hazards present at each site to determine which precautions should be taken or if
job should be attempted.
CMW
Plan Bore Path
Plan Bore Path

Plan the bore path, from entry to end, before drilling begins. The Ditch Witch Trac Management System
Plus is available for planning your bore path. This special software can be run in the field using a laptop
computer equipped with Windows® 95 or higher operating system. See your Ditch Witch dealer for details.
If not using Trac Management System Plus, mark the bore path on the ground with spray paint or flags, or
record it on paper for operator reference.
For complicated bores, consult an engineer. Have the jobsite surveyed and bore path calculated. Be sure
the engineer knows minimum entry pitch, bend limits of drill pipe, bend and tension limits of pullback
material, pipe lengths, and location of all underground utilities.
For less complicated bores, plan the bore based on four measurements:
• recommended bend limit

• entry pitch
• minimum setback
• minimum depth
IMPORTANT: See the following pages for more information about these measurements. If not using
Trac Management System Plus, see “Bore Path Calculator” on page 75 and use these measurements to
help plan your bore.
CMW
Plan Bore Path
Recommended Bend Limits

Ditch Witch drill pipes are designed to bend slightly during operation. Slight bending allows for steering and
correcting direction. Bending beyond recommended limits will cause damage that might not be visible. This
damage adds up and will later lead to sudden drill pipe failure.
IMPORTANT: Consider recommended bend limits during any bend, not just during bore entry.
Pipe Pitch
Ditch Witch drill pipe is tested to bend at a maximum

percent pitch. For JT2020 Mach 1 drill pipe, make sure
pitch (A) changes no more than 7% over the full length
of each pipe.
NOTICE: Bending drill pipe more sharply than

recommended will damage pipe and cause failure
over time. Changes in pitch must be equally
distributed over the length of a pipe. Maximum
changes in pitch within 1-2’ (300-600 mm) of pipe
create sharp bends that will damage pipe.
Monitor the pitch of each pipe with the 750 Display on

the operator’s console. See page 53.
Bend Radius
JT2020 Mach 1 drill pipes have a tested minimum

bend radius of 130’ (40 m). This means that a 90-
degree bend in the bore path:
• has a radius (A) of 130’ (40 m)

• requires approximately 204’ (62 m) of drill pipe
(B).
NOTICE: Bending drill pipe more sharply than

recommended will damage the pipe and cause
failure over time.
• If bend radius is reduced, drill pipe life is
reduced.
• If bend radius is increased, drill pipe life is
increased.
IMPORTANT: Use the charts on the next page to keep bends within safe limits.
CMW
Plan Bore Path
Pipe-By-Pipe Bend Limits
Pipe Forward (B) Deflection (A) Pipe Forward (B) Deflection (A)
(C) (C)
1 10 ft 0 in (3.0 m) 0 ft 5 in (0.1 m) 12 103 ft 8 in (31.6 m) 51 ft 7 in (15.7 m)
10 90 ft 5 in (27.6 m) 36 ft 7 in (11.2 m) 20.4 130 ft 0 in (39.6 m) 130 ft 0 in (39.6 m)
11 97 ft 4 in (29.7 m) 43 ft 10 in (13.4 m)
Pipe 10 is illustrated.
CMW
Plan Bore Path
Entry Pitch
Entry pitch is the slope of the drill frame compared with the slope of the ground. Determine entry pitch one
of two ways:
1. With Pitch Beacon

• Lay pitch beacon on the ground and read
pitch.
• Lay pitch beacon on drill frame and read pitch.
• Subtract ground pitch from drilling unit pitch.
2. With Measurements
• Measure from 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 (C), then multiply by 100.
This is your pitch.
IMPORTANT: A shallow entry pitch (A1) allows you

to reach horizontal sooner and with less bending.
Increasing entry pitch (A2) makes bore path longer
and deeper.
Minimum Setback
Setback is the distance from the entry point to where
pipe becomes horizontal (B1).
NOTICE: If setback is too small (B2), you will

exceed bend limits and damage the pipe.
CMW
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.
• To reduce minimum depth (D1), reduce entry

pitch. This also decreases setback.
• To increase minimum depth (D2), increase
entry pitch. This also increases setback.
Bore Path Calculator

Entry pitch, setback, and minimum depth work together with bend limits to determine the bore path. To find
the setback (B) and entry pitch (A) that will take you to the desired minimum depth (D), use the chart
below.
Minimum depth (D) Entry pitch (A) Setback (B) Depth to begin steering (S)
3 ft 7 in (1.1 m) -18% 31 ft 7 in (9.6 m) 1 ft 6 in (0.46 m)
IMPORTANT: Numbers in table based on 130’ (40 m) minimum bend radius, beacon housing, EZ-
Connect, connector, transition sub, and 1/3 of first drill pipe (L, totalling 8’ 8” [2.6 m]) in the ground
before steering.
CMW
Prepare Jobsite
Prepare Jobsite

equipment.
NOTICE:
• If jobsite classification is in question or if the possibility of unmarked electric utilities exists, classify
jobsite as electric.
• Cutting high voltage cable can cause electrocution. Expose lines by hand before digging.
• All vegetation near operator’s station must be removed. Contact with trees, shrubs, or weeds during
electrical strike could result in electrocution.
Mark Bore Path

Mark your planned bore path and all located utility lines with flags or paint.
Prepare Entry Point

For bore to be successful, first pipe must be straight as
it enters the ground.
To help ensure that the first pipe does not bend, dig a
small starting hole so that the first pipe is drilled into a
vertical surface.
To prevent bending or straining pipe, position drilling

unit for straight entry.
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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
• quick wrench (see page 135)
• transition sub
• anchoring equipment and accessories
• bits, screens, nozzles (see page 130)
• adapters, pipe, beacon housings
• marking flags or paint
• water and additional hoses
• fuel
• drilling fluid additives (see page 130)
• spare fuses
• keys
• backreamers, swivels, pulling devices (see page 130)
• wash down hose and spray gun
• duct tape
• spray lubricant
• tool joint compound (see page 163)
• electrically insulating boots and gloves
• personal protective equipment, such as hard hat and safety glasses
• notepad and pencil
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Prepare Equipment
Fluid Levels
• fuel
• hydraulic fluid
• engine coolant
• battery charge
• engine oil
Condition and Function
• filters (air, oil, hydraulic)

• fluid pump
• couplers
• tires and tracks
• pumps and motors
• drilling fluid mixer
• hoses and valves
• water tanks
Assemble Accessories
Fire Extinguisher
If required, mount a fire extinguisher near the power unit but away from possible points of ignition. The fire
extinguisher should always be classified for both oil and electric fires. It should meet legal and regulatory
requirements.
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JT2020 Mach 1 Operator’s Manual Drive - 79
Drive
Chapter Contents
Start Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Steer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Shut Down Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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Drive - 80 JT2020 Mach 1 Operator’s Manual
Start Unit
Start Unit
1. Insert key.
2. Turn key clockwise. See page 23 for more information.
3. Run engine at low throttle for 5 minutes.
Steer Unit
To steer drilling unit while using tethered ground drive controller, follow instructions
for type of steering desired.
To steer while moving forward, push forward and then move to left or right.
Drilling unit will gradually turn to left or right.
To steer while moving backward, pull back and then move to left or right. Drilling
unit will gradually turn to left or right. c00ic145h.eps
For tight steering in low speed, move control to center position and then to a corner. Tracks will counter-
rotate and turn drilling unit in a tight circle.
Tips to Reduce Track Wear

Rubber tracks are best suited at soil-based job sites with minimal rock and debris. Sharp objects such as
gravel, steel shards, and broken concrete will damage rubber tracks and undercarriage components.
Excessive operation on concrete or asphalt will shorten track life. When storing your machine, keep tracks
away from rain and direct sunlight.
Wash tracks daily to remove foreign objects and abrasive soil from sprockets and idler rollers. Drive slowly
and make wide turns when possible. Regularly check undercarriage components (sprocket, rollers, idler)
for wear and damage. Maintain proper track tension. (See “Check Track Tension and Condition” on
page 189.)
To prevent premature wear, avoid the following:
• Spinning tracks under heavy load.

• Turning on sharp objects such as stones, stumps and debris.
• Quick turns or “spin” turns on asphalt or concrete.
• Driving over curbs, ledges, and sharp objects.
• Driving with sidewall edges pressed against hard walls, curbs or other objects.
• Driving on slopes.
• Operating on corrosive materials such as salt or fertilizer. Wash immediately.
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JT2020 Mach 1 Operator’s Manual Drive - 81
Shut Down Unit
Shut Down Unit

1. Stop track movement.
2. Lower drill frame and stabilizers to the ground.
IMPORTANT: If frame and stabilizers cannot be lowered, use cylinder locks or other suitable
material to block the tracks and frame. Remove cylinder locks or chocks before driving unit.
3. Run engine at low throttle for 3 minutes to cool.

4. Turn key to the stop position.
5. Remove key.
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Drive - 82 JT2020 Mach 1 Operator’s Manual
Shut Down Unit
CMW
JT2020 Mach 1 Operator’s Manual Transport - 83
Transport
Chapter Contents
Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Haul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
• Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
• Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
• Unload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Tow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
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Transport - 84 JT2020 Mach 1 Operator’s Manual
Lift
Lift
This machine is not configured for lifting. If the machine must be lifted, load machine into a container or
onto a platform appropriate for lifting. See “Specifications” for weight of machine.
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Haul
Haul
Load
Crushing weight. If load falls or moves it could kill or crush you. Use
NOTICE:
• Load and unload trailer on level ground.

• Verify that trailer wheels are blocked.
• Incorrect loading can cause trailer swaying.
• Attach trailer to vehicle before loading or unloading.
• Ten to fifteen percent of total vehicle weight (equipment plus trailer) must be on tongue to help
prevent trailer sway.
With Tiedown Kit
1. Start drilling unit engine.

2. Using tethered ground drive controller, pull power mode switch into low position. See page 26.
3. Move drilling unit to rear of trailer and align with ramps.
4. Slowly drive unit onto trailer until track reaches chock.
5. Lower drill frame to drill frame rest.
6. Back unit until front of drill frame is seated in rest.
7. Lower stabilizers to trailer floor.
8. Stop engine.
9. Attach tiedowns at rear of unit where indicated on page 86.
Without Tiedown Kit

3. Move drilling unit to rear of trailer and align with ramps.
4. Slowly drive unit onto trailer until track reaches chock.
5. Lower stabilizers to trailer floor.
6. Lower drill frame to trailer floor.
7. Stop engine when unit is safely positioned on trailer bed for proper tongue weight.
8. Attach tiedowns to drilling unit where indicated on page 86.
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Haul
Tie Down
Points
Tiedown points are identified by tiedown decals. Securing to trailer at other

points is unsafe and can damage machinery.
Procedure

NOTICE: Wrenches can open after engine shutdown. Ensure that any downhole tool or pipe in tool joint
vises is attached to spindle or removed before transport.
With Tiedown Kit
Loop tiedowns around rear tiedown points. Make sure tiedowns are tight before transporting.
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Haul
Without Tiedown Kit
Loop tiedowns around unit at tiedown points. Make sure tiedowns are tight before transporting.
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Haul
Unload
Crushing weight. If load falls or moves it could kill or crush you. Use
NOTICE:
• Load and unload trailer on level ground.

• Ensure trailer wheels are blocked.
• Attach trailer to vehicle before loading or unloading.
With Tiedown Kit
1. Lower ramps.
2. Remove tiedowns.
5. Raise stabilizers.
6. Move drilling unit forward until track meets chock.
7. Raise drill frame.
8. Slowly back unit down trailer or ramps.
Without Tiedown Kit
1. Lower ramps.
2. Remove tiedowns.
5. Raise stabilizers.
6. Raise drill frame.
7. Slowly back unit down trailer or ramps.
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Tow
Tow
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.

• Open bypass valves.
• Open selector valves.
• Tow for short distances at less than 1 mph (1.6 km/h).
• Use maximum towing force of 1.5 times unit weight.
To open bypass valves for towing, rotate valve stems (shown) two full revolutions.
NOTICE: Do not open valves more than two turns.
To close bypass valves and return to normal operation, torque valve stems (shown) to 7-10 ft•lb (9.5-14
N•m).
NOTICE: Do not over-tighten bypass valves.
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Tow
To open selector valves for towing, loosen jam nut and tighten valve screw (shown) until it is fully
threaded.
To close selector valves and return to normal operation, unthread valve screw and tighten jam nut. To
attach chains to tow points, determine which points are facing towing vehicle.
To attach chains to tow points, determine which points are facing towing vehicle.
If back tow points are facing towing vehicle, loop chains through each tow point and bring them together to
a central pull point.
If front tow points are facing towing vehicle, loop chain through tow point and pull straight forward.
CMW
JT2020 Mach 1 Operator’s Manual Conduct a Bore - 91
Conduct a Bore
Chapter Contents
Position Equipment . . . . . . . . . . . . . . . . . . . . . . . . 93
Connect Fluid System . . . . . . . . . . . . . . . . . . . . . . 93
Start System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Prime Drilling Fluid Pump . . . . . . . . . . . . . . . . . . . 94
Operate Carriage Control . . . . . . . . . . . . . . . . . . . 95
Clamp Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Assemble Drill String . . . . . . . . . . . . . . . . . . . . . . . 97

• Prepare Beacon Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
• Attach Transition Sub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
• Connect Drill Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Drill First Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Enable Automated Pipeloader System . . . . . . . 101
Add Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Correct Direction . . . . . . . . . . . . . . . . . . . . . . . . . 104
• Basic Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
• Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
• Drill Head Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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Conduct a Bore - 92 JT2020 Mach 1 Operator’s Manual
Record Bore Path . . . . . . . . . . . . . . . . . . . . . . . . . 105
Surface Drill Head . . . . . . . . . . . . . . . . . . . . . . . . 106
Assemble Backream String . . . . . . . . . . . . . . . . 107
Remove Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Remove Pullback Device . . . . . . . . . . . . . . . . . . . 111
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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 67.
2. Move equipment into selected positions.
Connect Fluid System
NOTICE: If an electrical strike occurs while drilling unit is connected to a fluid system, the
fluid system will also become electrified. Do not connect drilling unit to a public or private
(business or home) water supply.
1. Connect fluid hose from mixing system to drilling

fluid pump. A 1.5” (38 mm) or larger, non-collapsible
hose is required.
2. Install y-strainer between mixing unit and drilling
fluid pump. Position strainer so that drilling fluid
flows in the direction of the arrow. In most cases,
positioning strainer at outlet of mixing unit gives
best results.
IMPORTANT:
• Clean y-strainer regularly. See page 172.

• Prime the remote drilling fluid pump after
switching to a new tank. See page 94.
Start System
1. Start drilling unit and remote fluid unit. Allow both engines to warm up.
IMPORTANT: Ensure that mixture of drilling fluid matches drilling conditions. See “Drilling Fluid”
on page 122.
2. Enable tracker control mode if desired. See “Tracker Control” on page 127.
3. Press top of drilling unit throttle switch until engine is at full throttle. If you do not want to use
autothrottle mode, return switch to center position.
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Prime Drilling Fluid Pump
Prime Drilling Fluid Pump

NOTICE: Failure to prime the drilling fluid pump will cause flow fluctuations, which will
make it difficult to control the washwand.
Pressurized fluid or air could pierce skin and cause injury

or death. Stay away.
Prime drilling fluid pump each time tank is changed. To prime the pump:
1. Fill drilling fluid hose and connect hose to unit.

2. Operate mixing/transfer pump at full speed for 1 - 3 minutes to discharge air from system.
3. Return mixing/transfer pump to normal operating speed and continue the bore.
4. If drilling fluid pressure surges are observed, repeat step 2.
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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.
Carriage Movement Rotation Direction
forward clockwise (makeup)
reverse counterclockwise (breakout)
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Clamp Pipe
Clamp Pipe
Turning shaft can kill you or crush arm or leg. Stay away.
NOTICE: Clamping anywhere else on the pipe will weaken the pipe. Pipe can later break,
even when operating under normal loads.

NOTICE: Wrenches can open after engine shutdown. Ensure that any downhole tool or pipe in tool joint
vises is attached to spindle or removed before transport.
Clamp on pipe when joint is centered between

wrenches (1 and 2). Always clamp on the larger
diameter areas on either side of the tool joint face.
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Assemble Drill String

Prepare Beacon Housing
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 130 for more information, or contact
your Ditch Witch dealer.
2. Insert nozzle into beacon housing.

3. Attach bit (2) to beacon housing (1).
4. Install beacon, following beacon instructions for:
• battery replacement
• beacon positioning
5. Install beacon housing lid. See “Beacon Housings”
on page 131.
6. Follow beacon instructions to check beacon operation.
7. Follow tracker instructions to calibrate beacon.
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Attach Transition Sub
Moving tools will kill or injure. Shut off drill string power when anyone can
be struck by moving or thrown tools. Never use pipe wrenches on drill string.
Use either machine torque or quick wrench to attach transition sub (2) to beacon housing (1).
Machine Torque
1. Pull beacon housing into front wrench.

2. Close wrench.
3. Lube joints.
4. Slowly make up joint.
5. Use full machine torque to tighten joint fully.
Quick Wrench
1. Lube joints with TJC.

2. Attach quick wrench to the joint in the join position and tighten joint. See “Quick Wrench” on page 135.
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Connect Drill Pipe

2. Align drill pipe in front wrench.
3. Clamp tool joint in front wrench. See “Clamp Pipe” on page 96.
4. Load pipe:
• Make sure pipe box is positioned correctly.
• Lower pipe lifters.
• Close grippers.
• Lubricate pipe threads (pipe loader end).
• Lubricate pipe threads (front wrench end).
• Move pipe to spindle.
• Raise pipe lifters.
5. Connect pipe:
• Move carriage forward until pipe joints meet at front wrench.
• Rotate spindle clockwise. Carriage will move forward as pipe threads tighten.
• Rotate clockwise until spindle stops turning, and joint is fully tightened.
• Open grippers.
• Retract shuttles fully.
• Open front wrench.
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Drill First Pipe
Drill First Pipe
NOTICE:
• Keep everyone at least 10’ (3 m) away from turning drill string.

• Push rod or pipe slowly. Forcing can bend string. Do not use bent rod or pipe.

equipment.
1. Turn on drilling fluid.

2. Set flow control to desired flow/pressure. See “Start System” on page 93.
3. Turn drill bit to starting position. See “Prepare Entry Point” on page 76.
4. Slowly move carriage forward. Drill in downhole tools and 1/3 of first pipe before steering.
5. Monitor gauges.
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Enable Automated Pipeloader System
Enable Automated Pipeloader System

Add Pipe Remove Pipe
1. Make sure pipe box is properly positioned. 1. Make sure pipe box is properly positioned.
See “Shift Pipe Box” on page 141. See “Shift Pipe Box” on page 141.
IMPORTANT: Carriage MUST be in center of IMPORTANT: Carriage MUST be in center of

drill frame. drill frame.
2. Open front wrench, retract shuttles, and grip 2. Open front wrench, retract shuttles, and grip
pipe for add pipe function to work. pipe for remove pipe function to work.
3. Press top of add pipe/manual/remove pipe 3. Press bottom of add pipe/manual/remove pipe
switch. Green control cycle light will come on. switch. Green control cycle light will come on.
4. Grippers will open, pipe will be lowered, and 4. Grippers will open, pipe will be lowered and
then green control cycle light will flash. lifted off shuttles, and then green control cycle
light will flash.
IMPORTANT: If you leave the seat during an add or remove pipe cycle, switch to manual control and
finish pipe cycle. Then switch back to add pipe or remove pipe. If you leave the seat between add or
remove pipe cycles, re-enabling system is not needed.
IMPORTANT: If gripper switch is not in the grip position when using optional pipeloader automation,
grippers will open when automation is stopped and gripped pipe could be dropped. To return a dropped
pipe to the drill string, see “Correct Dropped Pipe” on page 141.
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Add Pipe
Add Pipe
1. Press top of drilling unit throttle switch until engine is at full throttle.
2. Enable automated pipeloader system (automated pipeloader control only). See “Enable Automated
Pipeloader System” on page 101.
3. Break joint at saver sub:
Manual Pipeloader Controls Automated Pipeloader Control
• Clamp pipe joint. See “Clamp Pipe” on • Clamp pipe joint. See “Clamp Pipe” on
page 96. page 96.
• Locate drill head. • Locate drill head.
• Engage front wrench until pipe is clamped • Engage front wrench until pipe is clamped
and pressure develops. and pressure develops.
• Release control levers in detented clamp • Release control levers in detented clamp
position. position.
• Slowly rotate spindle counterclockwise. • Slowly rotate spindle counterclockwise.
Carriage will move back automatically as Carriage will move back automatically as
threads separate. threads separate.
• After threads are fully separated, stop • After threads are fully separated, stop
rotation and move carriage to back of rotation and move carriage to back of
frame. frame.
• Pull joystick straight back.
• While carriage is moving, green control
cycle light will come on. Grippers will grip,
pipe will be lubed, and then green control
cycle light will flash.
4. Load pipe:
• Make sure pipe lifters are completely • When carriage is moved to back of drill
lowered. frame, press resume switch. Green control
cycle light will come on.
• Close grippers.
• Pipe will be moved to spindle, front
• Lube pipe (pipe loader end).
threads will be lubed, pipe in box will be
• Lube pipe (front wrench end). lifted, and then green control cycle light
will flash.
• Move pipe to spindle.
• Raise pipe lifters.
CMW
Add Pipe
5. Connect new pipe to drill string:
• Move carriage forward until pipe joints • Move carriage forward until pipe joints
meet at front wrench. meet at front wrench.
• Rotate spindle clockwise. Carriage will • Rotate spindle clockwise. Carriage will
move forward as pipe threads tighten. move forward as pipe threads tighten.
• Rotate clockwise until spindle stops • Rotate clockwise until spindle stops
turning and joint is fully tightened. turning and joint is fully tightened.
• Open grippers. • Press resume. Green control cycle light
will come on.
• Retract shuttles fully.
• Grippers will open, shuttles will retract,
• Lower pipe lifters.
pipe lifters will lower, and then green
• Open wrench. control cycle light will flash.
• Open wrench.
6. Press and hold quick fill fluid pump switch until pipe fills and fluid pressure begins to rise.
7. Rotate spindle.
8. Slowly move carriage forward. Adjust rotation speed control according to bit size and soil conditions.
9. Engage and set cruise control as desired. See “Cruise Control” on page 146.
10. Monitor gauges.
11. Locate drill head with tracker at least every half-length of pipe.
12. Maintain drilling fluid and change drilling fluid tanks as necessary. See “Prime Drilling Fluid Pump” on
page 94.
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Correct Direction
Correct Direction
Correcting direction is a skill operators gain with experience and knowledge of equipment and soil
conditions. These instructions cover only basic procedures. For information about specific equipment or
jobsites, contact your Ditch Witch dealer.
To track progress and make corrections, one crew member locates the drill head and sends instructions to
the operator. Corrections are made by tracking the drill head, comparing current position to bore plan, and
steering drill head as needed.
Basic Rules
• Steering ability depends on soil condition; bit, drill head, and nozzle used; roll of drill head; and
distance pushed without outer rotation.
• All corrections should be made as gradually as possible. See “Recommended Bend Limits” on
page 72.
• Over correcting will cause “snaking.” This can damage pipe and will make drilling and pullback more
difficult. Begin to straighten out of each correction as early as possible.
• Do not push an entire piece of drill pipe into ground without rotation. This can exceed bend radius and
cause pipe failure.
Procedure
1. Locate drill head. Take readings available with your beacon and locating equipment such as:
• depth
• pitch
• left/right information
• temperature
• beacon roll
2. Compare position to bore plan. Determine direction drilling should go.
3. Position drill head.
4. Push in drill pipe as needed to change direction.
5. Rotate to drill in remaining length of drill pipe.
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Record Bore Path
Drill Head Position

The drill head position is determined by reading
beacon roll. Roll is displayed as a clock face
position.
1. Read beacon roll.

2. Slowly rotate pipe until locator displays desired
beacon roll.
To change direction:
1. Rotate pipe to clock position you intend to travel.

2. Push pipe into ground.
To move forward without changing direction:
Rotate pipe into ground.
Record Bore Path

Locate drill head every half-length of pipe. As the job is completed, record the actual data for each drill
pipe. List pitch and depth of each joint and a brief description of the procedure. In addition, draw a simple
sketch of the site and record depth and rough location of pullback.
The Trac Management System Plus is also available for plotting and tracking your bore path. It utilizes the
Subsite 750 Tracker, 750 Display, a tracking beacon, and special software. The display can store jobs in
its memory or the system can be run in the field using a laptop computer equipped with the Windows® 95
or higher operating system. See your Ditch Witch dealer for details.
CMW
Surface Drill Head
Surface Drill Head
NOTICE:
• Tracker operator and drill operator should maintain two-way communication.

• Keep everyone clear of the exposed drill string.
• No one should enter pit until clear communication is given by the drill operator that the drill unit is
shut down. If using tracker control (See “Tracker Control” on page 127.), do not enter pit until tracker
control is turned off and green light on drill unit is lit.
• Drill operator should be instructed to discontinue drill string rotation as soon as drill bit exits the
bore. Use thrust only to extend drill string beyond exit hole.
1. Guide drill head to target pit or up through surface. Make all bends gradual. See “Recommended Bend
Limits” on page 72.
2. Clean area around exit point.
3. If using tracker control mode, tracker operator turns off tracker to disable drilling unit thrust/pullback
and rotation hydraulics. Tracker operator waits for green light to enter pit and change tools.
If not using tracker control mode, tracker operator signals to drilling unit operator to stop engine before
changing downhole tools.
4. Turn fluid flow control to off position as soon as drill head emerges.
5. Clean drill head especially around threads.
6. Disconnect EZ-Connect joint or use quick wrench to remove drill head. Keep threads clean. See
“Quick Wrench” on page 135.
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Assemble Backream String

Sometimes it is necessary to enlarge the pilot hole to accommodate larger product. As a general rule, the
final hole should be 1.5 times larger than the diameter of the product being installed. The number of
passes needed depends on soil conditions. Do not try to increase hole size too much in one pass. Several
passes using successively larger reamers will save wear on machine.

equipment.
NOTICE: Continue to use strike system during backreaming.
NOTICE:
• Maintain two-way communication with tracker operator.

• Begin backream only when tracker operator has communicated that everyone is clear of the
exposed backream string or has disabled thrust and rotation hydraulics using tracker control.
• Do not allow anyone to stand to the side of the exposed drill string. Drill string and backreamer can
move sideways suddenly if rotated while away from the exit hole.
CMW
1. Select backreaming devices. See “Backreamers” on page 132.
2. Determine fluid rate requirements and install appropriate nozzles to provide sufficient flow. See
“Backream Fluid Requirements” on page 133 and “Nozzles” on page 130.
3. Attach backreamer to backream beacon housing if tracking backream.
4. Install beacon, following beacon instructions for:
• battery replacement
• beacon positioning
5. Install beacon housing lid. See “Beacon Housings” on page 131.
6. Follow beacon instructions to check 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 135.
9. Attach additional pullback devices or product to end of backreamer/beacon housing assembly.
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Remove Pipe
Remove Pipe
NOTICE: If engine is shut off during backreaming, drill pipe clamped by wrenches but not connected to
saver sub can be pulled downhole as vise wrenches loosen.
1. Enable automated pipeloader system (automated pipeloader control only). See page 101.
2. Stop carriage when pipes are aligned in wrenches.
3. Clamp pipe in front wrench. See page 96.
4. Clamp and rotate rear wrench to break front joint. See “Wrench control” on page 29.
5. Disengage rear wrench.
6. Extend shuttles to spindle.
7. Close grippers:
• Open grippers. • Press resume. Green control cycle light

will come on.
• Lift pipe off shuttles.
• Shuttles will extend, grippers will grip, pipe
• Extend shuttles to spindle position.
lifters will lower, and then green control
• Close grippers. cycle light will flash.
• Lower lifters.
8. Break front joint.

• Slowly rotate spindle counterclockwise to separate pipe. Carriage will move back automatically as
pipe threads separate.
• Move carriage back until pipe is properly positioned in rear wrench.
CMW
Remove Pipe
9. Break rear joint.
• Engage rear wrench.
• Slowly rotate spindle counterclockwise until joint is loosened. Do not fully separate joint.
• Disengage rear wrench.
• Move carriage back until front end of pipe is positioned inside front end of pipe box.
• Rotate spindle counterclockwise until saver sub is separated from pipe.
• Stop rotation and move carriage to back of frame.
10. Ensure pipe box is positioned correctly.
11. Load pipe into pipe box:
• Move shuttle under pipe box. • Press resume. Green control cycle light
will come on.
• Release grippers and raise pipe lifters to
place pipe in box. • Shuttles will retract, front threads will be
lubed, grippers will release pipe, pipe
• Lube front threads.
lifters will raise until pipe is off shuttles,
and then green control cycle light will
flash.
12. Attach saver sub to next pipe.

• Move carriage forward until saver sub touches pipe.
• Rotate spindle to connect to pipe. Slowly tighten joint to full machine torque.
13. Disengage front wrench to release pipe.
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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.
1. Press bottom of drilling unit throttle switch until engine is at low throttle.
2. Turn off drilling fluid.
3. Turn drilling unit engine off.
4. Clean pullback device.
5. Use quick wrench to remove pullback device. See “Quick Wrench” on page 135.
CMW
CMW
JT2020 Mach 1 Operator’s Manual Systems and Equipment - 113
Systems and Equipment
Chapter Contents
Anchor System . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
• Drive Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
• Remove Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Electric Strike System . . . . . . . . . . . . . . . . . . . . . 116

• FCC Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
• Assemble Voltage Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
• Test Strike System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
• Troubleshoot Strike System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
• Use Electric Strike Simulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Drilling Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

• Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
• Polymer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
• Bentonite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
• Mixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
• Basic Fluid Recipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
• Drilling Fluid Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
• Funnel Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Tracker Control . . . . . . . . . . . . . . . . . . . . . . . . . . 127

• Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
• Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
CMW
Systems and Equipment - 114 JT2020 Mach 1 Operator’s Manual
Downhole Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 130

• Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
• Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
• Beacon Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
• Backreamers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
• Backream Fluid Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Quick Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Drill Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

• Perform Regular Drill Pipe Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
• Use Drill Pipe Correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Pipeloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
• Shift Pipe Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
• Correct Dropped Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
• Correct Misaligned or Jammed Pipe . . . . . . . . . . . . . . . . . . . . . . . . . 142
• Rotate Drill Pipe Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
• Add/Remove Single Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

• Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
• Adjust Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
• Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
• Disengage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
• Resume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Interpret Diagnostic Codes . . . . . . . . . . . . . . . . . 147

• Diagnostic Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
• Code Severity Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
• Review Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
• Diagnostic Code Interpretation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
• Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
CMW
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 anchors properly before drilling.

• Stand on platform when operating anchor controls.
• Wear high-top protective boots with legs of pants completely tucked inside.
• Wear protective gloves.
• If you are not driving two anchors to full depth, drive optional ground rod into soil away from drilling
unit and connect ground rod to drilling unit.
NOTICE: Do not replace anchor collar bolt with one longer than original. Clothing could
catch on turning shaft.
Drive Anchors
IMPORTANT: Carefully time anchor rotation with

anchor movement. Properly driven anchors should
not auger up soil.
1. Use anchor rotation and thrust controls to drive

anchor into ground.
NOTICE: Centering cap MUST be

positioned in centering tube to prevent
damage to anchor.
2. Carefully position centering cap (1) into centering

tube (2) as anchor is being driven into ground.
3. Repeat process for other anchor.
CMW
Electric Strike System
Remove Anchors
1. Use anchor rotation and thrust controls to slowly remove anchor shaft from ground.
2. Repeat process for other anchor.

Any time you drill in an electric jobsite, electric strike system must be properly set up, tested, and used.
You must wear protective boots and gloves meeting the following standards:
• Boots must have high tops and meet the electric hazard protection requirements of ASTM F2413 when
tested at 14,000 volts. Tuck legs of pants completely inside boots.
• Gloves must have 17,000 AC maximum use voltage, according to ASTM specification D120-87.
If working around higher voltage, use gloves and boots with appropriately higher ratings.
NOTICE: The strike system does not prevent electric strikes or detect strikes before they occur. If
alarms are activated, a strike has already occurred and equipment is electrified.
Read and follow “Electric Jobsite Precautions” on page 69. Review safety procedures before each job.
FCC Statement
The Electric Strike System has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the
FCC rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated
in a commercial environment. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used
in accordance with the instructions, can cause harmful interference to radio communications. Operation of this equipment in a
residential area could cause harmful interference which the user will be required to correct at his own expense.
Changes or modifications not expressly approved in writing by The Charles Machine Works, Inc. may void the user's authority to
operate this equipment.
CMW
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” on page 118 on the following page.
Do not drill until test is completed successfully.
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 on, press self test button to
perform total test of strike system. During this test:
• All lights should glow.
• Alphanumeric readout should display numbers.
• Alarms and strobes on all connected units should sound.
4. If this test is successful, OK indicator and electrical power supply indicator lights will remain on.
5. Use Electric Strike Simulator to test voltage and current sensors. See page 120.
CMW
Troubleshoot Strike System

When strike system detects a problem, an error code will be displayed. Anytime this happens, press self
test button to retest. If error code is still displayed and does not appear in this chart, have control module
checked or replaced.
Other problem situations and their possible causes and solutions are listed in the chart below.
Problem Possible cause Possible solution
No lights or readings Problems in startup Push self test button. If problem goes
showing after drilling unit away, retest strike system
key has been on at least
one minute No power to strike system Check drilling unit electric system
control module
Check that harness from drilling unit
to control module is connected
Check that cable from drilling unit

carries more than 10V
Defective control module Have control module checked or

replaced
Screen is blank Strike system is not getting Check drilling unit electric system
adequate power from drilling
unit Check that harness from drilling unit


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 Strike system is not getting Check drilling unit electric system
electrical power supply adequate power from drilling
indicator is off unit Check that harness from drilling unit


replaced
Electrical power supply Problem detected during test Check for error code and have control
indicator is on, but OK module checked or replaced
indicator is off
replaced
CMW

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. Disconnect strobe and connect to
external 12V power source.
2. If strobe does not work, replace it.

replaced
Alarm on drilling unit does Improper connections with Check connections and wiring
not work during total test control module harness
Defective alarm 1. Disconnect strobe and connect to

external 12V power source.
2. If strobe does not work, replace it.

replaced
Strobe light and alarm on Improper connections with Check connections and wiring
drilling unit do not work control module harness
during total test
replaced
EC2 code displays and Improper connections with Check cable connections on control
current problem indicator is control module module and current transformer
on
Defective current transformer 1. Disconnect current transformer.
2. Check for 20-40 ohms from pin 1
to pin 4, 20-40 ohms from pin 1 to
pin 2, and less than 1 ohm from
pin 2 to pin 4.
Defective current transformer 1. Disconnect cable from

cable transformer and control module.
2. Check continuity of cable.
3. If continuity is zero or cable is
damaged, replace.

replaced
EV1 code displays and Improper connection of voltage Check voltage limiter connection to
voltage problem indicator is limiter to ground stake ground stake and verify that ground
on stake is driven into the ground
Defective voltage limiter Have voltage limiter checked or

replaced

replaced
CMW
EV2 code displays and Improper connections with Check cable connection on control
voltage problem indicator is control module module
on
Defective voltage limiter Have voltage limiter checked or
replaced

replaced
Use Electric Strike Simulator

Use the Electric Strike Simulator (p/n 259-506) to test voltage and current sensors on ESID. If readings are
less than indicated here, replace 9V battery in simulator and retest.
Current Test
To test for current at normal levels:
1. Thread one lead wire through current transformer.

2. Clip ends of lead wires together to make one loop.
3. Move simulator switch to "current" and press test button.
4. Watch screen and lights above display on strike system.
• Three or four lights should turn on.
• Current "A" should show 30-50% in display.
CMW
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:
• All lights should turn on.
• Alarm and strobe should turn on.
With two loops,
• Current "A" should be 80-110%.
• Strike indication might go on and off.
With three loops,
• Current should be 130-160%.
• Strike indication should be continuous.
Voltage Test
1. 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 limiter mount.
4. Move simulator switch to "voltage" and press test button.
5. Watch screen and lights above display on strike system.
• All lights should turn on.
• Alarm and strobe should turn on.
• Voltage "V" should show 90-110%.
It is normal for simulator voltage levels to drift below strike level. When this happens, light in triangle should
go off and alarm and strobe should stop working. If the level drifts above strike level again, light, alarm, and
strobe should be turned on again.
CMW
Drilling Fluid
Drilling Fluid
For productive drilling and equipment protection, use these recommended Baroid® products, available
from your Ditch Witch dealer.
• Soda ash
• Quik-Gel™ dry powder bentonite (p/n 259-804)
• E-Z Mud™ liquid polymer (p/n 259-805)
• Liqui-Trol™ liquid polymer suspension (p/n 259-808)
• Quik-Trol™ dry powder polymer (p/n 259-809)
• Bore-Gel™ drilling fluid (p/n 259-807)
• 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.
Soil type Drilling fluid recommendation
smooth, flowing sand bentonite or Bore-Gel + medium chain polymer
coarse sand or light soil bentonite or Bore-Gel
heavy clay long chain polymer + Con-Det
swelling clay long chain polymer + Con-Det
rock Bore-Gel
Polymer
This drilling fluid additive provides excellent lubrication and increases viscosity in average soils and heavy
clay. In swelling clay, polymer can reduce swelling that traps pipe in the bore.
There are two types of polymer:
• long chain such as Baroid EZ-Mud

• medium chain such as Baroid Quik-Trol
CMW
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.
Some things to remember when mixing bentonite:
• Use clean water free of salt, calcium, or excessive chlorine.

• Use water with pH level between 9 and 10.
• Use water with hardness of less than 120 ppm.
• Do not use bentonite containing sand.
• Mix bentonite thoroughly or it will settle in tank.
• Do not mix bentonite to a funnel viscosity of over 50.
For information on measuring funnel viscosity, see “Funnel Viscosity” on page 126.
Mixtures
Bentonite does not mix well in water containing polymer. To use both, mix bentonite first, then add polymer.
When adding other products follow the order listed below.
NOTICE:
• If chemicals are added in the wrong order, they will not mix properly and will form clumps.
• If tank contains bentonite/polymer mix and more drilling fluid is needed, completely empty tank and
start with fresh water before mixing another batch.
General mixing order:
1. Soda ash
2. Bentonite
3. Polymer
4. Con-Det
Bore-Gel contains premixed bentonite, polymer, and soda ash. Use approximately 15 lb/100 gal (7 kg/380
L) in normal drilling conditions, up to 45 lb/100 gal (21 kg/380 L) in sand or gravel and up to 50 lb/100 gal
(23 kg/380 L) in rock.
CMW
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 additional filtrate control
fine sand below water 40 lb (18 kg) Bore-Gel Add .5 - 1 gal (2-4 L) of Dinomul in high
table .75 lb (340 g) Quik-Trol torque situations
coarse sand below 40 lb (18 kg) Bore-Gel Add .5 - 1 gal (2-4 L) of Dinomul in high
water table .75 lb (340 g) Quik-Trol torque situations
.75 lb (340 g) No-Sag
gravel 50 lb (23 kg) Bore-Gel Add .5 lb (225 g) of Barolift to reduce loss

.75 lb (340 g) Quik-Trol of returns
.75 lb (340 g) No-Sag
cobble 50 lb (23 kg) Bore-Gel Add .5 lb (225 g) of Barolift to reduce loss

.75 lb (340 g) Quik-Trol of returns
.75 lb (340 g) No-Sag
sand, gravel, clay or 35 - 40 lb (16-18 kg) Bore-Gel Vary mixture according to percentage of
shale .5 pt (235 mL) EZ-Mud sand and clay
.5 gal (2 L) Con-Det
clay .5 lb (225 g) Poly Bore Flow rate should be 3-5 parts fluid to 1
.5 gal (2 L) Con-Det part soil. May use .25 - .5 gal (1-2 L) of
Penetrol instead of Con-Det
swelling/sticky clay .75 - 1 lb (340-450 g) Poly Bore Flow rate should be 3-5 parts fluid to 1
.5 - 1 gal (2-4 L) Con-Det part soil. May use .25 - .5 gal (1-2 L) of
Penetrol instead of Con-Det
solid rock (shale) 40 lb (18 kg) Bore-Gel Use .5 pt (235 mL) of No Sag for large
diameter or longer bores
solid rock (other than 40 - 50 lb (18-23 kg) Bore-Gel Use .5 pt (235 mL) of EZ-Mud in reactive
shale) shales
rock/clay mixture 40 - 50 lb (18-23 kg) Bore-Gel

.5 pt (235 mL) EZ-Mud
rock/sand mixture 40 - 50 lb (18-23 kg) Bore-Gel Use .5 pt (235 mL) of No Sag for large
diameter or longer bores
fractured rock 50 lb (23 kg) Bore-Gel Use .5 lb (225 g) of Barolift to reduce fluid
.5 - 1lb (225-450 g) No-Sag loss to formation
CMW
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.
• Bentonite and/or polymer
3. Check water quality.
• Use meter or pH test strips to test pH of water. If pH is below 9.0, add 1 lb (454 g) soda ash per
tank. Test and repeat until pH is between 9 and 10.
• Check water hardness using hardness test strips. Treat with soda ash if hardness exceeds 125
ppm.
CMW
Drilling Fluid
Funnel Viscosity
Viscosity is the measure of internal resistance of a fluid to flow; the greater the resistance, the higher the
viscosity. Viscosity of drilling fluids must be controlled.
To determine viscosity, you will need a Marsh funnel (p/n 259-267) and a measuring cup, available from
your Ditch Witch dealer.
IMPORTANT: Make sure Marsh funnel is clean and free of obstruction and that you have a stopwatch
available for timing the viscosity.
1. Using wash hose and a clean container, take a fresh

sample of drilling fluid. The sample must be at least
1.5 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 the screen.
3. Move funnel over 1 qt (.95 L) container.
4. Remove finger from bottom of funnel and use the
stopwatch to count the number of seconds it takes for
1 qt (.95 L) of fluid to pass through the funnel. The
number of seconds is the viscosity.
5. Thoroughly rinse measuring cup and Marsh funnel.
CMW
Tracker Control
Tracker Control
Overview

This mode allows the 750 Tracker operator to disable hydraulic power to drilling unit thrust and rotation.
NOTICE: This mode does not disable thrust and rotation immediately. Functions are disabled within 16
seconds.
Use tracker control any time you change downhole tools or during other times when the drill string is
exposed. Tracker control works by stopping communication between the tracker and the display. When
this happens, the green tracker control light on the drilling unit comes on and thrust and rotation are
disabled.
Operation
Enable Thrust and Rotation
1 2
1. Start drilling unit.
2. Turn off 750 Display.
3. Press and hold DOWNLOAD (1) while turning on
750 Display until a four-digit code (2) appears.
CH
SEL ON
OFF
j07om023c.eps
CMW
Tracker Control
4. Turn on 750/752 Tracker and check four-digit code.
If codes on tracker and display match, thrust and
rotation hydraulics on the drilling unit are enabled.
If codes on tracker and display do not match, adjust
tracker code:
• Press and hold fore/aft/left/right button while
making the following adjustments.
• Use ON/OFF to advance first two digits (1). Use
DEPTH to lower first two digits.
• Use up arrow to advance last two digits (2). Use
down arrow to lower last two digits.
• Press and hold each button to advance or lower
value quickly.
• To start sending code from the tracker to the
display, press and hold fore/aft/left/right button
and press MODE. Thrust and rotation hydraulics
on the drilling unit are now enabled.
5. Remove tracker control key (shown) from set-up

console at rear of drilling unit. Keep in tracker
operator’s possession.
6. Drill and track bore.
Troubleshooting Tip: If thrust and rotation are not

enabled:
• Check whether the green tracker control light

located on drilling unit anchoring console is on. If it
is, communication has probably stopped between
tracker and display, or tracker is set to incorrect
code.
• If communication cannot be restored, install tracker
control key (shown) in drilling unit and rotate
clockwise. Green tracker control light located on
anchoring console will go off. Thrust and rotation
will function.
NOTICE: Tracker operator cannot disable thrust and

rotation from tracker if tracker control key (shown) is
installed in drilling unit and turned to the disable
position. See “Tracker control key” on page 23 for more
information.
CMW
Tracker Control
Disable Thrust and Rotation
1. When drill head enters target pit or exits the ground,

turn off tracker.
After 8-16 seconds, green tracker control light
(shown), located on drilling unit anchoring console,
will come on. Hydraulic power to thrust and rotation
will be disabled.
IMPORTANT: Tracker operator cannot disable thrust

and rotation from tracker if tracker control key
(shown) is installed in drilling unit and turned to the
disable position. See “Tracker control key” on
page 22 for more information.
Incorrect procedures
could result in death, injury, or
property damage. Learn to use
equipment correctly.
NOTICE: If you are not using tracker control, turn off

drilling unit before changing downhole tools.
2. Change downhole tools.

3. If you are tracking backreamer’s path, turn on
tracker and enable code transmission. After 8-16
seconds, green tracker control light on drilling unit
anchoring console will go off and thrust and
rotation will function.
If you are not tracking backreamer’s path,
install tracker control key (shown) on drilling unit. Green tracker control light on drilling unit anchoring
console will go off and thrust and rotation will function.
CMW
Downhole Tools
Downhole Tools
Nozzles
Nozzles control fluid flow from the pipe to the bore. Select nozzles that will supply at least the amount of
fluid per minute needed for the flow and pressure you will be using. A nozzle that will supply more fluid per
minute is recommended. See your Ditch Witch dealer for nozzle recommendations.
Bits
Selection
These charts are meant as a guideline only. No one bit works well in all conditions. See your Ditch Witch
dealer for soil conditions and bit recommendations for your area. Also see our interactive Downhole Tool
Selector at www.ditchwitch.com.
• 1 = best
• 2 = good
• 3 = fair
• 4 = not recommended
Bit Sandy Soft Soil Medium Hard Rocky Soft Hard

Soil Soil Soil Soil Rock Rock
Sand bit 1 2 4 4 4 4 4
Durabit 2 2 1 1 4 4 4
Tuff bit 2 1 1 1 2 3 4
Steep Taper Tuff bit 4 3 2 1 1 2 4
Barracuda bit 2 1 1 2 3 4 4
Steep Taper bit 4 3 2 1 1 2 4
Hard Surface bit 2 1 2 3 4 4 4
Glacier bit 4 4 4 3 1 2 4
Rhino bit 4 4 3 3 1 1 3
Jetting assembly 4 4 3 2 1 2 3
Rockmaster 4 4 3 2 1 1 1
Talon Rock bit 4 3 2 1 1 1 4
CMW
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
rocky soil chunk rock, glacial till, cobble, rip rap, gravel
soft rock soft limestone, sandstone, shale, coral, caliche
hard rock granite, schist, marble, hard limestone
Installation
Remove all paint from mating surfaces before attaching any bit to housing. Install screws (p/n 107-277)
and tighten to 120 ft•lb (163 N•m).
Beacon Housings
Beacon Installation
To ensure beacon is installed correctly in housing, place battery end of beacon away from bit end of
housing.
CMW
Downhole Tools
Backreamers
A backreamer enlarges the hole as pipe is pulled back through the bore. No one backreamer works well in
all conditions. These charts are meant as a guideline only. See your local Ditch Witch dealer for soil
conditions and backreamer recommendations for your area. Also see our interactive Downhole Tool
Selector at www.ditchwitch.com.
• 1 = best
• 2 = good
• 3 = fair
• 4 = not recommended
Backreamer Sandy Soft Soil Medium Hard Rocky Soft Hard

Soil Soil Soil Soil Rock Rock
Beavertail 3 1 1 1 3 4 4
Three Wing 4 3 3 2 1 1 4
Water Wing 4 3 2 1 2 2 4
Compact Fluted 1 1 2 2 2 3 4
Kodiak 4 3 3 2 1 2 4
Rhino Rock 4 4 4 4 3 2 1
Rockmaster 4 4 4 4 3 1 1
Compaction 1 2 3 4 4 4 4
Cone
HC Hard 4 3 2 1 1 4 4
Condition
ST Saw Tooth 2 2 1 2 2 3 4
MX Mixer 2 2 3 4 4 4 4
CT Cutter 3 2 1 2 3 4 4
EX Expander 1 2 3 4 4 4 4
Fluted Cone 1 1 2 2 2 3 4
IMPORTANT: For soil definitions, see the chart on the previous page.
CMW
Downhole Tools
Backream Fluid Requirements

Backreaming is only successful when enough fluid reaches the bore. The amount of fluid needed depends
on size of bore and soil condition.
Follow these steps to find the minimum amount of fluid needed in perfect conditions.
IMPORTANT: Use more fluid than recommended or the backream might be dry and unsuccessful.
Instructions Example
1. Find amount of fluid needed for your size of U.S. A 6” backreamer requires at least 1.47
backreamer. See the table on the next page. gal/ft.
Metric A 152-mm backreamer requires at least

18.24 L/m.
2. Multiply this number by distance per minute U.S. 1.5 gal x 2 ft/min = 3 gal for each minute of
you plan to backream. The answer is an backreaming.
estimate of amount of fluid you will need for
each minute of backreaming. Metric 18 L x .5 m/min = 9 L for each minute of
backreaming
IMPORTANT: After you have determined how much fluid you will need, see your Ditch Witch dealer for
nozzle recommendations.
CMW
Downhole Tools
Backream Fluid Requirements
Backreamer/product Gal/ft L/m Backreamer/product Gal/ft L/m

diameter diameter
.5 in 13 mm 0.01 0.13 13.5 in 343 mm 7.44 92.35
1 in 25 mm 0.04 0.51 14 in 356 mm 8.00 99.31
1.5 in 38 mm 0.09 1.14 14.5 in 368 mm 8.58 106.54
2 in 51 mm 0.16 2.03 15 in 381 mm 9.18 114.01
2.5 in 64 mm 0.25 3.17 15.5 in 394 mm 9.80 121.74
3 in 76 mm 0.37 4.56 16 in 406 mm 10.44 129.72
3.5 in 89 mm 0.5 6.21 16.5 in 419 mm 11.11 137.95
4 in 102 mm 0.65 8.11 17 in 432 mm 11.79 146.44
4.5 in 114 mm 0.83 10.26 17.5 in 445 mm 12.49 155.18
5 in 127 mm 1.02 12.67 18 in 457 mm 13.22 164.17
5.5 in 139 mm 1.23 15.33 18.5 in 470 mm 13.96 173.42
6 in 152 mm 1.47 18.24 19 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 in 508 mm 16.32 202.68
7.5 in 190 mm 2.29 28.50 20.5 in 521 mm 17.15 212.94
8 in 203 mm 2.61 32.43 21 in 533 mm 17.99 223.46
8.5 in 216 mm 2.95 36.61 21.5 in 546 mm 18.86 234.23
9 in 229 mm 3.30 41.04 22 in 559 mm 19.75 245.25
9.5 in 241 mm 3.68 45.73 22.5 in 572 mm 20.65 256.52
10 in 254 mm 4.08 50.67 23 in 584 mm 21.58 268.05
10.5 in 267 mm 4.50 55.86 23.5 in 597 mm 22.53 279.83
11 in 289 mm 4.94 61.31 24 in 610 mm 23.50 291.86
11.5 in 292 mm 5.40 67.01 24.5 in 622 mm 24.49 304.15
12 in 305 mm 5.88 72.97 25 in 635 mm 25.50 316.69
12.5 in 318 mm 6.37 79.17 25.5 in 648 mm 26.53 329.49
13 in 330 mm 6.90 85.63 26 in 660 mm 27.58 342.53
CMW
Quick Wrench
Quick Wrench
To attach or remove downhole tools, use quick wrench to join or break the joint.
IMPORTANT: Apply TJC to threads and hand-tighten joint before attaching quick wrench components to
tighten joint.
Attach quick wrench in either the join or break position.
Join Break
• Unbolt vise (1) and place jaws around pipe.

• Bolt jaws of vise together.
• Place jaw (2) around pipe.
• Pin handles (3) to wrench jaws. Be sure handles are both up.
• Attach pivot nuts (4) to wrench handles so that screw drive handle (5) is over joint.
CMW
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.
A A
3. Turn handle until second line (B) meets first (A). B B
4. Turn handle opposite direction two turns to relieve
pressure.
5. Remove quick wrench components. A A
j07om071h.eps
To Break
1. Turn handle until joint is broken.

2. Turn handle opposite direction two turns to relieve pressure.
3. Remove quick wrench components.
CMW
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. See page 163 for correct lubricant.
2. Join pipe and tighten joint.
3. Break joint.
4. Move pipe back to box.
NOTICE: Failure to follow this procedure could result in fused joints. Pipe will be damaged or destroyed.
Lubricate Joints Before Each Use
Lubricate threads and shoulders of male joints with copper base tool joint compound. This prevents rust
and reduces wear on shoulders and threads. See page 163 for correct lubricant.
Clean the Threads
Clean the threads as needed with high-pressure water and detergent.
NOTICE: Do not use gasoline or other petroleum-based solvents. This prevents tool joint compound
from sticking to the joints and will reduce thread life.
CMW
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. Replace it
when it is worn, or it will damage your drill pipe. See page 191 for replacement procedure.
Precondition a new saver sub the same way you do new pipe. See “Precondition New Pipe” on page 137.
Rotate Pipe Order
Because the lead drill pipe is in the ground longer, it is subjected to higher shock loads and experiences
more wear. To help spread this wear evenly over all pipe, move the lead pipe from the previous job out of
the first position. See “Rotate Drill Pipe Order” on page 142.
CMW
Drill Pipe
Use Drill Pipe Correctly

Align the Joints
Always carefully align the male and female ends of

pipe before connecting them together. Poor alignment
can damage the threads and destroy the usefulness of
the joint.
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Clamp Pipe Correctly
Clamp on pipe when joint is centered between

wrenches. Clamp only on the tool joint of the drill pipe
as shown. This portion of the drill pipe is designed for
clamping and is considerably thicker and stronger than
the rest of the pipe.
NOTICE: Clamping anywhere else on the pipe will

weaken the pipe. Pipe can later break, even when
operating under normal loads. j07om032c.eps
See “Clamp Pipe” on page 96 for more information.
CMW
Drill Pipe
Make Up and Break Out Joints Correctly
Assisted Makeup protects threads by automatically matching carriage movement speed to rotation during
makeup and breakout.
• To connect pipes together and fully torque joint, slowly rotate pipe until spindle stops turning and
full pressure is developed. Improperly torqued joints will damage the shoulder faces and threads,
and will cause joints to leak or break while drilling or backreaming.
• To disconnect pipes, slowly rotate spindle counterclockwise. Carriage will move back automatically
as threads fully separate.
If assisted makeup is not functioning, press dual speed carriage control switch (see page 43) and follow
these two steps:
• Make up and break out joints slowly. Do not ram pipes together during makeup or force them
apart during breakout. Carefully time rotation with carriage travel speed, and always connect and
disconnect joints slowly and deliberately. This will help prevent thread crossing, galling, and
shoulder swelling.
• Tighten joints fully. Once the joint is connected and the shoulder faces are touching, tighten to
full machine torque. Improperly tightened joints will damage the shoulder faces and threads, and
will cause joints to leak or break while drilling or backreaming.
Do not Overwork the Pipe
Never exceed the bend radius for your pipe. See “Recommended Bend Limits” on page 72. Do not
oversteer.
NOTICE: Bending pipe more sharply than recommended will damage pipe and cause failure.
CMW
Pipeloader
Pipeloader
Shift Pipe Box
IMPORTANT: Lift arms must be fully raised for pipe box to move.
Drilling
1. Shift pipe box when both pipe box status lights are
off.
2. Release pipe box switch when box hits mechanical
stops, then move back to align mechanical pointer
in center of cutout (shown) for new column.
Backreaming
1. Shift pipe box when active column is full (8 pipes).

2. Release pipe box switch when mechanical pointer
is in center of cutout (shown) for new column.
Correct Dropped Pipe

When grippers are not closed before drill pipe automation is enabled, the pipeloader can drop a drill pipe
when automation is turned off. To prevent this, always grip pipe before enabling pipeloader automation.
See “Enable Automated Pipeloader System” on page 101.
To return a dropped pipe to the drill string, turn off engine and manually retrieve pipe. Return it to the pipe
box by one of the following methods:
• To return the pipe to its original position in the drill string, load it as a single piece of pipe. See
page 144.
• To return the pipe to a later position in the drill string, remove two pins over top of pipe box, manually
place the pipe into top of the active column, and install two pins.
CMW
Pipeloader
Correct Misaligned or Jammed Pipe

One pipe box status light on and one light off indicates a misaligned or jammed pipe. Turn off engine and
inspect pipe in active column.
• If one end of a drill pipe is jammed and will not drop correctly from pipe box, inspect pipe box position.
If pipe box appears to be improperly aligned with discharge chute, return to operator’s station and
move pipe box slightly until mechanical pointer is in center of cutout (see page 141) for active column.
• If drill pipe is bent, remove it from pipe box and discard.
NOTICE: If neither of the causes and solutions outlined above correct the misaligned or jammed pipe,
contact your Ditch Witch dealer for assistance.
Rotate Drill Pipe Order

Rotating the lead pipe to the back of the string is a manual process. Rotate drill pipes in the drill string
weekly.
Guidelines
• Rotate only as many columns as used on the longest bore of the week. For example, if the longest
bore was 320’ (98 m), then only rotate the four columns used.
• Plan to rotate the pipes during the longest bore of the week.
• The lead pipe can only be rotated to the very back of the drill string when a bore requires at least one
pipe from last (inner) column.
Procedure
1. During pullback, move to next column when only seven pipes are in last column from which pipe was
removed during drilling.
2. Follow regular pullback procedure to load pipe into all remaining columns.
3. When lead pipe is in grippers, disconnect from both ends of lead pipe and retract shuttles fully.
4. Follow procedure for removing a single pipe. See page 145.
5. Turn off engine.
6. Remove pins across top of pipe box.
7. Remove lead pipe from auxiliary shuttles and place into vacant slot in pipe box.
8. Install pins over drill pipe.
9. Close both auxiliary pipe loaders.
CMW
Pipeloader
Add/Remove Single Pipe

Load a single drill pipe or up to a whole column of drill pipe into an empty column of pipe box to finish bore
without changing pipe boxes.
NOTICE:
• Do not attempt to load and unload pipe while drilling or backreaming. Unprotected worker can be
injured by electric strike.
• On electrical jobsite, load and unload pipe only if grid mats are properly set up and connected to
drilling unit and loader is wearing electrically insulating boots and gloves.

NOTICE:
• Open or close both auxiliary pipe loaders. Moving shuttles with one auxiliary pipe loader open and
one closed will damage equipment and cause possible injury.
• Carriage must be in full back position to load and unload pipe.
CMW
Pipeloader
Add Single Pipe
1. Place grid mats on the ground on pipe box side of

drilling unit.
2. Connect mats.
3. Connect bonding cable to drilling unit (shown in
inset).
4. Position entire drill pipe box on mat (shown).
5. Ensure pipe box is positioned properly. See “Shift
Pipe Box” on page 141.
6. Move shuttles out fully.
Crushing weight. If load falls or moves it could kill or crush you.

Use proper procedures and equipment or stay away.
7. Lift pipe positioning aid (3, located on lower end of

pipeloader personnel restraint bar), rotate, and
lock into slot.
8. Pull pin (2) on shuttle, rotate auxiliary pipe loader
(1) down, and install pin.
9. Repeat process for other shuttle.
10. Lower pipe lifters.
11. Load a pipe in auxiliary pipe loaders with lower
end resting against pipe positioning aid.
12. Move auxiliary pipe loaders in fully.
13. Raise pipe.
14. Raise pipe into column.
15. Move shuttles all the way out.
16. Repeat steps 10-15 to load more pieces of pipe.
17. Move pipe to pipeloader grippers.
• Raise last pipe.
• Move shuttles out.
• Lower pipe into front grippers.
18. Before operating pipeloader:
• Close both auxiliary pipe loaders.
• Step away from drilling unit.
CMW
Pipeloader
Remove Single Pipe
Unload all drill pipe loaded with auxiliary pipe loaders.
1. Lift, rotate, and lock pipe positioning aid (3) into

stowed position.
2. Ensure pipe box is positioned properly. See “Shift
Pipe Box” on page 141.
3. Move shuttles out fully.
4. Pull pin (2) on shuttle, rotate auxiliary pipe loader
(1) down, and install pin.
5. Repeat process for other shuttle.
6. Raise pipe.
7. Move pipe to auxiliary pipe loaders.
• Move shuttles in.
• Lower pipe into auxiliary pipe loaders.
8. Move shuttles out.
Crushing weight. If load falls or moves it could kill or crush you.

Use proper procedures and equipment or stay away.
9. Remove pipe from auxiliary pipe loaders and store properly.

10. Repeat steps 5-8 to unload remaining added drill pipe.
11. After all added drill pipe is unloaded with auxiliary pipe loaders:
• Close both auxiliary pipe loaders.
• Step away from pipeloader.
• Finish loading remaining drill pipe using standard procedure. See “Remove Pipe” on page 109.
CMW
Cruise Control
Cruise Control
During the bore, you can set the desired thrust, pullback, and rotation speeds to match ground conditions.
Cruise control enables the unit to maintain these settings hands-free. You can engage, disengage,
override, and resume these settings at any time.
IMPORTANT: In order for cruise control to function, front wrench must be open and shuttles must be
under pipe box.
Engage
Thrust/Pullback and Rotation Control Thrust/Pullback Control Only
1. Position joystick so that thrust or pullback and 1. Position joystick to desired thrust or pullback
rotation are at desired speeds. setting.
2. Press set. Green control cycle light will come 2. Press set. Green control cycle light will come
on. on.
3. Release joystick. 3. Release joystick.
4. Operator controls rotation with joystick.
Adjust Settings
Setting Instructions
Thrust or Pullback • To increase thrust or pullback speed while joystick is in neutral position,
press resume.
• To decrease thrust or pullback speed while joystick is in neutral position,
press set.
Rotation • To increase rotation speed, move joystick to left and press resume.
• To decrease rotation speed, move joystick to left and press set.
CMW
Interpret Diagnostic Codes
Override
• To override settings, move joystick out of neutral and beyond current setting. Unit will increase to new
setting.
• To return to previous setting, release joystick.
Disengage
To disengage cruise control, move joystick out of neutral and in opposite direction of carriage travel. Green
control cycle light will go off.
Resume
RESUME /
1. Position joystick out of neutral in forward or backward direction.
2. Press resume. Green control cycle light will come on.
SET /
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Diagnostic Light
Use the red diagnostic light to learn the condition of the diagnostic system. Under normal operating
conditions, the diagnostic light will light steadily for two seconds after ignition is turned on to indicate light is
working. It will then go out and remain out unless a diagnostic code is recorded.
If diagnostic codes are detected, the diagnostic light will either flash on and off for 10 seconds to indicate a
non-essential code or remain on for 3 seconds and off for half a second to indicate an essential code.
Code Severity Levels

Diagnostic codes are given one of two levels of severity.
• A non-essential code affects non-essential functions of the unit. If the system detects a non-essential
problem, a diagnostic code will be recorded and the diagnostic light will flash for 10 seconds and then
go out. Each time ignition is turned on, full operation will be available until the diagnostic system
detects a problem.
• An essential code affects rotation, thrust, drilling fluid, or ground drive. If the system detects an
essential problem, a diagnostic code will be recorded and the diagnostic light will cycle on for three
seconds and off for 1/2 second. Some machine functions may not work until the problem is corrected.
Each time ignition is turned on, full operation will be available until the diagnostic system detects a
problem.
CMW
Review Modes
IMPORTANT: Do not turn off ignition. Diagnostic codes are cleared each time ignition is turned off.
View All Codes View Codes Individually
1. Ensure that engine is running and no one is 1. Ensure that engine is running and no one is
sitting in operator’s seat. sitting in operator’s seat.
2. Press and hold the resume button for two 2. Press and hold the set button for two
seconds. seconds.
3. Diagnostic light will flash code 12 (flash, 3. Diagnostic light will flash code 12 (flash,
pause, flash, flash, longer pause) to indicate pause, flash, flash, longer pause) to indicate
review mode is operational. review mode is operational.
4. After flashing code 12, all diagnostic codes 4. After code 12 is flashed, press set button to
detected since the last time the ignition was see first code.
turned on are flashed three times each.
• Press resume to see same code again or
5. To save diagnostic codes, continue normal press set to see next code.
operation. Do not turn ignition off. • Continue pressing set until all diagnostic
6. Once the problem has been corrected, clear codes detected since the last time the
all codes by turning ignition off. ignition was turned on are flashed.
5. To save diagnostic codes, continue normal
operation. Do not turn ignition off.
6. Once the problem has been corrected, clear
all codes by turning ignition off.
Diagnostic Code Interpretation

Diagnostic codes are displayed through a series of light flashes and pauses. Count number of flashes and
pauses to interpret code.
Example: “Flash, flash, flash, pause, flash, flash, longer pause” represents code 32.
Tips for interpreting codes:
• In View All Codes mode, the green control cycle light will come on the first time the red diagnostic light
flashes a code. The green control cycle light will then go off and the red diagnostic light will flash the
code two more times.
• Codes are displayed from lower to higher numbers.
• Code 11 is not used.
• Code 12 signals successful entry into and exit from review mode.
CMW
Diagnostic Codes
The following table lists the attributes of each diagnostic code. Information presented includes: code
number, condition causing code to be sent, result, and level of severity.
Code Condition Result Severity
12 normal review mode entry code is not stored n/a
13 no 12V power to controller drill and drive are blocked essential
14 no 5V power from controller drill and drive are blocked essential
15 unknown output driver continuity code is stored non-

problem essential
32 no continuity to shuttle extend add pipe or remove pipe is aborted non-

solenoid and code is stored essential
33 no continuity to shuttle retract add pipe or remove pipe is aborted non-

solenoid and code is stored essential
34 no continuity to pipe lift solenoid add pipe or remove pipe is aborted non-
and code is stored essential
35 no continuity to pipe lower solenoid add pipe or remove pipe is aborted non-
and code is aborted essential
42 no continuity to pipe release solenoid add pipe or remove pipe is aborted non-
43 no continuity to lube rear solenoid add pipe or remove pipe is aborted non-
44 no continuity to lube front solenoid add pipe or remove pipe is aborted non-
45 no continuity to carriage two speed code is stored non-

solenoid essential
51 no continuity to rotation cw solenoid cruise control is blocked essential
52 no continuity to rotation ccw solenoid cruise control is blocked essential
53 no continuity to thrust forward cruise control is blocked essential

solenoid
54 no continuity to thrust backward cruise control is blocked essential

solenoid
55 no continuity to left track forward drive is blocked essential

solenoid
61 no continuity to pipe box in solenoid code is stored non-

essential
62 no continuity to pipe box out solenoid code is stored non-

essential
CMW

63 no continuity to auxiliary dump valve add pipe or remove pipe aborted and non-
code is stored essential
65 no continuity to thrust/right track cruise control is blocked essential

neutral valve
71 no continuity to drive selector valve drive is blocked essential
73 no continuity to throttle up solenoid code is stored non-

essential
74 no continuity to throttle down solenoid code is stored non-

essential
111 no continuity to left track reverse drive is blocked essential

solenoid
112 no continuity to right track forward drive is blocked essential

solenoid
113 no continuity to right track reverse drive is blocked essential

solenoid
114 no continuity to drilling fluid pump code is stored essential

solenoid
131 no continuity to thrust rear home add pipe and remove pipe are non-
switch blocked essential
132 no continuity to thrust front home add pipe and remove pipe are non-
switch blocked essential
133 no continuity to shuttle home switch add pipe and remove pipe are non-
blocked essential
134 no continuity to front wrench switch add pipe and remove pipe are non-
blocked essential
144 drive joystick left/right out of range drive is blocked essential
145 drive joystick forward/backward out of drive is blocked essential

range
151 drill joystick left/right out of range rotation and cruise control are blocked essential
152 drill joystick forward/backward out of rotation and cruise control are blocked essential
range
154 drilling fluid potentiometer out of code is stored essential

range
161 no continuity to front pipe box switch code is stored non-

essential
162 no continuity to rear pipe box switch code is stored non-

essential
CMW

163 no continuity to pipe up switch pipe box movement is blocked and non-
code is stored essential
164 no continuity to tracker control input code is stored non-

essential
166 no continuity to thrust rear stop switch code is stored non-

essential
171 no continuity to pipe grip rocker switch code is stored non-

essential
172 no continuity to pipe shuttle rocker code is stored non-

switch essential
173 no continuity to pipe lift rocker switch code is stored non-

essential
174 no continuity to pipe box rocker switch code is stored non-

essential
175 no continuity to pipe lube rocker code is stored non-

switch essential
184 no continuity to throttle rocker switch code is stored non-

essential
185 no continuity to set/resume rocker code is stored non-

switch essential
191 no continuity to engine speed sensor code is stored non-

essential
215 no continuity to float position sensor assisted makeup is blocked and code non-
is stored essential
221 system voltage is below 12.5V code is stored non-

essential
233 drill and drive inputs both on drill and drive are blocked essential
234 add pipe and remove pipe inputs both add pipe and remove pipe are non-
on blocked essential
235 front home and rear home inputs both add pipe and remove pipe are non-
on blocked essential
241 shuttles not responding correctly add pipe or remove pipe is aborted non-
251 float sensor is reading out of range assisted makeup is blocked and code non-
is stored essential
254 error reading setup table information add pipe and remove pipe are essential
blocked
CMW

255 undefinable diagnostic code reported code is stored non-
essential
CMW
JT2020 Mach 1 Operator’s Manual Complete the Job - 153
Complete the Job
Chapter Contents
Antifreeze Drilling Unit . . . . . . . . . . . . . . . . . . . . 154
• Add Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
• Reclaim Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Rinse Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 156
Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Stow Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
CMW
Complete the Job - 154 JT2020 Mach 1 Operator’s Manual
Antifreeze Drilling Unit

Your drilling unit can be left overnight in freezing conditions by circulating a polypropylene-based antifreeze
(p/n 265-644) through optional antifreeze system before shutdown.
Add Antifreeze
1. Fill antifreeze tank with 3 gal (11 L) of approved
antifreeze.
2. Move carriage to front of drill frame.
3. Position 3-gal (11-L) bucket under spindle.
4. Install plug at quick coupler for drilling fluid pump
(shown).
5. Open valve between antifreeze tank and head of
drilling fluid pump.
6. Turn drilling fluid potentiometer counterclockwise to
zero position.
7. Start unit and set throttle to slow position.
8. Slowly turn drilling fluid potentiometer clockwise
until indicator light comes on. If light does not come
on, press drilling fluid pump switch.
9. Run drilling fluid pump until antifreeze comes out of spindle.
10. Turn drilling fluid potentiometer counterclockwise to zero position.
11. Open valve below operator’s console (shown).
12. Slowly turn drilling fluid potentiometer clockwise
until indicator light comes on.
13. Close valve below console when antifreeze runs
out of valve below console.
14. Turn drilling fluid potentiometer counterclockwise
to zero position.
CMW
Reclaim Antifreeze
1. Connect remote fluid system. See page 93.
2. Turn on remote fluid system engine.
3. Start drilling unit and run at low throttle.
4. Move carriage to front of drill frame.
5. Position 3-gal (11-L) bucket under spindle.
6. Turn drilling fluid pump on low speed.
7. Turn drilling fluid pump off when drilling fluid comes out of spindle.
8. Open hood and pour antifreeze into tank.
IMPORTANT: Antifreeze can be removed from antifreeze tank and disposed of properly or it can be
reused until it is too diluted with drilling fluid to protect against freezing.
CMW
Rinse Equipment
Rinse Equipment
Using Washwand
Connect the washwand at quick connect (1) at rear of
unit. Open valve (2) to start water flow. Close valve to
stop water flow.

NOTICE: Failure to prime the drilling fluid pump will cause flow fluctuations, which will
make it difficult to control the washwand. For instructions, see “Prime Drilling Fluid Pump”
on page 94.
Pressurized fluid or air could pierce skin and cause injury

or death. Stay away.
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.
CMW
Disconnect
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, pullback devices, and other tools are loaded and properly secured on
trailer.
CMW
Stow Tools
CMW
JT2020 Mach 1 Operator’s Manual Service - 159
Service
Chapter Contents
Service Precautions . . . . . . . . . . . . . . . . . . . . . . . 161
• Welding Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
• Washing Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
• Working Under Drilling Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Recommended Lubricants/Service Key . . . . . . 163

• Approved Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
• Approved Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
10 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
25 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
250 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
500 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
750 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
1000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

2000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
As Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
CMW
Service - 160 JT2020 Mach 1 Operator’s Manual
Service Precautions
Service Precautions

NOTICES:
• Unless otherwise instructed, all service should be performed with engine off.
• Refer to engine manufacturer’s manual for engine maintenance instructions.
Welding Precaution
NOTICE: Welding can damage electronics.
• Disconnect battery to prevent damage to battery. Do not turn off battery disconnect switch with
engine running, or alternator and other electronic devices may be damaged.
• Connect welder ground clamp close to welding point and make sure no electronic components
are in the ground path.
Washing Precaution
NOTICE: Water can damage electronics. When cleaning equipment, do not spray electrical components
with water.
CMW
Service Precautions
Working Under Drilling Unit
Crushing weight could cause death or serious injury. Use

Before working under area of drilling unit supported by a stabilizer, make sure drilling unit is parked on
hard surface.
1. Remove cylinder locks from storage at rear of pipe box and place over extended cylinder rods (shown)
with curved ends toward stabilizer shoes.
2. Raise stabilizers to lower unit until load is supported by cylinder locks.
If working under raised drill frame, support front and back of drill frame with jack stands or equivalent
brace capable of supporting the weight of the unit.
CMW
Service Precautions
Opening/Closing Front Hood

To open:
1. Unlock hood at handles (1, 2) if hood is locked.

2. Unlatch handles (1) and rotate handle (2)
counterclockwise.
3. Grasp upper and lower (2, 4) handles.
4. Lift hood upward and outward.
5. Continue lifting hood and push inward until up-latch
(5, below) engages.
To close:
1. Disengage the up-latch (5) by holding it up as the

hood is pulled outward using the lower handle (4).
2. Pull outward on the hood until it begins to move
downward.
3. Place other hand on top outer surface of hood (1)
and firmly push downward until hood is in place.
4. Latch handles (1) and rotate handle (2) to secure
hood.
5. Lock hood at handle (1,2), if desired.
CMW
Recommended Lubricants/Service Key

Item Description
DEO Diesel engine oil meeting or exceeding Cummins CES 20078, API CI-4, ACEA E-5,
JAMA DH-1, or Global DHD-1.
API American Petroleum Institute, ACEA European Automobile Manufacturer’s

Association, JAMA Japanese Automobile Manufacturer’s Association.
Use viscosity grade SAE 15W40 unless ambient temperatures below 5° F (-15° C) are
expected. Lower viscosity oils must meet the performance specifications shown above.
NDO SAE 30 Non-detergent oil
MPG Multipurpose grease. Use polyurea based NLGI GC-LB Grade 1.5 or lithium based
NLGI GC-LB Grade 2.
EPG Open gear extreme pressure lubricant (p/n 256-666)
EPS Open gear extreme pressure lubricant, spray (p/n 256-034)
MPL Multipurpose gear oil meeting API service classification GL-5 (SAE 80W90)
THF Tractor hydraulic fluid, similar to Phillips 66 HG, Mobilfluid 424, Chevron Tractor
Hydraulic Fluid, Texaco TDH Oil, or equivalent
TJC Tool joint compound: Ditch Witch standard (p/n 259-858) or

summer grade (p/n 256-031)
DEAC Diesel engine antifreeze/coolant meeting ASTM D6210 (fully formulated) or D4985 (low
silicate)
Check level of fluid or lubricant
Check condition
Filter
Change, replace, adjust, service or test
Proper lubrication and maintenance protects Ditch Witch equipment from damage and failure. Service
intervals listed are for minimum requirements. In extreme conditions, service machine more frequently.
Use only recommended lubricants. Fill to capacities listed in “Fluid Capacities” on page 195.
CMW
For more information on engine lubrication and maintenance, see your engine manual.
NOTICE:
• Use only genuine Ditch Witch parts, filters, approved lubricants, TJC, and approved coolants to
maintain warranty.
• Use the “Service Record” on page 159 to record all required service to your machine.
Approved Fuel
This engine is designed to run on diesel fuel. Use only high quality fuel meeting ASTM D975 No. 2D,
EN590, or equivalent. At temperatures below 32° F (0° C) winter fuel blends are acceptable. See the
engine operation manual for more information.
IMPORTANT: Fuel sulfur content should be less than 5000 ppm (0.5%). Worldwide, fuel sulfur
regulations vary widely. Fuel used should always comply with local regulations. If using lube oil meeting
API CJ-4, (or other low SAPS equivalent) and fuel with sulfur content above 15 ppm (0.0015%), ULSD
in the U.S.), reduce oil change interval to 125 hours.
Biodiesel blends up to 5% (B5) are approved for use in this unit. The fuel used must meet the
specifications for diesel fuel shown above. In certain markets, higher blends may be used if certain steps
are taken. Extra attention is needed when using biodiesel, especially when operating in cold weather or
storing fuel. Contact your Ditch Witch dealer or the engine manufacturer for more information.
Approved Coolant
This unit was filled with John Deere Cool-Gard coolant before shipment from factory. Add only John Deere
Cool-Gard (p/n 255-006) or any fully-formulated, ethylene glycol based, low-silicate, heavy-duty diesel
engine coolant meeting ASTM specification D6210 or D4985.
NOTICE:
• Do not use water or high-silicate automotive-type coolant. This will lead to engine damage or
premature engine failure.
• Do not mix heavy-duty diesel engine coolant and automotive-type coolant. This will lead to coolant
breakdown and engine damage.
• Use only distilled water for mixing coolants. Do not use tap water.
CMW
Startup/10 Hour
Startup/10 Hour
Location Task Notes
DRILLING Check fuel filter water separator

UNIT
Check air filter indicator and clean dust trap
Check engine oil level DEO
Check engine coolant level DEAC
Check hydraulic hoses
Check hydraulic fluid level THF
Check fluid pump oil level NDO
Test control switches
Check pipe lube applicator
Check pipe auto lubricator spray nozzle
Check pipe auto lubricator TJC level TJC
Check drilling fluid y-strainer
Drilling Unit
Check Fuel Filter Water Separator
Check fuel filter water separators before startup and every 10 hours of operation. Drain water at plug
(shown) as needed.
CMW
Startup/10 Hour
Check Air Filter Indicator and Clean Dust Trap
Check air filter indicator (1) and inspect dust trap (2) for cracks every 10 hours. Change filter elements
when indicator reaches the red zone. See “Change Air Filter” on page 190.
NOTICE: Only open the air filter canister when air restriction is indicated. Change the elements, do not
attempt to clean them.
• Compressed air or water may damage filter elements.

• Tapping filter elements to loosen dirt may damage filter seals.
Check Engine Oil Level
j10om020h.eps
Check engine oil at dipstick before startup and every 10 hours of operation. Check with unit on level
surface and at least 15 minutes after stopping engine. Add DEO at fill as necessary to keep oil level at
highest line on dipstick.
CMW
Startup/10 Hour
Check Engine Coolant Level
Check coolant level, with engine cool, at expansion tank before startup and every 10 hours of operation.
Maintain coolant level at halfway point on sight glass. If low, add DEAC.
IMPORTANT: See “Approved Fuel” on page 164 for information on approved coolants.
CMW
Startup/10 Hour
Check Hydraulic Hoses
j10om024h.eps
Check hydraulic hoses for leaks before startup and every 10 hours of operation.
Fluid or air pressure 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.
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 container.
• Before using system, check that all connections are tight and all lines are undamaged.
• Fluid leaks can be hard to detect. Use a piece of cardboard or wood, rather than hands, to search
for leaks.
• Wear protective clothing, including gloves and eye protection.
• If you are injured, seek immediate medical attention from a doctor familiar with this type of injury.
CMW
Startup/10 Hour
Check Hydraulic Fluid Level
Check hydraulic fluid level before startup and every 10 hours of operation. Maintain fluid level at halfway
point on sight glass (2), when engine is off and fluid is cool. Refill with THF at hydraulic fluid fill (1).
Check Fluid Pump Oil Level
Check fluid pump oil level at fill plug (1) before startup and every 10 hours of operation. Maintain fluid level
at fill plug. Add NDO at fill plug (1) as needed.
CMW
Startup/10 Hour
Test Control Switches
Check control proximity switches before startup and every 10 hours of operation and clean or replace as
needed.
1. front pipe box switch 4. rear home switch

2. rear pipe box switch 5. shuttle position switch
3. rear stop switch 6. front home switch
To test:
1. Turn ignition switch to the on position. Do not start engine.

2. Place metal object above target on each switch.
3. If yellow LED on switch lights, switch sensor is working.
CMW
Startup/10 Hour
Check Pipe Lube Applicator
Check pipe lube applicator before startup and every 10 hours of operation. Replace if damaged or badly
worn.
Check Pipe Auto Lubricator Spray Nozzle
Check pipe auto lubricator spray nozzle before startup and every 10 hours of operation. Ensure that nozzle
is free of obstructions and operates properly. Clean as needed.
NOTICE: Ditch Witch tool joint compound is specially formulated to work with Ditch Witch pipe
lubrication system. Use of other tool joint compounds will clog system. See “Recommended Lubricants/
Service Key” on page 163 for more information.
To clean:
1. Rotate handle to the upward, or cleanout, position (A).

2. Operate pump until obstruction is flushed.
3. Rotate handle to the downward, or spray, position (B).
4. Clean nozzle guard. If necessary, pull handle/nozzle insert out of housing to clean with fine wire or
solvent.
CMW
Startup/10 Hour
Check Pipe Auto Lubricator TJC Level
Check pipe auto lubricator TJC level before startup and every 10 hours of operation. Change pail as
needed. See “Change Auto Lubricator TJC Pail” on page 186 for procedure.
NOTICE: Ditch Witch tool joint compound is specially formulated to work with Ditch Witch pipe
lubrication system. Use of other tool joint compounds will clog system. See “Recommended Lubricants/
Service Key” on page 163 for more information.
Clean Drilling Fluid Y-Strainer
Clean drilling fluid y-strainer before startup and every 10 hours of operation. Ensure that strainer is free of
debris.
CMW
50 Hour
50 Hour
Location Task Notes
DRILLING Change fluid pump oil Initial service, NDO

UNIT
Check radiator
Change hydraulic filter Initial service
Check ground drive gearbox oil level 2 gearboxes, MPL
Check rotation gearbox oil level MPL
Lube rotation gearbox sliding output shaft EPS
Inspect thrust rollers
Drilling Unit
Change Fluid Pump Oil (Initial Service)
Change fluid pump oil after first 50 hours and every 1000 hours thereafter. Drain at plug (2) and fill with
NDO engine oil at plug (1). Maintain fluid level at fill plug.
CMW
50 Hour
Check Radiator
Check radiator for dirt, grass, and other debris every 50 hours. Check more often if operating in dusty or
grassy conditions. Clean as needed.
To clean:
• Clean fins with compressed air or spray wash.

• Open rear hood and spray through radiator toward engine.
• If grease and oil are present on radiator, spray with solvent and allow to soak overnight.
IMPORTANT: Be careful not to damage fins with high pressure air or water.
Change Hydraulic Filter (Initial Service)
Change hydraulic filter after first 50 hours. Replace filter every 500 hours thereafter. Change filter more
often if indicated by filter indicator. See “Specifications” on page 193.
CMW
50 Hour
Check Ground Drive Gearbox Oil Level
Check oil level in both ground drive gearboxes every 50 hours.
To check:
Open check plug (2). If oil does not come out, open fill plug (1) and add MPL until level with check plug (2).
IMPORTANT:
• Drilling unit must be on level ground for accurate reading.

• Use helper to assist in positioning gearbox plugs for checking and adding oil.
• Do not overfill.
Check Rotation Gearbox Oil Level
Check rotation gearbox oil level every 50 hours. Fill through plug (1) with MPL as needed.
IMPORTANT: Drill frame must be level for accurate reading.
CMW
50 Hour
Lube Rotation Gearbox Sliding Output Shaft
Lube rotation gearbox sliding output shaft with EPS every 50 hours.
To lube:
• Stop engine and turn battery disconnect switch to the off position.
• Clean exposed portion of sliding output shaft with pressure washer to remove grime.
• Blow dry with compressed air.
• Apply EPS spray lube to all exposed shaft surfaces while manually moving the shaft in and out.
• Turn battery disconnect switch to the on position.
Inspect Thrust Rollers
Inspect thrust rollers (at each end of carriage) every 50 hours. Clean or replace if they do not turn freely.
CMW
250 Hour
250 Hour
Location Task Notes
DRILLING Inspect air intake system

UNIT
Change engine oil and filter DEO
Drilling Unit
Inspect Air Intake System
Inspect intake piping for cracked hoses, loose clamps, or punctures. Tighten or replace parts as necessary.
Change Engine Oil and Filter
Change engine oil and filter every 250 hours for normal service. Drain oil (3), change filter (2), and add 8.5
qt (8 L) of DEO at fill (1).
CMW
500 Hour
500 Hour
Location Task Notes
DRILLING Change hydraulic fluid and filter Normal conditions

UNIT
Change fuel filter
Check batteries
Drilling Unit
Change Hydraulic Fluid and Filter (Normal Conditions)
Change hydraulic filter every 500 hours. Change filter more often if indicated by filter indicator.
Change Fuel Filter
Replace fuel filter every 500 hours. See parts manual or contact your Ditch Witch dealer for correct
replacement filter.
CMW
500 Hour
Check Battery
Check battery every 500 hours. Keep batteries clean and terminals free of corrosion.
To clean:
1. Turn battery disconnect switch to the off position.

2. Ensure that no ignition sources are near batteries.
3. Loosen and remove battery cable clamps carefully, negative (-) cable first.
4. Clean cable clamps and terminals with wire brush or battery cleaning tool to remove dull glaze.
5. Check for signs of internal corrosion in cables.
6. Apply MPG to terminals after cleaning to reduce corrosion.
7. Connect battery cable clamps, positive (+) cable first.
8. Tighten any loose connections.
9. Ensure that battery tiedowns are secure.
10. Turn battery disconnect switch to the on position.

NOTICE: To avoid explosion, do not create sparks and do not short across battery terminals for any
reason.
CMW
750 Hour
750 Hour
Location Task Notes
DRILLING Change fluid pump oil NDO

UNIT
Drilling Unit
Change Fluid Pump Oil
Change fluid pump oil after first 50 hours and every 750 hours thereafter. Drain at plug (2) and fill with NDO
engine oil at plug (1). Maintain fluid level at fill plug. Capacity for pump is 1 qt (0.9 L).
CMW
1000 Hour
1000 Hour
Location Task Notes
DRILLING Change ground drive gearbox oil 2 gearboxes, MPL

UNIT
Lube rotation gearbox internal splines EPG
Change rotation gearbox oil MPL
Drilling Unit
Change Ground Drive Gearbox Oil
Change oil in both ground drive gearboxes every 1000 hours.
To change:
Drain MPL at plug (3). Add MPL at plug (1) until level with check plug (2).
IMPORTANT:
• Drill unit must be parked on level surface for accurate reading.

• Use helper to assist in positioning gearbox plugs for checking and adding oil.
• Do not overfill.
CMW
1000 Hour
Lube Rotation Gearbox Internal Splines
Lube rotation gearbox internal splines with EPG every 1000 hours.
To lube:
• Turn battery disconnect switch to the off position.

• Clean rotation gearbox area with pressure washer to remove grime.
• Disconnect hose and remove water swivel.
• Using special socket, remove thrust locknut, tang lock washer, and nut.
• Remove sliding shaft from front side of gearbox. Clean and dry all components.
• Coat internal splines in gearbox with EPG.
• Reinstall shaft and components in reverse order of removal.
• Apply EPS spray lube to sliding shaft surfaces. See page 176.
• Turn battery disconnect switch to the on position.
CMW
1000 Hour
Change Rotation Gearbox Oil
Drain oil at gearbox oil drain (2) every 1000 hours. Replace drain plug. Fill with MPL at fill plug (1). Replace
fill plug.
IMPORTANT: Drill frame must be level for accurate reading.
CMW
2000 Hour
2000 Hour
Location Task Notes
DRILLING Change engine coolant DEAC

UNIT
Drilling Unit
Change Engine Coolant
Drain cooling system at drain (2) every two years or 2000 hours. Refill according to instructions below with
approved coolant. See “Specifications” on page 193 for coolant capacity.
NOTICE:
• The use of non-approved coolant may lead to engine damage or premature engine failure and will
void engine warranty.
• See “Approved Fuel” on page 164 for list of approved coolants.
• Use only distilled water for mixing coolants. Do not use tap water.
To fill:
1. Add coolant at expansion tank (1) fill until full.

2. Run engine for 30 seconds.
3. Stop engine and add coolant at expansion tank fill until full.
4. Run engine with thermostat open (>195°F/90°C engine temperature) for several minutes.
5. Stop engine and let it cool.
6. Add coolant at expansion tank fill until full.
CMW
As Needed
As Needed
Location Task Notes
DRILLING Change pipe auto lubricator pail TJC

UNIT
Change hydraulic filter Any time system is opened
Check pipeloader pads
Check front pipe guide inserts
Check fluid pump ball valve
Check track tension and condition
Change/Adjust engine drive belt
Change air filter
Check saver sub
Replace fuses
CMW
As Needed
Drilling Unit
Change Auto Lubricator TJC Pail
Check pipe auto lubricator TJC level and change pail as needed.
To change pail:
1. Remove wingnuts and bolts attaching base ring (4) to pail cover (1).
2. Rotate base ring slightly to clear hooks on cover and remove pail from cover.
3. Remove follower plate (3) from empty pail and install into new pail. Press firmly on follower plate until
TJC comes up in center opening.
4. Remove base ring from empty pail and install onto new pail.
5. Install pail into place over pump dip tube. Use hooks on cover to support base ring.
6. Install bolts and wingnuts.
7. Remove cap (2) from discharge tee on pump. Operate pump until discharged TJC is free of air
pockets. Replace cap.
NOTICE: Use only genuine Ditch Witch tool joint compound to maintain warranty. See “Recommended
Lubricants/Service Key” on page 163 for more information.
CMW
As Needed
Change Hydraulic Filter (Anytime System Opened)
Change hydraulic filter anytime system is opened for repair. Change filter and refill with THF at hydraulic
oil fill.
Check Pipeloader Inserts
Check pipeloader inserts at indicated areas for wear. Flip gripper inserts for longer wear, or replace as
needed. See your Ditch Witch dealer for replacement parts.
1. wear pad 3. shuttle gripper pad

2. shuttle wear pad 4. gripper pad
IMPORTANT: Ensure bolts are tightened evenly to enable inserts to slide freely and wear evenly.
CMW
As Needed
Check Front Pipe Guide Inserts
Check front pipe guide inserts (3) for wear. Rotate inserts for longer wear, or replace as needed. See your
Ditch Witch dealer for replacement parts.
To replace:
1. Remove lynch pins (1, one on each side).

2. Remove guide inserts (3).
3. Remove pin (2) and open pipe guide.
4. Remove guide inserts (3).
5. Replace in reverse order.
Check Fluid Pump Ball Valve
Check ball valve for leaks. Tighten stem packing as needed. See your Ditch Witch dealer for replacement
packing.
CMW
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:
1. Pump MPG into fitting (A) until dimension (B) is 21 7/8” (555 mm).
2. Drive straight forward one machine length and check tension again.
Change/Adjust Drive Belt
Change or adjust engine drive belt as needed.
To adjust:
1. Turn off engine and remove key.

2. Apply moderate thumb pressure to belt between pulleys, as shown.
3. Belt is properly tensioned when deflection is about 3/8” (10 mm).
4. If needed, loosen alternator bolts and pull alternator out until correct tension is reached.
5. Tighten alternator bolts.
CMW
As Needed
Change Air Filter
Change air filter when red band on air filter service indicator pops up.
To change:
1. Disengage clasps (1) and remove end cup.

2. Remove primary element (3).
3. Remove secondary element (2), if dirty.
4. Wipe inside of housing and wash end cup (4).
5. Install new element(s).
6. Install end cup and engage clasps.
7. Reset air filter service indicator (5).
CMW
As Needed
Check Saver Sub
Check saver sub and replace as needed. See your Ditch Witch dealer for replacement parts.
To replace:
1. Remove eight bolts that attach saver sub to spindle. Do not remove indexing dowels from spindle.
2. Remove and replace o-ring, if necessary.
3. Install in reverse order and torque eight bolts in a cross pattern to 47 ft•lb (64 N•m). Apply Loctite® 242
to bolts before installation.
Replace Fuses
Change fuses as needed. Refer to decal inside panels to identify fuses.
CMW
As Needed
CMW
JT2020 Mach 1 Operator’s Manual Specifications - 193
Specifications
Dimensions U.S. Metric
L, overall machine length (per SAE J2022) 207 in 5.26 m
W, overall machine width (per SAE J2022) 51.5 in 1.31 m
H, overall machine height (per SAE J2022) 90 in 2.39 m
Entry angle (per SAE J2022) 10-14° 10-14°
Entry angle 18-24% 18-24%
Angle of approach 18° 18°
Angle of departure 18° 18°
Operating weight (per SAE J2022) 11,600 lb 5260 kg
Power Pipe U.S. Metric
Length (per SAE J2022), nominal 120 in 3.05 m
Joint diameter (per SAE J2022) 2.63 in 67 mm
Tubing diameter (per SAE J2022) 2.06 in 52 mm
Minimum bend radius 135 ft 41 m
Weight (per SAE J2022), lined 67 lb 30.4 kg
CMW
Specifications - 194 JT2020 Mach 1 Operator’s Manual
Operational U.S. Metric
Maximum spindle speed (per SAE J2022) 225 rpm 225 rpm
Maximum spindle torque (per SAE J2022) 2200 ft•lb 2980N•m
Thrust force (per SAE J2022) 17,000 lb 75.6 kN
Pullback force (per SAE J2022) 20,000 lb 89 kN
Thrust travel speed (per SAE J2022) 140 fpm 43 m/min
Pullback travel speed (per SAE J2022) 140 fpm 43 m/min
Minimum bore diameter 4 in 102 mm
Backream diameter (soil dependent) variable variable
Ground travel speed
forward (per SAE J2022) 0-3.2 mph 0-5.2 km/h
reverse (per SAE J2022) 0-3.2 mph 0-5.2 km/h
Ground bearing pressure (per SAE J2022) 7.7 psi 0.54 kg/cm2
Power U.S. Metric
Engine: Cummins B3.3TAA, EPA Tier 3, EU Stage IIIA
Fuel: diesel
Cooling medium: liquid
Injection: direct
Aspiration: turbo and charge air cooled

Cylinders: 4
Displacement 199 in3 3.3 L
Bore 3.7 in 95 mm
Stroke 4.5 in 115 mm
Power
manufacturer’s gross power rating (per SAE J1995) 85 hp 63 kW
rated speed 2600 rpm 2600 rpm
Drilling Fluid System (Onboard) U.S. Metric
Maximum drilling fluid flow (per SAE J2022) 32 gpm 120 L/min
CMW
JT2020 Mach 1 Operator’s Manual Specifications - 195
Drilling Fluid System (Onboard) U.S. Metric

Maximum drilling fluid pressure (per SAE J2022) 1500 psi 103 bar
Fluid Capacities U.S. Metric
Fuel tank * 30 gal 114 L
Hydraulic reservoir 19 gal 72 L
Engine oil, including filter 8.5 qt 8L
Cooling system 4.4 gal 17 L

* Under normal operating conditions, a full tank of fuel will last 10 hours.
Battery
SAE reserve capacity 195 min, 12V, negative ground, SAE cold crank @ 0°F (-18°C), 950 amps.
Vibration Level
Vibration transmitted to the operator’s hand and whole body during normal operation does not exceed
2.5 m/s2 and 0.5 m/s2 respectively.
Operator seat complies with ISO 7096.
Noise Levels
Operator ear sound pressure level is 86 dBA sound pressure per ISO 6394
Exterior sound power level is 103 dBA per ISO 6393
Specifications are called out according to SAE recommended practices where indicated. Specifications are general and subject
tochange without notice. If exact measurements are required, equipment should be weighed and measured. Due to selected options,
delivered equipment may not necessarily match that shown.
CMW
Specifications - 196 JT2020 Mach 1 Operator’s Manual
CMW
JT2020 Mach 1 Operator’s Manual Support - 155
Procedure
Support
Procedure
Notify your dealer immediately of any malfunction or failure of Ditch Witch equipment.
Always give model, serial number, and approximate date of your equipment purchase. This information
should be recorded and placed on file by the owner at the time of purchase.
Return damaged parts to dealer for inspection and warranty consideration if in warranty time frame.
Order genuine Ditch Witch replacement or repair parts from your authorized Ditch Witch dealer. Use of
another manufacturer's parts may void warranty consideration.
Resources
Publications
Contact your Ditch Witch dealer for publications and videos covering safety, operation, service, and repair
of your equipment.
Ditch Witch Training

For information about on-site, individualized training, contact your Ditch Witch dealer.
CMW
Warranty - 156 JT2020 Mach 1 Operator’s Manual
Warranty
Ditch Witch Equipment and Replacement Parts
Limited Warranty Policy
Subject to the limitation and exclusions herein, free replacement parts will be provided at any authorized Ditch Witch dealership for
any Ditch Witch equipment or parts manufactured by The Charles Machine Works, Inc. (CMW) that fail due to a defect in material or
workmanship within one (1) year of first commercial use (Exception: 2 years for all SK5 attachments). Free labor will be provided at
any authorized Ditch Witch dealership for installation of parts under this warranty during the first year following “initial commercial”
use of the serial-numbered Ditch Witch equipment on which it is installed. The customer is responsible for transporting their
equipment to an authorized Ditch Witch dealership for all warranty work.
Exclusions from Product Warranty

• All incidental or consequential damages.
• All defects, damages, or injuries caused by misuse, abuse, improper installation, alteration, neglect, or uses other than those for
which products were intended.
• All defects, damages, or injuries caused by improper training, operation, or servicing of products in a manner inconsistent with
manufacturer’s recommendations.
• All engines and engine accessories (these are covered by original manufacturer’s warranty).
• Tires, belts, and other parts which may be subject to another manufacturer’s warranty (such warranty will be available to
purchaser).
• ALL IMPLIED WARRANTIES NOT EXPRESSLY STATED HEREIN, INCLUDING ANY WARRANTY OF FITNESS FOR A
PARTICULAR PURPOSE AND MERCHANTABILITY.
IF THE PRODUCTS ARE PURCHASED FOR COMMERCIAL PURPOSES, AS DEFINED BY THE UNIFORM COMMERCIAL
CODE, THEN THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE FACE HEREOF AND THERE ARE NO IMPLIED
WARRANTIES OF ANY KIND WHICH EXTEND TO A COMMERCIAL BUYER. ALL OTHER PROVISIONS OF THIS LIMITED
WARRANTY APPLY INCLUDING THE DUTIES IMPOSED.
Ditch Witch products have been tested to deliver acceptable performance in most conditions. This does not imply they will deliver
acceptable performance in all conditions. Therefore, to assure suitability, products should be operated under anticipated working
conditions prior to purchase.
Defects will be determined by an inspection within thirty (30) days of the date of failure of the product or part by CMW or its authorized
dealer. CMW will provide the location of its inspection facilities or its nearest authorized dealer upon inquiry. CMW reserves the right
to supply remanufactured replacements parts under this warranty as it deems appropriate.
Extended warranties are available upon request from your local Ditch Witch dealer or CMW.
Some states do not allow exclusion or limitation of incidental or consequential damages, so above limitation of exclusion may not
apply. Further, some states do not allow exclusion of or limitation of how long an implied warranty lasts, so the above limitation may
not apply. This limited warranty gives product owner specific legal rights and the product owner may also have other rights which vary
from state to state.
For information regarding this limited warranty, contact CMW’s Product Support department, P.O. Box 66, Perry, OK 73077-0066, or
contact your local Ditch Witch dealer.
First version: 1/91; Latest version: 7/05
CMW
JT2020 Mach 1 Operator’s Manual Service Record - 159
Service Record
Service Performed Date Hours
CMW
Service Record - 160 JT2020 Mach 1 Operator’s Manual
Service Performed Date Hours
CMW

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053-1361 JT2020T3 - 3-0

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JT2020 Mach 1

About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Serial Number Location

drilling unit serial number

engine serial number

trailer serial number

1. Operator’s station 6. Pipeloader

About This Manual

indicates that a procedure is continued on the next page.

The Charles Machine Works, Inc.

Thank you for buying and using Ditch Witch equipment.

JT2020 Mach 1 (Tier 3)

Issue number 3.0/OM-4/11

Copyright 2009, 2010, 2011

This product is covered by one or more of the following patents:

Systems and Equipment 113

Complete the Job 153

Service Record 201

Safety Alert Classifications . . . . . . . . . . . . . . . . . . 13

Safety Alert Classifications

Watch for two other words: NOTICE and IMPORTANT.

Deadly gases. Lack of oxygen or presence of gas will cause sickness or

Jobsite hazards could cause death or serious injury. Use

Crushing weight could cause death or serious injury. Use

Moving parts could cut off hand or foot. Stay away.

Explosion possible. Serious injury or equipment damage could occur.

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

Pressurized fluid or air could pierce skin and cause injury or

Fire or explosion possible. Fumes could ignite and cause burns. No

Moving traffic - hazardous situation. Death or serious injury could result.

Hot parts may cause burns. Do not touch until cool.

Battery acid may cause burns. Avoid contact.

Improper handling or use of chemicals may result in illness, injury, or

Jobsite hazards could cause death or serious injury. Use

Electric Strike Description

When working near electric cables, remember the following:

If an Electric Line is Damaged

• Warn people nearby that an electric strike has occurred.

If a Gas Line is Damaged

Fire or explosion possible. Fumes could ignite and cause burns. No

Explosion possible. Serious injury or equipment damage could occur.

If a Fiber Optic Cable is Damaged

If Machine Catches on Fire

• Immediately move battery disconnect switch (if equipped) to disconnect position.

Tethered Ground Drive Controller . . . . . . . . . . . . 25

Left Control Console . . . . . . . . . . . . . . . . . . . . . . . 27

Right Control Console . . . . . . . . . . . . . . . . . . . . . . 42

Anchoring System Console . . . . . . . . . . . . . . . . . 44

1. Tracker control key 5. Right track switch

Item Description Notes

To override tracker control

Item Description Notes

Wait until light goes off before

3. Ignition switch To start engine, insert key and IMPORTANT:

NOTICE: Stand clear of stabilizer to

Item Description Notes

To lower front end of drill

NOTICE: Stand clear of stabilizer to

Tethered Ground Drive Controller