Ditch Witch JT100AT User Manual

JT100/JT100 All Terrain

Operator’s Manual

CMW

Issue 1.0

Original Instruction

053-2546

JT100/JT100 All Terrain Operator’s Manual Overview - 1

Overview

Chapter Contents

Serial Number Location . . . . . . . . . . . . . . . . . . . . . . 2

Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Equipment Modification . . . . . . . . . . . . . . . . . . . . . 3

Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Operator Orientation . . . . . . . . . . . . . . . . . . . . . . . . 4

About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 4

• Bulleted Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

• Numbered Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

• “Continued” Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Overview - 2 JT100/JT100 All Terrain Operator’s Manual

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 driver/loader serial number engine serial number

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JT100/JT100 All Terrain Operator’s Manual Overview - 3

Intended Use

The JT100/JT100 All Terrain is a self-contained horizontal directional drilling unit capable of drilling and backreaming through solid rock, cobblestone, broken rock, gravel, and other soil/rock mixes, as well as less extreme soil conditions. It is designed to install buried cable and pipe at distances to 2,000’ (610 m) depending on soil conditions and is intended for operation in ambient temperatures from 0° to 115°F (-18° to 46°C). Use in any other way is considered contrary to the intended use.

The unit can be used with Ditch Witch drilling fluid units and Ditch Witch operated, serviced, and repaired only by persons familiar with its particular characteristics and acquainted with the relevant safety procedures.

tracking equipment. It should be

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.

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Overview - 4 JT100/JT100 All Terrain Operator’s Manual

Unit Components

1. Driver/loader attachment (optional)

2. Pipeloader

3. Front and rear wrenches

4. Spindle

5. Rotation carriage

6. Thrust carriage

Operator Orientation

1. Front of unit

2. Right side of unit

3. Rear of unit

4. Left side of unit

7. Front and rear stabilizers

8. Tracks

9. Operator’s station

10. Drill frame

11. Anchoring system (optional)

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JT100/JT100 All Terrain Operator’s Manual Overview - 5

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.

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Overview - 6 JT100/JT100 All Terrain Operator’s Manual

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JT100/JT100 All Terrain 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

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.

equipment.

Thank you for buying and using Ditch Witch equipment.

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Foreword - 8 JT100/JT100 All Terrain Operator’s Manual

JT100/JT100 All Terrain

(Tier 4i)

Operator’s Manual

Issue number 1.0/OM-3/14

Part number 053-2546

by The Charles Machine Works, Inc.

, Ditch Witch, Jet Trac, Fluid Miser, Power Pipe, and CMW are registered

trademarks of The Charles Machine Works, Inc.

This product is covered by one or more of the following patents: US 5,490,569; 5,684,466; 5,740,703; 5,758,553; 5,794,719; 5,880,680; 6,085,852C1; 6,109,371; 6,179,065; 6,250,403; 6,250,404; 6,311,790; 6,411,094; 6,543,551; 6,550,547; 6,672,409; 6,739,413; 6,761, 231; 6,808,210; 6,827,158; 6,848,506; 6, 871,712; 7,011,166; 7,018,164; 7, 025,152; 7, 038,454; 7,240,742; 7,347,283; 7,392,858; 7,413,031; 7,600,584; 7,628,226; 7,759,824; 7,987,924; 8,201,644; 8,534,388; RE38,418; CA 2,156,398; 2,217,899; DE 603 04 320; 694 17 019; 695 29 633; 697 28 716; 698 29 107; 197 12 641; FR 674,093; GB 2,312,006; UK0674093; UK0984132; UK1466068; UK817901; EP927892; JP 3,458,247; other U.S. and foreign patents pending.

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JT100/JT100 All Terrain Operator’s Manual Contents - 9

Overview

machine serial number, information about the type of work this machine is designed to perform, basic machine components, and how to use this manual

Foreword

part number, revision level, and publication date of this manual, and factory contact information

Safety

machine safety alerts and emergency procedures

Controls

machine controls, gauges, and indicators and how to use them

Operation Overview

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

procedures for inspecting and classifying the jobsite, planning the installation path, and preparing the jobsite for work

Drive

procedures for startup, cold start, driving, and shutdown

101

Transport

procedures for lifting, hauling, and towing

Conduct a Bore

procedures for drilling and backreaming

Systems and Equipment

downhole tools and drill pipe, anchor, electric strike, tracker control, and fluid systems

Complete the Job

procedures for backfilling and restoring the jobsite and rinsing and storing equipment

Service

service intervals and instructions for this machine including lubrication, replacement of wear items, and basic maintenance

105

111

133

179

185

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Contents - 10 JT100/JT100 All Terrain Operator’s Manual

Specifications

machine specifications including weights, measurements, power ratings, and fluid capacities

Support

the warranty policy for this machine, and procedures for obtaining warranty consideration and training

Service Record

a record of major service performed on the machine

231

239

237

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JT100/JT100 All Terrain Operator’s Manual Safety - 11

Safety

Chapter Contents

Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Emergency Procedures . . . . . . . . . . . . . . . . . . . . . 13

• Electric Strike Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

• If an Electric Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

• If a Gas Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

• If a Fiber Optic Cable is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

• If Machine Catches on Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Safety Alert Classifications . . . . . . . . . . . . . . . . . . 21

Machine Safety Alerts . . . . . . . . . . . . . . . . . . . . . . 22

Attachment Safety Alerts . . . . . . . . . . . . . . . . . . . 25

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Safety - 12 JT100/JT100 All Terrain Operator’s Manual

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. Mark proposed path with white paint prior to contacting One-Call or utilities.

• 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

• Replace missing or damaged safety shields and safety signs.

• Use equipment carefully. Stop operation and investigate anything that does not look or feel right.

dealer.

• 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.

• Complete the equipment checklist located at www.ditchwitch.com/resources/safety.

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JT100/JT100 All Terrain Operator’s Manual Safety - 13

Emergency Procedures

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

Before operating any equipment, review emergency procedures and check that all safety precautions have been taken.

EMERGENCY SHUTDOWN - Turn ignition switch to stop position or push remote engine stop button (if equipped).

Electric Strike Description

Electric shock. Contacting electric lines will cause death or serious injury.

Know location of lines and stay away.

When working near electric cables, remember the following:

• Electricity follows all paths to ground, not just path of least resistance.

• Pipes, hoses, and cables will conduct electricity back to all equipment.

• Low voltage current 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.

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Safety - 14 JT100/JT100 All Terrain Operator’s Manual

Emergency Procedures

If an Electric Line is Damaged

If you suspect an electric line has been damaged and you are on drilling unit or bonded equipment, DO NOT MOVE. Remain on drilling machine 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 self test 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.

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JT100/JT100 All Terrain Operator’s Manual Safety - 15

Emergency Procedures

If a Gas Line is Damaged

Fire or explosion possible. Fumes could ignite and cause

burns. No smoking, no flame, no spark.

Explosion possible. Serious injury or equipment damage could occur.

Follow directions carefully.

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.

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Safety - 16 JT100/JT100 All Terrain Operator’s Manual

Emergency Procedures

If a Fiber Optic Cable is Damaged

Do not look into cut ends of fiber optic or unidentified cable. Vision damage can occur. Contact utility company.

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 and accessible) 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.

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JT100/JT100 All Terrrain Operator’s Manual Safety - 17

Driver/Loader Precautions

Intended Use

The driver/loader is to be used for driving anchors and loading and unloading pipe boxes only. Use in any other way is considered contrary to the intended use.

Preparation

Visually inspect driver/loader each day to determine that it is in good condition before it is used. Check the following:

• Make sure driver/loader is free of excess oil, grease, mud and debris before operation.

• Test driver/loader at the beginning of each shift to determine that the operating systems are in good working order.

• Check safety devices to ensure they are functioning and in place.

• Check boom, hoses and connecting pins for wear and damage.

Transportation

• Always store auxiliary stabilizer before moving unit.

• Always store driver/loader properly for transportation.

• Never drive with load suspended from driver/loader.

Jobsite Setup

• Always use unit stabilizers during driver/loader operation. Ensure that they are firmly positioned on solid footings.

• Always install auxiliary stabilizer for driver/loader operation on engine side of unit.

• If auxiliary stabilizer rests on curb or other object that prevents it from supporting load, consider blocking under the arm of the auxiliary stabilizer as near the outer end as possible to support load.

• If auxiliary stabilizer does not rest on ground due to holes or grades, it must be blocked up to provide level and firm support for the unit.

• When working in soft soil conditions, use wide pad under auxiliary stabilizer foot to prevent sinking.

• Ensure loads are securely attached before lifting.

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Safety - 18 JT100/JT100 All Terrrain Operator’s Manual

Driver/Loader Precautions

Operation

General

Riding on boom or load will result in death or serious

injury. No riders. Keep off.

• Never place chain link on tip of hook to lift load.

• Close hook throat before lifting load.

• Never use a sling bar or anything larger than the hook throat that could prevent hook latch from closing. This prevents damage to material being hoisted and helps prevent injury to personnel.

• No unqualified or unauthorized person shall be allowed to operate the loader/driver.

• Always comply with load chart capacities. Weight of heavy load can create enough tipping momentum to overturn drilling unit.

• Observe operating area obstructions or power lines that might be a hazard.

• Keep objects and personnel clear of driver/loader path during operation.

• Do not take your eyes off a moving load. Always look in the direction load is moving.

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JT100/JT100 All Terrrain Operator’s Manual Safety - 19

Driver/Loader Precautions

• Never swing a load over people.

• Consider overall height of unit when moving under objects with low overhead clearance.

• Operate controls smoothly and do not stop load sharply in midair so that it swings.

• Fluid pressure from broken hydraulic line could pierce skin and cause injury or death. Stay away.

• Keep loader/driver boom length as short as possible for maximum lifting capacity and safety. Longer booms require additional care in accelerating and decelerating the swing motion and thus slow down the working cycle and reduce production.

• Never use loader/driver for towing or pulling a load sideways. Keep load directly under boom point at all times. Boom can fail far below its rated capacity if the driver/loader is side loaded.

• Always walk around unit and check for obstructions before moving load.

• Do not lift personnel with driver/loader.

• Know weight of rigging and load to avoid overloading driver/loader.

• Heavy loads can create enough tipping movement to overturn vehicle. Always install auxiliary stabilizer when lifting on the engine side of unit.

• Except for anchoring drilling unit, do not apply down force with boom extensions, lift, or outer boom function.

Driver/Loader Overload

If driver/loader becomes overloaded, driver/ loader components will not move in some directions (see illustration) until overload condition is overcome.

• Bring load closer to unit to overcome overload.

• Confirm load before continuing.

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Safety - 20 JT100/JT100 All Terrrain Operator’s Manual

Driver/Loader Precautions

Near Electrical Power Lines

Do not get boom near power lines. Death or serious injury will occur. Keep required distance between boom and power lines. Use a spotter.

Never operate the driver/loader within 10’ (3 m) of electric power lines carrying up to 50 kV. Add 1’ (305 mm) of clearance for each additional 30 kV or less (see table on left). Follow OSHA or other guidelines for working around power lines. Also observe minimum clearance requirements during transport (see table on right).

Normal voltage (phase to phase)

up to 50 kV 10’ 3 m 51-200 kV 15’ 4.6 m 201-350 kV 20’ 6 m 351-500 kV 25’ 7.6 m 501-750 kV 35’ 10.7 m 751-1000 kV 45’ 13.7 m

Do not enter the danger zone (A), unless one of the following conditions is met:

• An appointed person has confirmed that the electrical distribution and transmission lines have been deenergized and visibly grounded at the point of work.

• Insulating barriers (not a part of the attachment or driver/loader) have been erected to prevent physical contact with the lines.

Minimum operating clearance required

Normal voltage (phase to phase)

up to 0.75 kV 4’ 1.2 m

0.76-200 kV 6’ 1.8 m 50-345 kV 10’ 3.8 m 346-750 kV 16’ 4.9 m 751-1000 kV 20’ 6.1 m unknown 20’ 6.1 m

Minimum transporting clearance required

Maintenance

• Before working on the driver/loader, lower boom to the ground, turn driver/loader controls off and relieve hydraulic pressure from circuits.

• Never weld, modify, or use unauthorized components on driver/loader attachment. This will void any warranty or liability, and driver/loader failure could result.

• Check hook before each use for distortions or cracks.

• Stop all operations when cleaning, adjusting or lubricating the machine.

• Install all guards before returning driver/loader to service.

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JT100/JT100 All Terrrain Operator’s Manual Safety - 21

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 a hazardous situation that, if not avoided, will result in death or serious injury. This

signal word is to be limited to the most extreme situations.

indicates a hazardous situation that, if not avoided, could result in death or serious injury.

indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

Watch for two other words: NOTICE and IMPORTANT. NOTICE indicates information considered important, but not hazard-related (e.g., messages relating to

property damage).

IMPORTANT can help you do a better job or make your job easier in some way.

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Safety - 22 JT100/JT100 All Terrrain Operator’s Manual

Machine Safety Alerts

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JT100/JT100 All Terrrain Operator’s Manual Safety - 23

Machine Safety Alerts

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.

Moving parts could cut off hand. Keep hands away.

Turning shaft will kill you or crush arm or leg. Stay

away.

Read operator’s manual. Know how to use all

controls. Your safety is at stake.

Jobsite hazards could cause death or serious

injury. Use correct equipment and work methods. Use and maintain proper safety equipment.

Electric shock will cause death or serious injury.

Disconnect all power to this equipment before servicing.

Crushing weight could cause death or serious

injury. Use proper procedures and equipment or stay away.

Tiedown location. See Transport chapter for more information.

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Safety - 24 JT100/JT100 All Terrrain Operator’s Manual

Machine Safety Alerts

Hot parts may cause burns. Do not touch until cool

or wear gloves.

Fire or explosion possible. Fumes could ignite and

cause burns. No smoking, no flame, no spark.

Crushing weight could cause death or serious

injury. Use proper procedures and equipment or stay away.

Fall possible. Riders can fall from machine and be

injured or killed. Only operator is allowed on machine.

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JT100/JT100 All Terrrain Operator’s Manual Safety - 25

Attachment Safety Alerts

Driver/Loader Attachment

Riding on boom or load will result in death or

serious injury. No riders. Keep off.

Moving parts could cut off hand. Keep hands away.

Read operator’s manual. Know how to use all controls. Your safety is at stake.

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Safety - 26 JT100/JT100 All Terrrain Operator’s Manual

Attachment Safety Alerts

Do not get boom near power lines. Death or

serious injury will occur. Keep required distance between boom and power lines. Use a spotter.

Auxiliary stabilizer must be properly installed with contact on firm surface before operating pipebox loader on the engine side of the unit. Working loads should be limited to those shown.

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JT100/JT100 All Terrain Operator’s Manual Controls - 27

Controls

Chapter Contents

Set-Up Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Tethered Driver/Loader Controller . . . . . . . . . . . . 31

Overhead Console . . . . . . . . . . . . . . . . . . . . . . . . . 34

Left Control Console . . . . . . . . . . . . . . . . . . . . . . . 36

• Pipeloading Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

• Drilling Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

• Operation Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Right Control Console . . . . . . . . . . . . . . . . . . . . . . 48

• Engine Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

• Gauges and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

• Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

• Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Fluid Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

JT/AT System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Override Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Miscellaneous Controls . . . . . . . . . . . . . . . . . . . . . 65

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

ESID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

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Controls - 28 JT100/JT100 All Terrain Operator’s Manual

Setup Console

1. Engine throttle switch

2. Remote engine stop switch

3. Auxiliary light switch

4. Left rear stabilizer control

5. Right rear stabilizer control

Item Description Notes

1. Engine throttle switch To increase engine

speed, press To decrease engine

speed, press

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6. Left front stabilizer control

7. Right front stabilizer control

8. Auxiliary hydraulic pressure gauge

9. Levels

IMPORTANT: Throttle switch at operator’s station must be in center position for this switch to control speed.

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JT100/JT100 All Terrain Operator’s Manual Controls - 29

Setup Console

Item Description Notes

2. Remote engine stop switch

3. Auxiliary light switch To turn on, press

4. Left rear stabilizer control

To stop engine, press. To restart engine, turn ignition

off and then back to start.

To turn off, press

To lower, push. To raise, pull.

IMPORTANT:

• If this switch is used to stop 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.

Lower both rear stabilizers to the ground together and then adjust individually.

5. Right rear stabilizer control

To lower, push. To raise, pull.

Lower both rear stabilizers to the ground together and then adjust individually.

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