Ditch Witch JT25 User Manual

JT25

Tier 3 and Tier 4i

Operator’s Manual

CMW

Issue 1.0

Original Instruction

053-2593

JT25 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

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Overview - 2 JT25 Operator’s Manual

Serial Number Location

Record serial numbers and date of purchase in spaces provided. Drilling unit serial number is located as shown.

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Item

date of manufacture date of purchase drilling unit serial number engine serial number

JT25 Operator’s Manual Overview - 3

Intended Use

The JT25 is a self-contained horizontal directional drilling unit designed to install buried cable and pipe to distances of 650’ (200 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.

The JT25 should be used with genuine Ditch Witch drilling fluid units and Ditch Witch tracking equipment. It should be operated, serviced, and repaired only by persons familiar with its particular characteristics and acquainted with the relevant safety procedures.

Use in any other way is considered contrary to the intended use.

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 JT25 Operator’s Manual

Unit Components

1. Operator’s station

2. Spindle

3. Carriage

4. Drill frame

5. Stabilizer

6. Tracks

7. Pipeloader

8. Vise wrenches

9. Anchoring system

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JT25 Operator’s Manual Overview - 5

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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

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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.

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Overview - 6 JT25 Operator’s Manual

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JT25 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.

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Foreword - 8 JT25 Operator’s Manual

JT25

Tier 3 and Tier 4i

Operator’s Manual

Issue number 1.0/OM-03/13

Part number 053-2593

by The Charles Machine Works, Inc.

, Ditch Witch, CMW, Jet Trac, Fluid Miser, Power Pipe, and The Underground

Authority are registered trademarks of The Charles Machine Works, Inc.

This product is covered by one or more of the following patents: U.S. 5490569; 5684466; 5713423; 5794719; 5880680; 5941322; 6085852; 6109371; 6179065; 6250403; 6250404; 6311790; 6411094; 6543551; 6550547; 6672409; 6739413; 6761231; 6776246; 6808210; 6827158; 6848506; 6871712; 7011166; 7038454; 7759824; 7025152; 7347283; 7413031; 7392858; 7600584; 7628226; 7987924; RE37,450; 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; 697 28 716; 69829107.7-08, 19712641;

66942993.5; EP 0683845; FR 674093; GB 2312006; 817901; 146608; EP 927892; EP674,093; EP846,841; UK 0984132; JP 3,458,247; other U.S. and foreign patents pending.

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JT25 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

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, fluid systems, and diagnostic codes

Complete the Job

procedures for 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

107

155

161

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Contents - 10 JT25 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

193

197

201

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JT25 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

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Safety - 12 JT25 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 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.

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JT25 Operator’s Manual Safety - 13

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 - 14 JT25 Operator’s Manual

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.

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.

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

proper procedures and equipment or stay away.

Explosion possible. Serious injury or equipment damage could occur.

Follow directions carefully.

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.

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

Learn to use equipment correctly.

JT25 Operator’s Manual Safety - 15

Safety Alerts

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.

Avoid static electricity when fueling. Ultra Low Sulfur Diesel (ULSD) poses a greater static ignition hazard than earlier diesel formulations. Avoid death or serious injury from fire or explosion. Consult with your fuel system supplier to ensure the delivery system is in compliance with fueling standards for proper grounding and bonding practices.

Moving traffic - hazardous situation. Death or serious injury could result. Avoid moving vehicles, wear high visibility clothing, post appropriate warning signs.

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Safety - 16 JT25 Operator’s Manual

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).

Breathing crystalline silica dust may cause lung disease. Cutting, drilling, or working materials such as concrete, sand, or rock containing quartz may result in exposure to silica dust. Use dust control methods or appropriate breathing protection when exposed to silica dust.

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JT25 Operator’s Manual Safety - 17

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 - 18 JT25 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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JT25 Operator’s Manual Safety - 19

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 - 20 JT25 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.

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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JT25 Operator’s Manual Controls - 21

Controls

Chapter Contents

Set-Up Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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

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

• Engine Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

• Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Right Control Console . . . . . . . . . . . . . . . . . . . . . . 33

• Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

• Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Anchoring System Console. . . . . . . . . . . . . . . . . . 40

Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Cab Controls (optional) . . . . . . . . . . . . . . . . . . . . . 43

• Top/Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

• Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Engine Compartment Controls . . . . . . . . . . . . . . . 47

ESID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Controls - 22 JT25 Operator’s Manual

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Set-Up Console

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1. Engine shutdown override switch

2. Rear hood switch

3. Cold start wait indicator

6. Left track switch

7. Right stabilizer control

8. Left stabilizer control

4. Ignition switch

5. Right track switch

9. Back frame tilt control

10. Front frame tilt control

Item Description Notes

1. Engine shutdown override switch

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If engine shutdown indicator comes on, turn ignition switch to STOP and press to delay engine shutdown for 30 seconds.

This control allows a temporary override of engine shutdown.

NOTICE: After 30 seconds, engine will again shut down unless fault condition has been cleared on diagnostic gauge.

IMPORTANT: See “Electronic Controlled Engine Overview” on page 142 for more information on Tier 3 engines.

JT25 Operator’s Manual Controls - 23

Set-Up Console

Item Description Notes

2. Rear hood switch To open rear hood, press left

side of switch. To close rear hood, press

right side of switch.

3. Cold start wait indicator Lights when intake air pre-

heater is operating. Wait until light goes off before

starting engine.

4. Ignition switch To start engine, insert key and

turn clockwise. To stop engine, turn key

counterclockwise.

5. Right track switch To move forward, press top.

To move backward, press bottom.

NOTICE: If indicator is on, wait until it goes out before starting engine.

IMPORTANT: If ignition switch is turned to start position before indicator goes out, the system will be disabled and must be reset.

To reset, turn ignition switch to STOP, then to run.

IMPORTANT:

• Restart engine with ignition switch after it has been turned off with tethered control 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.

IMPORTANT: Use track switches only if tethered control is inoperable.

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Controls - 24 JT25 Operator’s Manual

Set-Up Console

Item Description Notes

6. Left track switch To move forward, press top.

To move backward, press bottom.

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7. Right stabilizer control To raise, pull up. To lower, push down.

8. Left stabilizer control To raise, pull up. To lower, push down.

IMPORTANT: Use track switches only if tethered control is inoperable.

IMPORTANT: Lower left and right stabilizers to the ground together, then adjust individually.

WARNING: Crushing weight could cause death or serious injury. Use proper procedures and equipment or stay away.

IMPORTANT: Lower left and right stabilizers to the ground to stabilize unit and then adjust for side-to-side stability.

9. Back frame tilt control To raise, pull up. To lower, push down.

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10. Front frame tilt control To raise, pull up. To lower, push down.

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WARNING: Crushing weight could cause death or serious injury. Use proper procedures and equipment or stay away.

IMPORTANT: To ensure a stable platform for drilling, use front and back tilt controls together to set frame at desired pitch without raising tracks off the ground.

JT25 Operator’s Manual Controls - 25

Tethered Ground Drive Controller

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1. Speed/direction control

2. Drive mode switch

3. Remote engine stop

Item Description Notes

1. Speed/direction control To move forward, push.

To move backward, pull. To steer, move left or right

while moving forward or backward.

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4. Operator presence switch

5. Throttle switch

IMPORTANT:

• Operator presence switch must

• See “Steer Unit” on page 76 for

be pressed and operator seat must be empty for control to work.

more information.

Controls - 26 JT25 Operator’s Manual

Tethered Ground Drive Controller

Item Description Notes

2. Drive 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 button.

4. Operator presence

switch

To operate ground drive with tethered controller, press.

To disable controller, release.

5. Throttle switch To increase engine speed, press top.

To decrease engine speed, bottom.

IMPORTANT: To restart engine, turn ignition switch off and then back on.

JT25 Operator’s Manual Controls - 27

Left Control Console

Engine Display

1. Fuel gauge

2. Tachometer

3. Drilling fluid flow display

4. Engine coolant temperature gauge

5. Hour meter

6. Engine oil pressure gauge

Item Description Notes

1. Fuel gauge Displays amount of fuel

remaining in tank.

2. Tachometer Displays engine speed.

3. Drilling fluid flow

display

Displays the estimated GPM or LPM of drilling fluid being pumped.

7. Soft key

8. Soft key

9. Main menu key

10. Soft key

11. Day/Night mode key

12. Voltmeter display

See “Approved Fuel” on page 167.

Controls - 28 JT25 Operator’s Manual

Left Control Console

Item Description Notes

4. Engine coolant

temperature gauge

5. Hour meter Displays number of hours

6. Engine oil pressure

gauge

7. Soft key Press to select a soft key

8. Soft key

9. Main menu key Press from main screen

10. Soft key Press to select a soft key

11. Day/Night mode key Press from main screen

12. Voltmeter display Shows system voltage. Normal voltage is 13-14V with engine

Displays engine coolant temperature.

engine has been running. Displays engine oil pressure. Full load reading should be 60-80 psi

command.

(gauges) to select main menu.

command.

(gauges) to toggle between day and night modes.

Normal coolant temperature is 160°212° F (71°-100° C).

(4.1-5.5 bar). Soft key commands change with each

menu screen and are displayed next to the key.

Soft key commands change with each menu screen and are displayed next to the key.

running.

Most engine display functions are self-explanatory. For more information about functions, see the manufacturer’s instructions at www.fwmurphy.com.

Main Menu

IMPORTANT: Soft key commands change with each menu screen and are displayed next to the key.

Item Description Notes

11. System settings key Press to select system

settings menu.

10. User settings key Press to select user settings menu.

9. Main screen key Press to return to main screen (gauges).

8. Engine diagnostics key Press to select engine diagnostics menu.

System settings menu displays information about the system. Diagnostic information is only available to dealer technicians.

User settings menu allows user to change the language and unit settings, and to set the time and date.

For dealer technician use only.

JT25 Operator’s Manual Controls - 29

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Left Control Console

Controls

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1. Wrench control

2. Set/Resume switch

3. Pipe gripper switch

4. Pipe shuttle switch

5. Pipe lift switch

6. Pipe lubricator switch

7. Carve potentiometer

8. Carve switch

9. Fluid flow control

10. Engine throttle switch

11. High/Low rotation switch

12. Shuttle stop switch

+ 173 hidden pages