Ditch Witch JT25 User Manual

Download

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

CMW

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.

CMW

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.

CMW

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

CMW

JT25 Operator’s Manual Overview - 5

j37om003h.eps

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

j37om003h.eps

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.

CMW

Overview - 6 JT25 Operator’s Manual

CMW

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.

CMW

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.

CMW

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

CMW

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

CMW

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

CMW

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.

CMW

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.

CMW

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.

CMW

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.

CMW

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.

CMW

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.

CMW

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.

CMW

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.

CMW

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.

CMW

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

j37om004h.eps

Set-Up Console

j37om004h.eps

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

c00ic178h.eps

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.

c00ic148h.eps

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.

c00ic147h.eps

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.

c00ic606h.eps

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

c00ic607h.eps

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

j10om016h.eps

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.

c00ic145h.eps

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.

c00ic146h.eps

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

j37om007h.eps

Left Control Console

Controls

j37om007h.eps

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

Controls - 30 JT25 Operator’s Manual

Left Control Console

Item Description Notes

1. Wrench control To clamp and rotate rear

wrench, push forward. To unclamp rear wrench, pull

back. To clamp front wrench, move

to right.

c00ic612h.eps

To unclamp rear wrench, move to left.

2. Set/Resume switch To resume operation or increase operation levels, press top.

To set operating conditions or reduce operation levels, press bottom.

3. Pipe gripper switch To close, press top. To open, press bottom.

4. Pipe shuttle switch To move toward pipe box, press top.

To move toward spindle, press bottom.

See “Cruise Control” on page 140.

JT25 Operator’s Manual Controls - 31

Left Control Console

Item Description Notes

5. Pipe lift switch To raise, press top.

To lower, press bottom.

6. Pipe lubricator switch To apply joint compound, press.

c00ic616h.eps

7. Carve window control To increase carve window range, turn clockwise.

To decrease carve window range, turn counterclockwise.

c00ic609h.eps

8. AutoCarve switch To enable autocarve, press top.

To deactivate autocarve, press bottom.

c00ic608h.eps

9. Fluid flow control To increase flow, turn clockwise.

To decrease flow, turn counterclockwise.

See “Use AutoCarve” on page 98.

Two-speed thrust is not allowed in autocarve mode.

Controls - 32 JT25 Operator’s Manual

Left Control Console

Item Description Notes

10. Engine throttle switch To increase speed, press top.

To enable autothrottle mode, leave switch in top position.

To disable autothrottle mode, return switch to center after desired speed is reached.

c00ic243h.eps

To decrease speed, press bottom.

11. Two-speed rotation

switch

To rotate in high speed, press top.

To rotate in low speed, press bottom.

c00ic610h.eps

12. Shuttle stop switch To lower shuttle stop, push up.

To raise shuttle stop, pull down.

Autothrottle mode slows the engine to low throttle after 15 seconds of inactivity involving thrust, rotation, drilling fluid flow, or pipeloader functions. To return to high speed, activate thrust, rotation, drilling fluid, or an add/remove pipe cycle.

IMPORTANT: Look at pipe row indicator on drill frame to see which row shuttles will stop under.

c00ic611h.eps

JT25 Operator’s Manual Controls - 33

j37om008h.eps

Right Control Console

Lights

j37om008h.eps

1. Diagnostic light (red)

2. Rear stop status light

3. Rear home status light

4. Front home status light

5. Shuttle home status light

7. Control cycle light (green)

8. Remote display

9. Rotation pressure gauge

10. Drilling fluid pump status indicator

11. Drilling fluid pressure gauge

6. Operator presence light

12. Thrust pressure gauge

Controls - 34 JT25 Operator’s Manual

Right Control Console

Item Description Notes

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

code is recorded, light should 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. Rear stop status light If carriage is at rear stop, light

should be on. If carriage is away from rear

stop, light should be off.

c00ic617h.eps

3. Rear home status light If carriage is at rear of drill

frame, light should be on. If carriage is away from rear

of drill frame, light should be off.

See “Diagnostic Codes” on page 142.

c00ic618h.eps

4. Front home status light If carriage is at front of drill

frame, light should be on. If carriage is away from front

of drill frame, light should be off.

c00ic619h.eps

JT25 Operator’s Manual Controls - 35

Right Control Console

Item Description Notes

5. Shuttle home status

light

If shuttle is retracted, light should be on.

If shuttle is extended, light should be off.

c00ic620h.eps

6. Operator presence light If seat switch is engaged, light

should be on. If seat switch is not engaged,

light should be off.

c00ic621h.eps

7. Control cycle light

(green)

If nothing is being controlled, 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.

8. Remote display Displays information from the

tracker at the drilling unit operator’s station.

9. Rotation pressure

gauge

Displays hydraulic fluid pressure to rotation motor when spindle is turned clockwise.

See tracking system operator’s manual for information.

Controls - 36 JT25 Operator’s Manual

Right Control Console

Item Description Notes

10. Drilling fluid pump

Lights when pump is on.

status light

11. Drilling fluid pressure

gauge

c00ic627h.eps

Displays drilling fluid pressure.

12. Thrust pressure gauge Displays hydraulic fluid

pressure to thrust motor during thrust and pullback.

IMPORTANT: Monitor this gauge and drilling fluid flowmeter carefully to see if values are rising or falling at the same time. If they are not, nozzle might be plugged.

JT25 Operator’s Manual Controls - 37

Right Control Console

Controls

1. Dual speed carriage control

2. Thrust and rotation control

3. Remote engine start switch

4. Remote engine stop switch

5. Anchor enable switch

Item Description Notes

1. Dual speed carriage control

To increase carriage travel speed, push and hold.

To return to normal carriage speed, release.

6. Operator’s station pivot switch

7. Add pipe/manual/remove pipe switch

8. Drilling fluid pump switch

9. Drilling fluid quick fill switch

Use during bore or pullback when no pipe is in spindle to save time.

Controls - 38 JT25 Operator’s Manual

Right Control Console

Item Description Notes

2. Thrust and rotation control

c00ic622h.eps

3. Remote engine start switch

4. Remote engine stop switch

To move carriage forward, push.

To move carriage backward, pull.

To rotate spindle counterclockwise (breakout), move right.

To rotate spindle clockwise (makeup), move left.

To start engine, press. IMPORTANT: Ignition switch on rear

console must be on to start engine remotely.

To stop engine, press. To restart engine, press

remote engine start switch.

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.

5. Anchor enable control Press to activate pump and allow flow to the anchor valve.

Sit in operator’s seat to return pump to standby mode and stop flow.

• If wrenches are engaged when remote stop is pressed, wrenches will remain engaged but could gradually open.

JT25 Operator’s Manual Controls - 39

Right Control Console

Item Description Notes

6. Operator’s station pivot control switch

c00ic624h.eps

7. Add pipe/manual/ remove pipe switch

8. Drilling fluid pump switch

To pivot into drilling position, press top.

To pivot into transport position, press bottom.

To select “add pipe” automated pipeloader function, press top.

To use manual pipeloader controls, move to center.

To select “remove pipe” automated pipeloader function, press bottom.

To turn on, press once. To turn off, press once.

NOTICE: Move carriage only when operator’s station is in drilling position.

See “Add Pipe” on page 94.

See “Remove Pipe” on page 103.

9. Drilling fluid quick fill switch

For full pump flow to fill pipe with fluid, press and hold.

To return fluid flow to flow control setting, release.

Controls - 40 JT25 Operator’s Manual

j37om013h.eps

Anchoring System Console

j37om013h.eps

1. Left rotation control 3. Right rotation control

2. Left thrust control 4. Right thrust control

Item Description Notes

1. Left rotation control To drive anchor, pull.

To remove anchor, push.

c00ic625h.eps

2. Left thrust control To move anchor down, pull.

To move anchor up, push.

c00ic623h.eps

JT25 Operator’s Manual Controls - 41

Anchoring System Console

Item Description Notes

3. Right rotation control To drive anchor, pull.

To remove anchor, push.

c00ic625h.eps

4. Right thrust control To move anchor down, pull.

To move anchor up, push.

c00ic623h.eps

Controls - 42 JT25 Operator’s Manual

Seat

1. Seat recline control

2. Seat slide control

Item Description Notes

1. Seat recline control To raise seatback, turn

toward anchors. To recline seatback, turn

toward engine compartment.

2. Seat slide control To slide forward or backward,

move left. To lock seat in position,

release.

3. Seat lumbar control To have least support, move

up. To have medium support,

move down. To have maximum support,

move toward engine compartment.

3. Seat lumbar control

JT25 Operator’s Manual Controls - 43

Cab Controls (optional)

Top/Rear

j29om002t.eps

1. Dome light switch

2. Air conditioner on/off switch

3. Air conditioner temperature dial

Item Description Notes

1. Dome light switch To turn on dome light, press

right. To turn off dome light, press

left.

4. Air conditioner fan speed dial

5. Air conditioner filter

Controls - 44 JT25 Operator’s Manual

Cab Controls (optional)

Item Description Notes

2. AC on/off switch To turn air conditioner on,

press left. To turn air conditioner off,

press right.

3. AC temperature dial To adjust air temperature,

turn dial.

4. AC fan speed dial To adjust fan speed, turn dial.

5. Air conditioner filter Filters air coming into cab. Clean or replace air filter as needed.

JT25 Operator’s Manual Controls - 45

Cab Controls (optional)

Front

j29om003t.eps

1. Washer switch

2. Wiper switch

Item Description Notes

1. Washer switch To spray washer fluid, press

top. To stop, press bottom.

3. Worklight switch

2. Wiper switch To start wiper blade, press

top. To stop wiper blade, press

bottom.

Controls - 46 JT25 Operator’s Manual

Cab Controls (optional)

Item Description Notes

3. Worklight switch To turn on, press top.

To turn off, press bottom.

c00ic626h.eps

JT25 Operator’s Manual Controls - 47

Engine Compartment Controls

1. Throttle switch

2. Tracker Control key

3. J1939 CAN diagnostic port, engine

Item Description Notes

1. Throttle switch To increase engine speed,

press top. To decrease engine speed,

press bottom. To further increase or

decrease speed, press

c00ic243h.eps

additional times (or hold until desired speed is reached).

4. Air intake service indicator

5. Battery disconnect switch

Use this switch only if throttle switch on console does not work.

Controls - 48 JT25 Operator’s Manual

Engine Compartment Controls

Item Description Notes

2. Tracker Control key To allow tracker operator to

stop thrust and rotation, move key to enable position (up).

To override tracker control mode, move key to disable position (right).

3. J1939 CAN diagnostic port, engine

4. Air intake restriction indicator

5. Battery disconnect switch

For use only by qualified Ditch Witch technicians.

Shows air intake restriction. Replace the air filter elements when

To connect, move clockwise. To disconnect, move

counterclockwise.

IMPORTANT: Remove key and keep in tracker operator’s possession.

the indicator reaches the red zone. See “Change Air Filter” on page 190.

IMPORTANT: Use battery disconnect switch when servicing, welding, and during long-term storage.

JT25 Operator’s Manual Controls - 49

j37om005h.eps

Miscellaneous Controls

j37om005h.eps

1. EDT diagnostic port, controller

2. Auxiliary outlet

Item Description Notes

1. EDT diagnostic port, controller

2. Auxiliary outlet Supplies power to 12V

3. Work light switch To turn on, press top.

c00ic151h.eps

For use only by qualified Ditch Witch technicians.

devices.

To turn off, press bottom.

3. Work light switch

4. Audible alarm

Controls - 50 JT25 Operator’s Manual

Miscellaneous Controls

Item Description Notes

4. Audible alarm Beeps when key is in run

position, but engine is not running.

Sounds continuously when hydraulic fluid temperature is too high.

JT25 Operator’s Manual Controls - 51

ESID

j07om042h.eps

1. Alphanumeric display 5. Current problem indicator

2. Strike indicator 6. OK indicator

3. Alarm interrupt button 7. Electrical power supply indicator

4. Voltage problem indicator 8. Self test button

Item Description Notes

1. Alphanumeric display Display 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

in display increase. Light in triangle represents

strike warning condition and will trigger alarm(s) and strobe(s).

Remember that system can go from one or two lights to an electric strike immediately.

NOTICE: The ESID does not indicate proximity to electric lines. System will activate only when voltage and/or amperage detected at the drilling unit are above threshold minimum limits.

Controls - 52 JT25 Operator’s Manual

ESID

Item Description Notes

3. Alarm interrupt button To turn off strike alarm at

drilling unit, press.

4. Voltage problem indicator

5. Current problem indicator

6. OK indicator Green light means system

Red light indicates a voltage indicator problem.

Red light indicates a current indicator problem.

self test detected no problems.

See “Troubleshoot Strike System” on page 113.

Strike system is ready to operate.

JT25 Operator’s Manual Controls - 53

ESID

Item Description Notes

7. Electrical power supply indicator

8. Self test button To start manual self test,

Green light means control box has sufficient electrical power for operation.

Strike system is ready to operate if OK indicator is also on.

press. To reset system after a strike

has been detected, press.

Checks all systems and circuits except voltage limiter.

NOTICE: See “If an Electric Line is Damaged” on page 18.

Controls - 54 JT25 Operator’s Manual

ESID

JT25 Operator’s Manual Operation Overview - 55

Operation Overview

Chapter Contents

Planning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Setting Up at Jobsite . . . . . . . . . . . . . . . . . . . . . . . 56

Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Backreaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Leaving Jobsite. . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Storing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 58

CMW

Operation Overview - 56 JT25 Operator’s Manual

Planning

1. Gather information about jobsite. See page 61.

2. Inspect jobsite. See page 62.

3. Classify jobsite. See page 64.

4. Plan bore path. See page 66.

5. Check supplies and prepare equipment. See page 72.

6. Load equipment. See page 80.

Setting Up at Jobsite

1. Prepare jobsite. See page 71.

2. Mix drilling fluid. See page 117.

3. Unload drilling unit from trailer. See page 82.

4. Assemble drill string. See page 73.

5. Position drilling unit and drill frame. See page 87.

6. Assemble strike system. See page 111.

7. Anchor drilling unit. See page 109.

8. Connect fluid system. See page 87.

9. Calibrate tracker with beacon that will be installed in beacon housing. See tracker operator’s manual.

CMW

JT25 Operator’s Manual Operation Overview - 57

Drilling

1. Start system. See page 88.

2. Engage tracker control if desired. See page 121.

3. Drill first pipe. See page 93.

4. Record bore path. See page 100.

5. Enable automated pipeloader system. See page 93.

6. Add pipe. See page 94.

7. Drill remaining pipes in pipe box.

• Correct direction. See page 96.

• Engage cruise control. See page 140.

8. Add additional drill pipe to empty box (see page 136) to complete bore.

9. Surface drill head. See page 100.

• Remove drill head.

CMW

Operation Overview - 58 JT25 Operator’s Manual

Backreaming

1. Assemble backream string. See page 102.

2. Start drilling unit and adjust throttle.

3. Set drilling fluid flow. Check that fluid flows through all nozzles.

4. Remove extra drill pipe from pipe box (see page 138) to complete backream.

5. Remove remaining pipe to complete backream.

6. Remove pullback device. See page 105.

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.

2. Remove anchors. See page 110.

3. Rinse unit and downhole tools. See page 158.

4. Disassemble strike system and disconnect from fluid system. See page 111.

5. Stow tools. See page 159.

6. Load unit onto trailer. See page 80.

Storing Equipment

1. For cold weather storage, antifreeze drilling unit. See page 156.

2. For long-term storage, disconnect battery disconnect switch.

CMW

JT25 Manual Prepare - 59

Prepare

Chapter Contents

Gather Information . . . . . . . . . . . . . . . . . . . . . . . . . 61

• Review Job Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

• Notify One-Call Services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

• Examine Pullback Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

• Arrange for Traffic Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

• Plan for Emergency Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Inspect Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

• Identify Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

• Select Start and End Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Classify Jobsite. . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

• Inspect Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

• Select a Classification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

• Apply Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Plan Bore Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

• Recommended Bend Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

• Entry Pitch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

• Minimum Setback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

• Minimum Depth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

• Bore Path Calculator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

CMW

Prepare - 60 JT25 Manual

Prepare Jobsite. . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

• Mark Bore Path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

• Prepare Entry Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Check Supplies and Prepare Equipment . . . . . . . 72

• Check Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

• Prepare Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

• Assemble Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

CMW

JT25 Manual Prepare - 61

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 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.

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

Prepare - 62 JT25 Manual

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 64.)

• traffic

• access

• soil type and condition

• water supply

• sources of locator and tracker 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 64.

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

To help avoid injury:

• 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

JT25 Manual Prepare - 63

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 69.

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

Prepare - 64 JT25 Manual

Classify Jobsite

Inspect Jobsite

• Follow U.S. Department of Labor regulations on excavating and trenching (Part 1926, Subpart P) and other similar regulations.

• 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 proposed 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 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.

crystalline silica (quartz) dust

CMW

JT25 Manual Prepare - 65

Classify Jobsite

Apply Precautions

Once classified, precautions appropriate for jobsite must be taken.

Electric Jobsite Precautions

se one or both of these methods.

• Expose line by careful hand digging or soft excavation. Use beacon to track bore path. If utility must be crossed, tracker operator must watch the during drilling and backreaming. The tracker operator must have communication with the drill operator or tracker control must be enabled with the tracker control key in the tracker operator’s possession.

• Have service shut down while work is in progress. Have electric company test lines before returning them to service.

Natural Gas Jobsite Precautions

Position equipment upwind from gas lines and use one or both of these methods.

• Expose lines by careful hand digging or soft excavation. Use beacon to track bore path. If utility must be crossed, tracker operator must watch the during drilling and backreaming. The tracker operator must have communication with the drill operator or tracker control must be enabled with the tracker control key in the tracker operator’s possession.

• Have gas shut off while work is in progress. Have gas company test lines before returning them to service.

Crystalline Silica (Quartz) Dust Precautions

Crystalline silica dust is a naturally occur i ng substance found in soil, sand, concrete, granite, and quartz. Breathing silica dust particles while cutting, drilling, or working materials may cause lung disease or cancer. To reduce exposure:

• Use water spray or other means to control dust.

• Refer to U.S. Department of Labor Occupational Safety and Health Administration guidelines to learn more about appropriate breathing protection and permissible exposure limits.

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

Prepare - 66 JT25 Manual

Plan Bore Path

Plan the bore path, from entry to end, before drilling begins. Ditch Witch bore planning software is available for planning your bore path. This special software can be run in the field using a laptop computer. See your Ditch Witch dealer for details.

If not using bore planning software, 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 bore planning software, see “Bore Path Calculator” on page 70 and use these measurements to help plan your bore.

CMW

JT25 Manual Prepare - 67

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.

Make sure pitch (A) changes no more than 6.5% 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 tracker remote display on the operator’s console.

Bend Radius

JT25 drill pipes have a tested minimum bend radius of 155’ (44.2 m). This means that a 90-degree bend in the bore path:

• has a radius (A) of 155’ (44.2 m)

• requires approximately 243’ (74 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

Prepare - 68 JT25 Manual

Plan Bore Path

Pipe-By-Pipe Bend Limits

Pipe

(C)

1 9’ 10” (3.0 m) 0’ 3.7” (0.1 m) 14 120’ 4.2” (36.7 m) 57’ 3.8” (17.5 m) 2 19’ 7.6” (6.0 m) 1’ 3” (0.4 m) 15 126’ 3.7” (38.5 m) 65’ 1.9” (19.9 m) 3 29’ 4.2” (8.9 m) 2’ 9.6” (0.9 m) 16 131’ 9” (40.2 m) 73’ 4.2” (22.4 m) 4 38’ 11.4” (11.9 m) 4’ 11.7” (1.5 m) 17 136’ 8” (41.7 m) 81’ 10.5” (25.0 m) 5 48’ 4.7” (14.7 m) 7’ 9” (2.3 m) 18 141’ 0.4” (43.0 m) 90’ 8.3” (27.6 m) 6 57’ 7.6” (17.6 m) 11’ 1.4” (3.4 m) 19 144’ 9.9” (44.1 m) 99’ 9.3” (30.4 m) 7 66’ 7.8” (20.3 m) 15’ 0.7” (4.6 m) 20 148’ 0.5” (45.1 m) 109’ 0.9” (33.2 m) 8 75’ 4.8” (23.0 m) 19’ 6.9” (6.0 m) 21 150’ 7.9” (45.9 m) 118’ 6.8” (36.1 m) 9 83’ 10.1” (25.6 m) 24’ 7.6” (7.5 m) 22 152’ 8” (46.5 m) 128’ 2.4” (39.1 m) 10 91’ 11.3” (28.0 m) 30’ 2.6” (9.2 m) 23 154’ 0.7” (47 m) 137’ 11.3” (42.0 m) 11 99’ 8.1” (30.4 m) 36’ 3.6” (11.1 m) 24 154’ 10” (47.2 m) 147’ 9” (45.0 m) 12 107’ 0.1” (32.6 m) 42’ 10.4” (13.1 m) 25 155’ (47.2 m) 155’ (47.2 m) 13 113’ 10.9” (34.7 m) 49’ 10.6” (15.2 m)

Forward (B) Deflection (A) Pipe

(C)

Forward (B) Deflection (A)

j22om001t.eps

15.2m 49ft. 10.6in.

47.2m 155ft.

Pipe 13 is illustrated.

47.2m 155ft.

34.7m 113ft. 10.9in.

CMW

JT25 Manual Prepare - 69

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 minimum setback 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

Prepare - 70 JT25 Manual

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)

4 ft 0 in (1.3 m) 18% / 10.2° 36 ft 0 in (11.0 m) 1 ft 6 in (0.46 m) 4 ft 9 in (1.5 m) 20% / 11.3° 38 ft 11 in (11.9 m) 1 ft 8 in (0.51 m) 5 ft 6 in (1.8 m) 22% / 12.4° 41 ft 9 in (12.7 m) 1 ft 10 in (0.56 m) 6 ft 4 in (2.1 m) 24% / 13.5° 44 ft 7 in (13.6 m) 2 ft 0 in (0.61 m) 7 ft 2 in (2.4 m) 26% / 14.6° 47 ft 5 in (14.5 m) 2 ft 2 in (0.66 m) 8 ft 1 in (2.7 m) 28% / 15.6° 50 ft 2 in (15.3 m) 2 ft 4 in (0.71 m) 9 ft 0 in (3.0 m) 30% / 16.7° 52 ft 10 in (16.1 m) 2 ft 6 in (0.76 m)

IMPORTANT: Numbers in table based on 155’ (47.2 m) minimum bend radius, beacon housing, EZ- Connect, connector, transition sub, and 1/3 of first drill pipe (L, totaling 8’ 8” [2.6 m]) in the ground before steering.

CMW

JT25 Manual Prepare - 71

Prepare Jobsite

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

To help avoid injury:

• Classify jobsite as electric if jobsite classification is in question or if the possibility of unmarked electric utilities exists.

• Expose lines by hand before digging. Cutting high voltage cable can cause electrocution.

• Remove all vegetation near operator’s station. 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. “Align the Joints” on page 132.

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. Steer down as required at start. Drill head will tend to move in easiest direction (toward surface) when rotated near the surface.

To prevent bending or straining pipe, position drilling unit for straight entry.

CMW

Prepare - 72 JT25 Manual

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 129)

• transition sub

• anchoring equipment and accessories

• bits, screens, nozzles (see page 124)

• adapters, pipe, beacon housings

• marking flags or paint

• water and additional hoses

• fuel

• drilling fluid additives (see page 120)

• spare fuses

• keys

• backreamers, swivels, pulling devices (see page 126)

• wash down hose and spray gun

• duct tape

• spray lubricant

• tool joint compound (see page 165)

• electrically insulating boots and gloves

• personal protective equipment, such as hard hat and safety glasses

• notepad and pencil

CMW

JT25 Manual Prepare - 73

Check Supplies and Prepare Equipment

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.

CMW

Prepare - 74 JT25 Manual

CMW

JT25 Operator’s Manual Drive - 75

Drive

Chapter Contents

Start Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Steer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Shut Down Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

CMW

Drive - 76 JT25 Operator’s Manual

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 move to left or right. Drilling unit

will turn to left or right.

To steer while moving backward, pull back and move to left or right. Drilling unit will turn to left or right.

For tight steering in low speed, move control to left or right limit, then forward or backward as needed. Tracks will counter-rotate and turn drilling unit in a tight circle.

c00ic145h.eps

CMW

JT25 Operator’s Manual Drive - 77

Shut Down Unit

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 169.)

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 track edges pressed against hard walls, curbs or other objects.

• Driving on slopes.

• Operating on corrosive materials such as salt or fertilizer. Wash immediately.

Shut Down Unit

1. Stop track movement.

2. Lower drill frame and stabilizers to the ground.

3. Run engine at low throttle for 3 minutes to cool.

4. Turn ignition switch to STOP.

5. Remove key.

CMW

Drive - 78 JT25 Operator’s Manual

Shut Down Unit

CMW

JT25 Operator’s Manual Transport - 79

Transport

Chapter Contents

Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

• Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

• Unload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Tow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

CMW

Transport - 80 JT25 Operator’s Manual

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.

Pipe Box Lifting Procedure

Pipe Box lifting points are identified by lifting decals. Lifting at other points is unsafe and can damage machinery.

See “Remove/Install Pipe Box” on page 134.

Load

Crushing weight. If load falls or moves it could kill or crush you. Use

proper procedures and equipment or stay away.

To help avoid injury:

• Attach trailer to tow vehicle before loading or unloading.

• Load and unload trailer on level ground.

• Block trailer wheels.

• Prevent trailer sway by loading ten to fifteen percent of total vehicle weight (equipment plus trailer) on tongue.

1. Start drilling unit engine.

2. Using tethered ground drive controller, pull drive mode switch into low position. See page 25.

3. Move drilling unit to rear of trailer and align with ramps.

4. Slowly drive unit onto trailer.

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 81.

9. Ensure that all covers are properly secured.

CMW

JT25 Operator’s Manual Transport - 81

Load

Tie Down

Points

Tiedown points are identified by tiedown decals. Securing to trailer at other points can damage machinery.

Procedure

NOTICE:

• Wrenches can open after engine shutdown. Ensure that any downhole tool or pipe in wrenches is attached to spindle or removed before transport.

• Use Grade 7-3/8” (18.7 cm) transport chain to secure drilling unit.

Loop a transport chain around each tie down point. See chart below for correct distances between tiedown ends. Make sure tiedowns are tight before transporting.

Distance U.S. Metric

A 12-45” 31-114 cm B 12-45” 31-114 cm C less than 55” less than 140 cm

CMW

Transport - 82 JT25 Operator’s Manual

Tow

Unload

Crushing weight. If load falls or moves it could kill or crush you. Use

proper procedures and equipment or stay away.

To help avoid injury:

• Attach trailer to vehicle before loading or unloading.

• Load and unload trailer on level ground.

• Ensure trailer wheels are blocked.

1. Lower ramps.

2. Remove tiedowns.

3. Start drilling unit engine.

4. Using tethered ground drive controller, pull power mode switch into low position. See page 25.

5. Raise stabilizers.

6. Raise drill frame.

7. Slowly back unit down trailer or ramps.

Tow

Under normal conditions, drilling unit should not be towed. If towing is necessary:

• tow for short distances at less than 1 mph (1.6 km/h),

• attach chains to indicated tow points facing towing vehicle (shown),

• use maximum towing force of 1.5 times unit weight,

• disengage track planetaries.

If front tow points are facing towing vehicle, loop chain (1) through tow point and pull straight forward. If back tow points are facing towing vehicle, loop chain (2) through each tow point and bring them together to a central pull point.

CMW

JT25 Operator’s Manual Transport - 83

Tow

To disengage track planetaries, reverse small cover plate in center of planetary on each track drive.

IMPORTANT: When planetaries are disengaged, unit has no brakes.

A. Normal operation B. Towing

CMW

Transport - 84 JT25 Operator’s Manual

Tow

CMW

JT25 Operator’s Manual Conduct a Bore - 85

Conduct a Bore

Chapter Contents

Position Equipment . . . . . . . . . . . . . . . . . . . . . . . . 87

Connect Fluid System . . . . . . . . . . . . . . . . . . . . . . 87

Start System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Prime Drilling Fluid Pump . . . . . . . . . . . . . . . . . . . 88

Operate Carriage Control . . . . . . . . . . . . . . . . . . . 89

Clamp Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Assemble Drill String . . . . . . . . . . . . . . . . . . . . . . . 91

• Prepare Beacon Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

• Attach Transition Sub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

• Attach Beacon Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

• Connect Drill Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Drill First Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Enable Automated Pipeloader System . . . . . . . . 93

Add Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Correct Direction . . . . . . . . . . . . . . . . . . . . . . . . . . 96

• Basic Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

• Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

• Drill Head Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

CMW

Conduct a Bore - 86 JT25 Operator’s Manual

Use Carve Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Record Bore Path . . . . . . . . . . . . . . . . . . . . . . . . . 100

Surface Drill Head . . . . . . . . . . . . . . . . . . . . . . . . 100

Backream. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Remove Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Remove Pullback Device . . . . . . . . . . . . . . . . . . . 105

CMW

JT25 Operator’s Manual Conduct a Bore - 87

Position Equipment

1. Review bore plan and select drilling unit position and fluid unit position. See “Select Start and End Points” on page 63.

2. Move equipment into selected positions.

Connect Fluid System

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

Know location of lines and stay away.

To help avoid injury: Do not connect drilling unit to a public or private (business or home) water supply. If an electrical strike occurs while drilling unit is connected to a fluid system, the fluid system will also become electrified.

1. Connect fluid hose from mixing system to drilling fluid pump. A 2.0” (50.8 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 174.

CMW

Conduct a Bore - 88 JT25 Operator’s Manual

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 117.

2. Enable tracker control mode if desired. See “Tracker Control” on page 121.

3. Press top of drilling unit throttle switch. Engine will increase to full throttle. If you do not want to use autothrottle mode, return switch to center position.

Prime Drilling Fluid Pump

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

Learn to use equipment correctly. 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.

CMW

JT25 Operator’s Manual Conduct a Bore - 89

Operate Carriage Control

Drilling

During normal drilling operation, the thrust/rotation joystick controls both operations and allows any combination of the two based on the position of the joystick:

• Push joystick toward 1A for forward thrust with clockwise rotation.

NOTICE: Counterclockwise rotation can unthread pipe in the ground.

• Push joystick toward 2A for forward thrust with counterclockwise rotation.

• Pull joystick toward 2B for reverse thrust, with counterclockwise rotation.

• Pull joystick toward 1B reverse thrust, with clockwise rotation.

Coordinated Make-up

During pipe change operations when front wrench is closed and carriage is on front or rear home, the thrust/rotation joystick only controls the speed and direction of rotation. The machine controller manages thrust and matches the speed and direction of rotation to smoothly thread or unthread pipe sections.

Push joystick toward 1A for clockwise rotation (machine controlled makeup). Push joystick toward 2B for counterclockwise rotation (machine controlled

breakout).

IMPORTANT:

• If the thrust/rotation joystick is moved straight forward or backward so there is no rotation, thrust is controlled by the operator.

• While rotating the operator can adjust thrust speed slightly with joystick.

CMW

Conduct a Bore - 90 JT25 Operator’s Manual

Clamp Pipe

Turning shaft can kill you or crush arm or leg. Stay away.

To help avoid injury: Only clamp pipe at reinforced end. 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 between wrenches (1 and 2). Always clamp on the larger diameter areas on either side of the tool joint face.

NOTICE: Clamping pipes on top of female end threads can damage threads. Only clamp female pipe ends behind the threads.

CMW

JT25 Operator’s Manual Conduct a Bore - 91

Assemble Drill String

1. bit

2. beacon housing

3. adapter

4. collar

5. transition sub

6. JT25 drill pipe

Prepare Beacon Housing

1. Select nozzles and bit.

IMPORTANT: A variety of nozzles and bits are available to suit your particular job conditions. See page 146 for more information, or contact your Ditch Witch dealer.

2. Insert nozzle into beacon housing.

3. Attach bit to beacon housing.

4. Install beacon, following beacon instructions for:

• battery replacement

• beacon positioning.

5. Install beacon housing lid.

6. Follow beacon instructions to check beacon operation.

7. Follow tracker instructions to calibrate beacon.

Attach Transition Sub

1. Remove blocks from pipe guides.

2. Pull transition sub into front wrench.

3. Close wrench.

4. Lube joints.

5. Use machine torque to tighten joint fully.

CMW

Conduct a Bore - 92 JT25 Operator’s Manual

Assemble Drill String

Attach Beacon Housing

Use machine torque to attach beacon housing.

1. Pull beacon housing into front wrench.

2. Close wrench.

3. Use machine torque to tighten joint fully.

Connect Drill Pipe

1. Start drilling unit engine.

2. Align drill pipe in front wrench.

3. Clamp tool joint in front wrench. See “Clamp Pipe” on page 90.

4. Disconnect from pipe:

• Rotate spindle counterclockwise until threads on pipe segments are disengaged from each other. Carriage will move backward as pipe rotates counterclockwise.

• Stop rotation and move carriage backward until it stops on the rear stop switch.

5. Load pipe:

• Make sure pipe box is positioned correctly.

• Open grippers or make sure they are open.

• Grippers open as pipe is lowered.

• Close grippers around pipe.

• Lubricate pipe threads at front wrench.

• Move pipe to spindle.

• Raise pipe lifters.

6. Connect pipe:

• Move carriage forward until spindle meets back end of pipe joint. Rotate spindle clockwise until pipe begins to spin. Relax grippers slightly.

• 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.

CMW

JT25 Operator’s Manual Conduct a Bore - 93

Drill First Pipe

Turning shaft can kill you or crush arm or leg. Stay away.

To help avoid injury:

• Keep everyone at least 10’ (3 m) away from turning drill string.

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

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

1. Turn on drilling fluid.

2. Visually check for drilling fluid flow.

3. Turn drill bit to starting position.

4. Slowly move carriage forward. Drill first pipe as straight as possible.

5. Monitor gauges.

Enable Automated Pipeloader System

Add Pipe Remove Pipe

1. Open front wrench and retract shuttles for add pipe function to work.

2. Press top of add pipe/manual/remove pipe switch. Green control cycle light will come on.

3. Grippers will open, pipe will be lowered, and then green control cycle light will flash.

IMPORTANT: If you leave the seat during an add or remove pipe cycle, turn automated pipeloader system off (switch to manual control) and then back to add pipe or remove pipe. If you leave the seat between add or remove pipe cycles, re-enabling system is not needed.

1. Open front wrench and retract shuttles for remove pipe function to work.

2. Press bottom of add pipe/manual/remove pipe switch. Green control cycle light will come on.

3. Grippers will open, pipe will be lowered and lifted off shuttles, and then green control cycle light will flash.

CMW

Conduct a Bore - 94 JT25 Operator’s Manual

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 93.

3. Break joint at SaverLok.

Manual Pipeloader Controls Automated Pipeloader Control

• Clamp pipe joint. See “Clamp Pipe” on page 90.

• Locate drill head.

• Engage front wrench until pipe is clamped and pressure develops.

• Slowly move carriage back until movement stops.

• Slowly rotate spindle counterclockwise. Carriage will move back as threads separate.

• After threads are fully separated, stop rotation and move carriage to back of frame.

4. Load pipe.

Manual Pipeloader Controls Automated Pipeloader Control

• Clamp pipe joint. See “Clamp Pipe” on page 90.

• Locate drill head.

• Engage front wrench until pipe is clamped and pressure develops.

• Slowly move carriage back until movement stops.

• Slowly rotate spindle counterclockwise. Carriage will move back as threads separate.

• After threads are fully separated, stop rotation and move carriage to back of frame.

• 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.

• Make sure shuttle stop is properly positioned on pipeloader and lift arms are completely lowered.

• Close grippers.

• Lube upper pipe threads.

• Move pipe to spindle and lube lower threads.

• Raise pipe in box.

CMW

• Make sure shuttle stop is properly positioned on pipeloader.

• When carriage is moved to back of drill frame, press RESUME. Green control cycle light will come on.

• Pipe will be moved to spindle, front threads will be lubed, pipe in box will be lifted, and then green control cycle light will flash.

JT25 Operator’s Manual Conduct a Bore - 95

Add Pipe

5. Connect pipe to SaverLok.

Manual Pipeloader Controls Automated Pipeloader Control IMPORTANT: Always rotate clockwise unless

breaking pipe joint. Rotating counterclockwise will separate joints.

• Move carriage forward until SaverLok meets pipe.

• Continue to slowly advance carriage and rotate spindle until pipe threads tighten.

• Relax grippers.

6. Connect new pipe.

Manual Pipeloader Controls Automated Pipeloader Control

• Slowly move carriage forward and rotate spindle until pipe threads tighten.

• To fully torque joint, slowly rotate pipe until spindle stops turning.

• Open wrench.

IMPORTANT: Always rotate clockwise unless breaking pipe joint. Rotating counterclockwise will separate joints.

• Move carriage forward until SaverLok meets pipe.

• Continue to slowly advance carriage and rotate spindle until pipe threads tighten.

• Press RESUME. Green control cycle light will come on.

• Grippers will relax and then green control cycle light will flash.

• Slowly move carriage forward and rotate spindle until pipe threads tighten.

• To fully torque joint, slowly rotate pipe until spindle stops turning.

• Open wrench.

• Open grippers fully.

• Retract shuttles against shuttle stop.

• Lower pipe lifters.

7. Press and hold quick fill fluid pump switch until pipe fills and fluid pressure begins to rise.

8. Rotate spindle.

9. Slowly move carriage forward. Adjust rotation speed control according to bit size and soil conditions.

10. Engage and set cruise control as desired. See “Cruise Control” on page 140.

11. Monitor gauges.

12. Locate drill head with tracker at least every half-length of pipe.

• Press RESUME. Green control cycle light will come on.

• Grippers will open, shuttles will retract, pipe lifters will lower, and then green control cycle light will flash.

CMW

Conduct a Bore - 96 JT25 Operator’s Manual

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 tracks 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

General

• 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 67.

• 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.

CMW

JT25 Operator’s Manual Conduct a Bore - 97

Correct Direction

Procedure

1. Locate drill head. Take readings available with your beacon and tracking 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. Drill in pipe.

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 tracker 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:

1. Rotate pipe.

2. Push pipe into ground.

CMW

Conduct a Bore - 98 JT25 Operator’s Manual

Use AutoCarve

AutoCarve helps the operator change direction when thrust stalls in difficult soil conditions. AutoCarve rotates the bit clockwise and counterclockwise to grind away soil, clearing a path to improve steering through tough formations.

Movement Description

alternating clockwise and counterclockwise rotation

carve window The range of alternating rotation. thrust In autocarve mode, initial thrust speed is very slow or fully stopped. Adjust

pullback Thrust and rotation operate normally when joystick is pulled rearward.

Enables the downhole tool to carve tough soil formations. Rotation speed can be adjusted during autocarving.

NOTICE: To reduce the chance of unthreading pipe sections downhole, rotation pressure is limited during counterclockwise rotation; however, the operator should monitor carve operation and adjust thrust and rotation to prevent unthreading.

speed anytime during carving.

High-speed pullback is not available in autocarve mode.

CMW

JT25 Operator’s Manual Conduct a Bore - 99

Use AutoCarve

Operation

IMPORTANT:

• 2-speed thrust is not allowed in AutoCarve mode.

• AutoCarve mode is disabled while front wrench is closed.

• Adding or removing pipe does not affect AutoCarve position.

1. Position downhole tool for carving. Rotate the toolhead to the desired position.

2. Turn on AutoCarve mode. Press top of AutoCarve switch.

3. Begin carving. Push joystick fully forward then release to neutral to start alternating rotation. Adjust thrust and rotation speed as needed during carving.

4. Adjust thrust speed. Press and hold the Resume switch until carriage begins to move forward, then release switch. Press Resume repeatedly to increase thrust speed to desired setting. To reduce thrust speed, press Set switch.

5. Set carve window. Use the Carve Window Potentiometer to set the desired range of travel. Adjust as needed while carving.

6. Adjust rotation speed. Move joystick fully left of neutral. Press the Set/Resume switch to decrease/ increase rotation speed. Adjust as needed while carving.

IMPORTANT: For finer adjustment, press the multi-use button while adjusting thrust or rotation. Be aware, however, this also activates the reaming function and will change steering direction unless the tool is stopped at the original position before releasing multi-use button.

7. Pause carving. Pull joystick away from neutral.

8. Resume carving. Push joystick fully forward then release to neutral to start alternating rotation.

9. Ream a newly carved section. After carving a few inches, press and hold the 2-Speed button and move the joystick fully left for maximum rotation. When tool rotates freely, reduce rotation speed and stop at desired carve position. Release 2-Speed button and resume carving.

IMPORTANT: If full rotation seems restricted and insufficient to ream the hole, move carriage back slightly until full rotation is possible, then move carriage forward while rotating.

10. Exit carve mode. Press bottom of AutoCarve switch. Carriage movement and rotation will stop. Continue normal drilling.

Note: For quicker setup during a long bore, autocarve thrust and rotation settings are retained until the unit is shut down.

CMW

Ditch Witch JT25 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Overview

Serial Number Location

Intended Use

Equipment Modification

Unit Components

Operator Orientation

About This Manual

Bulleted Lists

Numbered Lists

Foreword

Contents

Safety

Guidelines

Safety Alert Classifications

Safety Alerts

Emergency Procedures

Electric Strike Description

If an Electric Line is Damaged

If a Gas Line is Damaged

If a Fiber Optic Cable is Damaged

If Machine Catches on Fire

Controls

Set-Up Console

Tethered Ground Drive Controller

Left Control Console

Engine Display

Controls

Right Control Console

Lights

Controls

Anchoring System Console

Seat

Cab Controls (optional)

Top/Rear

Front

Engine Compartment Controls

Miscellaneous Controls

ESID

Operation Overview

Planning

Setting Up at Jobsite

Drilling

Backreaming

Backreaming Tips

Leaving Jobsite

Storing Equipment

Prepare

Gather Information

Review Job Plan

Notify One-Call Services

Examine Pullback Material

Arrange for Traffic Control

Plan for Emergency Services

Inspect Site

Identify Hazards

Select Start and End Points

Classify Jobsite

Inspect Jobsite

Select a Classification

Apply Precautions

Plan Bore Path

Recommended Bend Limits

Entry Pitch

Minimum Setback

Minimum Depth

Bore Path Calculator

Prepare Jobsite

Mark Bore Path

Prepare Entry Point

Check Supplies and Prepare Equipment

Check Supplies

Prepare Equipment

Assemble Accessories

Drive

Start Unit

Steer Unit