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Ditch Witch
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JT30AT
User Manual
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Ditch Witch JT30AT User Manual

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JT30/JT30 All Terrain
Tier 3 and Tier 4i
Operator’s Manual
CMW
®
Issue 1.0
Original Instruction
053-2544

Overview

Chapter Contents
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . 3
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Equipment Modification . . . . . . . . . . . . . . . . . . . . . . 4
Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operator Orientation. . . . . . . . . . . . . . . . . . . . . . . . . 6
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 6
• Bulleted Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
• Numbered Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
• “Continued” Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Overview - 3 JT30 /JT30 All Terrain Operator’s Manual

Serial Number Location

Serial Number Location
Record serial numbers and date of purchase in spaces provided. Drilling unit serial number is located as shown.
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Item
date of manufacture date of purchase drilling unit serial number engine serial number

Intended Use

Intended Use
The JT30 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. Its All Terrain version is designed to drill through rock, cobblestone, broken rock, gravel, and caliche.
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 JT30/JT30 All Terrain 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 - 5 JT30 /JT30 All Terrain Operator’s Manual

Unit Components

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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Operator Orientation

Operator Orientation
IMPORTANT: Top view of unit is shown.
1. Front of unit
2. Right side of unit
3. Rear of unit
4. Left side of unit

About This Manual

This manual contains information for the proper use of this machine. See the beige Operation Overview pages for basic operating procedures. Cross references such as “See page 50” will direct you to detailed procedures.

Bulleted Lists

Bulleted lists provide helpful or important information or contain procedures that do not have to be performed in a specific order.

Numbered Lists

Numbered lists contain illustration callouts or list steps that must be performed in order.
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Overview - 7 JT30 /JT30 All Terrain Operator’s Manual
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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 - 9 JT30 /JT30 All Terrain Operator’s Manual
JT30/JT30 All Terrain
Tier 3 and Tier 4i
Operator’s Manual
Issue number 1.0/OM-07/12
Part number 053-2544
Copyright 2012
by The Charles Machine Works, Inc.
, Ditch Witch, CMW, Jet Trac, Subsite, 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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Contents

Overview
machine serial number, information about the type of work this machine is designed to perform, basic machine components, and how to use this manual
Foreword
part number, revision level, and publication date of this manual, and factory contact 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
2
8
12
22
64
68
88
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
92
100
128
190
196
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Contents - 11 JT30 /JT30 All Terrain Operator’s Manual
Specifications
machine specifications including weights, measurements, power ratings, and fluid capacities
Support
the warranty policy for this machine, and procedures for obtaining warranty consideration and training
Service Record
a record of major service performed on the machine
234
240
244
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Safety

Chapter Contents
Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety Alert Classifications . . . . . . . . . . . . . . . . . . 14
Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Emergency Procedures . . . . . . . . . . . . . . . . . . . . . 18
• Electric Strike Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
• If an Electric Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
• If a Gas Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
• If a Fiber Optic Cable is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
• If Machine Catches on Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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Safety - 13 JT30/JT30 All Terrain Operator’s Manual

Guidelines

Guidelines
Follow these guidelines before operating any jobsite equipment:
• Complete proper training and read operator’s manual before using equipment.
• Contact your local One-Call (811 in USA) or the One-Call referral number (888-258-0808 in USA and Canada) to have underground utilities located before digging. Also contact any utilities that do not participate in the One-Call service.
• Classify jobsite based on its hazards and use correct tools and machinery, safety equipment, and work methods for jobsite.
• Mark jobsite clearly and keep spectators away.
• Wear personal protective equipment.
• Review jobsite hazards, safety and emergency procedures, and individual responsibilities with all personnel before work begins. Safety videos are available from your Ditch Witch dealer.
• Replace missing or damaged safety shields and safety signs.
• Use equipment carefully. Stop operation and investigate anything that does not look or feel right.
• Do not operate unit where flammable gas may be present.
• Contact your Ditch Witch dealer if you have any question about operation, maintenance, or equipment use.
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Safety Alert Classifications

Safety Alert Classifications
These classifications and the icons defined on the following pages work together to alert you to situations which could be harmful to you, jobsite bystanders or your equipment. When you see these words and icons in the book or on the machine, carefully read and follow all instructions. YOUR SAFETY IS AT STAKE.
Watch for the three safety alert levels: DANGER, WARNING and CAUTION. Learn what each level means.
indicates 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 - 15 JT30/JT30 All Terrain Operator’s Manual

Safety Alerts

Safety Alerts
Turning shaft will kill you or crush arm or leg. Stay away.
Electric shock. Contacting electric lines will cause death or serious injury.
Know location of lines and stay away.
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.
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.
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 - 17 JT30/JT30 All Terrain 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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Emergency Procedures

Emergency Procedures
Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment.
Before operating any equipment, review emergency procedures and check that all safety precautions have been taken.
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 - 19 JT30/JT30 All Terrain Operator’s Manual
Emergency Procedures

If an Electric Line is Damaged

If you suspect an electric line has been damaged and you are on drilling unit or bonded equipment, DO NOT MOVE. Remain on drilling machine and take the following actions. The order and degree of action will depend on the situation.
• Warn people nearby that an electric strike has occurred.
• Have someone contact electric company.
• Reverse drilling direction and try to break contact. Do not touch drill pipe with hands or hand-held tools.
• Press electric strike system status button.
• If alarm sounds again, stay where you are and wait for electric company to shut off power.
• If alarm does not sound and there is no other indication of a strike, wait at least one full minute
before moving away from equipment. Utility might use automatic reclosers which will restart current flow. If alarm sounds again while waiting, stay where you are until electric company shuts off power.
• If alarm does not sound but all lights in strike indicator are on, assume strike is continuing and stay
where you are until electric company shuts off power.
• Do not resume drilling or allow anyone into area until given permission by electric company.
If you suspect an electric line has been damaged and you are off drilling unit or bonded equipment, DO NOT TOUCH ANY EQUIPMENT connected to drilling unit. Take the following actions. The order and degree of action will depend on the situation.
• Stay where you are unless you are wearing electric insulating boots. If you leave, do not return to area or allow anyone into area until given permission by electric company.
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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 - 21 JT30/JT30 All Terrain Operator’s Manual
Emergency Procedures

If a Fiber Optic Cable is Damaged

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

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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Controls

Chapter Contents
Set-Up Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Tethered Ground Drive Controller . . . . . . . . . . . . 27
Left Control Console . . . . . . . . . . . . . . . . . . . . . . . 29
• Engine Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
• Pipeloading controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
• Drilling/Operation controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Right Control Console . . . . . . . . . . . . . . . . . . . . . . 40
• Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
• Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
• Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Information Center . . . . . . . . . . . . . . . . . . . . . . . . . 49
• Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
• Soft keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Anchoring System Console. . . . . . . . . . . . . . . . . . 53
Seat/Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Cab Controls (Optional) . . . . . . . . . . . . . . . . . . . . . 57
Engine Compartment Controls . . . . . . . . . . . . . . . 60
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Controls - 23 JT30 /JT30 All Terrain Operator’s Manual

Set-Up Console

Set-Up Console
1. Tracker control key
2. Cold start wait indicator
3. Ignition switch
4. Left track switch
5. Right track switch
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6. Engine shutdown override switch
7. Right stabilizer control
8. Left stabilizer control
9. Back frame tilt control
10. Front frame tilt control
Set-Up Console
Item Description Notes
1. 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).
2. Cold start wait indicator Lights when intake air pre­heater is operating.
Wait until light goes off before starting engine.
3. Ignition switch To start engine, insert key and turn clockwise.
To stop engine, turn key counterclockwise.
IMPORTANT: Remove key and keep in tracker operator’s possession.
IMPORTANT:
• Restart engine with ignition switch after it has been turned off with tethered control remote engine stop switch.
4. Left track switch To move forward, press top. To move backward, press
bottom.
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• 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 - 25 JT30 /JT30 All Terrain Operator’s Manual
Set-Up Console
Item Description Notes
5. Right track switch To move forward, press top.
To move backward, press bottom.
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6. Engine shutdown override switch
If engine shutdown indicator comes on, turn ignition switch to STOP and press to delay engine shutdown for 30 seconds.
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7. Left stabilizer control To raise, pull up.
To lower, push down.
IMPORTANT: Use track switches only if tethered control is inoperable.
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 169 for more information on Tier 3 engines.
IMPORTANT: Lower left and right stabilizers to the ground together, then adjust individually.
8. Right stabilizer control To raise, pull up.
To lower, push down.
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.
WARNING: Crushing weight could cause death or serious injury. Use proper procedures and equipment or stay away.
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Set-Up Console
Item Description Notes
9. Back frame tilt control To raise, pull up.
To lower, push down.
10. Front frame tilt control To raise, pull up.
To lower, push down.
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.
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.
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Controls - 27 JT30 /JT30 All Terrain Operator’s Manual

Tethered Ground Drive Controller

Tethered Ground Drive Controller
1
5
2
4
3
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 89 for
be pressed and operator seat must be empty for control to work.
more information.
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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
5. Throttle switch To increase engine speed,
To operate ground drive with tethered controller, press.
To disable controller, release.
press top. To decrease engine speed,
bottom.
IMPORTANT: To restart engine, turn ignition switch off and then back on.
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Controls - 29 JT30 /JT30 All Terrain Operator’s Manual

Left Control Console

Left Control Console

Indicators

2
j34om011w.eps
1
7
6
5
34
1. USB port
2. Engine display
3. Hydraulic fluid temperature indicator
4. Hydraulic filter service indicator
Item Description Notes
1. USB port Provides power for mobile
devices.
2. Engine display Communicates status of
engine operation.
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5. Diagnostic port
6. Auxiliary outlet
7. Horn
DC5V, 1A (5W)
See “Engine Display” on page 31.
Left Control Console
Item Description Notes
3. Hydraulic fluid temperature indicator
4. Hydraulic filter service indicator
5. Diagnostic port For use by only by qualified Ditch Witch technicians.
6. Auxiliary outlet Provides power for other
Indicates hydraulic fluid is overheating.
Indicates hydraulic fluid filter needs replacing.
equipment.
Check hydraulic fluid level.
Change filter when indicator lights continuously and as indicated on page 218.
Power output is 12VDC, 5A.
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7. Horn Provides audible alarm for
strike system and tracker control.
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