Ditch Witch JT5 User Manual

JT5

Operator’s Manual

CMW

Issue 1.0

Original Instruction

053-2380

JT5 Operator’s Manual Overview - 1

Overview

Chapter Contents

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

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

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

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

Operator Orientation. . . . . . . . . . . . . . . . . . . . . . . . . 5

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

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

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

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

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Overview - 2 JT5 Operator’s Manual

Serial Number Location

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

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Item

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

JT5 Operator’s Manual Overview - 3

Intended Use

The JT5 is a self-contained horizontal directional drilling unit designed to install buried cable and pipe at distances to 150’ (45.7 m) depending on soil conditions and is intended for operation in ambient temperatures from 0° to 115°F (-18° to 46°C). Use in any other way is considered contrary to the intended use.

The JT5 can be used with Ditch Witch drilling fluid units and Ditch Witch locating equipment. It should be operated, serviced, and repaired only by persons familiar with its particular characteristics and acquainted with the relevant safety procedures.

Equipment Modification

This equipment was designed and built in accordance with applicable standards and regulations. Modification of equipment could mean that it will no longer meet regulations and may not function properly or in accordance with the operating instructions. Modification of equipment should only be made by competent personnel possessing knowledge of applicable standards, regulations, equipment design functionality/requirements and any required specialized testing.

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Overview - 4 JT5 Operator’s Manual

Unit Components

1. Anchoring system

2. Operator’s station

3. Carriage

4. Stabilizer

5. Tracks

6. Spindle

7. Drill frame

8. Wrench

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JT5 Operator’s Manual Overview - 5

Operator Orientation

IMPORTANT: Top view of unit is shown.

1. Front of unit

2. Right side of unit

3. Rear of unit

4. Left side of unit

About This Manual

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

Bulleted Lists

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

Numbered Lists

Numbered lists contain illustration callouts or list steps that must be performed in order.

“Continued” Indicators

indicates that a procedure is continued on the next page.

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Overview - 6 JT5 Operator’s Manual

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JT5 Operator’s Manual Foreword - 7

Foreword

This manual is an important part of your equipment. It provides safety information and operation instructions to help you use and maintain your Ditch Witch equipment.

Read this manual before using your equipment. Keep it with the equipment at all times for future reference. If you sell your equipment, be sure to give this manual to the new owner.

If you need a replacement copy, contact your Ditch Witch dealer. If you need assistance in locating a dealer, visit our website at www.ditchwitch.com or write to the following address:

The Charles Machine Works, Inc. Attn: Marketing Department PO Box 66 Perry, OK 73077-0066 USA

The descriptions and specifications in this manual are subject to change without notice. The Charles Machine Works, Inc. reserves the right to improve equipment. Some product improvements may have taken place after this manual was published. For the latest information on Ditch Witch equipment, see your Ditch Witch dealer.

Thank you for buying and using Ditch Witch equipment.

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Foreword - 8 JT5 Operator’s Manual

JT5

Operator’s Manual

Issue number 1.0/OM- 4/11

Part number 053-2380

by The Charles Machine Works, Inc.

, Ditch Witch, CMW, AutoCrowd, Jet Trac, Roto Witch, Subsite, Fluid Miser, Power Pipe, Super Witch, Pierce Airrow, The Underground, The Underground Authority Worldwide, and Zahn are registered trademarks of The Charles Machine Works, Inc.

This product is covered by one or more of the following patents: U.S. B1 4,858,704; 4,953,638; 5,148,880; 5,242,026; 5,341,887; 5,490,569; 5,684,466; 5,713,423; 5,794,719; 5,880,680; 5,941,322; 6,085,852; 6,109,371; 6,179,065; 6,216,803; 6,250,403; 6,250,404; 6,290,606; 6,311,790; 6,411,094; 6,543,551; 6,550,547; 6,672,409; 6,739,413; 6,761,231; 6,776,246; 6,808,210; 6,827,158; 6,848,506; 6,871,712; RE37,450; RE37,923; RE37,975; RE38,418; AU 689,533; 706,544; 718,034; 755,862; CA 2,156,398; 2,217,899; DE 694 17 019; 695 29 634; 297 01 406; EP 0683845; 0674093; 0817901; 0846841; 0927892; FR 674,093; GB 2,309,239; 2,312,006; EP674,093; EP846,841; JP 3,458,247; other U.S. and foreign patents pending.

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JT520 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, and fluid systems

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

121

127

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Contents - 10 JT520 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

151

155

159

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JT2720 Mach 1/All Terrain Operator’s Manual Safety - 11

Safety

Chapter Contents

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

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

Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Emergency Procedures . . . . . . . . . . . . . . . . . . . . . 17

• Electric Strike Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

• If an Electric Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

• If a Gas Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

• If a Fiber Optic Cable is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

• If Machine Catches on Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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Safety - 12 JT2720 Mach 1/All Terrain Operator’s Manual

Guidelines

Follow these guidelines before operating any jobsite equipment:

• Complete proper training and read operator’s manual before using equipment.

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

Canada) to have underground utilities located before digging. Also contact any utilities that do not participate in the One-Call service.

• 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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JT2720 Mach 1/All Terrain 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 an imminently hazardous situation which, if not avoided, will result in death or

serious injury.

indicates a potentially hazardous situation which, if not avoided, could result in death or

serious injury.

indicates a potentially hazardous situation which, if not avoided, may result in minor or

moderate injury.

Watch for two other words: NOTICE and IMPORTANT. NOTICE can keep you from doing something that might damage the machine or someone's property. It

can also alert you against unsafe practices.

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

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Safety - 14 JT2720 Mach 1/All Terrain 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.

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

death. Provide ventilation.

Moving tools will kill or injure. Shut off drill string power when anyone can be

struck by moving or thrown tools. Never use pipe wrenches on drill string.

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

Crushing weight could cause death or serious injury. Use

proper procedures and equipment or stay away.

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

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JT2720 Mach 1/All Terrain Operator’s Manual Safety - 15

Safety Alerts

Explosion possible. Serious injury or equipment damage could occur.

Follow directions carefully.

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

Learn to use equipment correctly.

Improper control function could cause death or serious injury. If control does

not work as described in instructions, stop machine and have it serviced.

Looking into fiber optic cable could result in permanent vision damage. Do

not look into ends of fiber optic or unidentified cable.

Pressurized fluid or air could pierce skin and cause injury or

death. Stay away.

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

smoking, no flame, no spark.

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

Avoid moving vehicles, wear high visibility clothing, post appropriate warning signs.

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Safety - 16 JT2720 Mach 1/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).

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JT2720 Mach 1/All Terrain Operator’s Manual Safety - 17

Emergency Procedures

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

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

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

Electric Strike Description

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

Know location of lines and stay away.

When working near electric cables, remember the following:

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

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

• Low voltage current can injure or kill. Many work-related electrocutions result from contact with less than 440 volts.

Most electric strikes are not noticeable, but indications of a strike include:

• power outage

• smoke

• explosion

• popping noises

• arcing electricity

If any of these occur, or if strike alarm sounds or flashes, assume an electric strike has occurred.

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Safety - 18 JT2720 Mach 1/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 or mats and take the following actions. The order and degree of action will depend on the situation.

• Warn people nearby that an electric strike has occurred.

• Have someone contact electric company.

• Reverse drilling direction and try to break contact. Do not touch drill pipe with hands or hand-held tools.

• Press electric strike system status button.

• If alarm sounds again, stay where you are and wait for electric company to shut off power.

• If alarm does not sound and there is no other indication of a strike, wait at least one full minute

before moving away from equipment. Utility might use automatic reclosers which will restart current flow. If alarm sounds again while waiting, stay where you are until electric company shuts off power.

• If alarm does not sound but all lights in strike indicator are on, assume strike is continuing and stay

where you are until electric company shuts off power.

• Do not resume drilling or allow anyone into area until given permission by electric company.

If you suspect an electric line has been damaged and you are off drilling unit or bonded equipment, DO NOT TOUCH ANY EQUIPMENT connected to drilling unit. Take the following actions. The order and degree of action will depend on the situation.

• Stay where you are unless you are wearing electric insulating boots. If you leave, do not return to area or allow anyone into area until given permission by electric company.

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JT2720 Mach 1/All Terrain Operator’s Manual Safety - 19

Emergency Procedures

If a Gas Line is Damaged

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

smoking, no flame, no spark.

Explosion possible. Serious injury or equipment damage could occur.

Follow directions carefully.

If you suspect a gas line has been damaged, take the following actions. The order and degree of action will depend on the situation.

• Immediately shut off engine(s), if this can be done safely and quickly.

• Remove any ignition source(s), if this can be done safely and quickly.

• Warn others that a gas line has been cut and that they should leave the area.

• Leave jobsite as quickly as possible.

• Immediately call your local emergency phone number and utility company.

• If jobsite is along street, stop traffic from driving near jobsite.

• Do not return to jobsite until given permission by emergency personnel and utility company.

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Safety - 20 JT2720 Mach 1/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) 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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JT5 Operator’s Manual Controls - 21

Controls

Chapter Contents

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

Anchor Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Operator’s Station . . . . . . . . . . . . . . . . . . . . . . . . . 26

• Gauges and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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

Engine Compartment . . . . . . . . . . . . . . . . . . . . . . . 32

ESID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

750/752 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

• Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

• Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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Controls - 22 JT5 Operator’s Manual

Set-up Console

1. Engine stop button

2. Stabilizer and frame tilt control

Item Description Notes

1. Engine stop button To stop engine, press. IMPORTANT:

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3. Left track control

4. Right track control

• If this switch is used to stop drilling unit, turn ignition switch off if machine will be left unattended for long periods of time. Battery discharge can occur.

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

JT5 Operator’s Manual Controls - 23

Set-up Console

Item Description Notes

2. Stabilizer and frame tilt control

To raise stabilizer and decrease frame tilt, pull.

To lower stabilizer and increase frame tilt, push.

3. Left track control To move forward, push.

To move backward, pull. To stop, move to center.

c00ic147h.eps

4. Right track control To move forward, push.

To move backward, pull.

Note: Stabilizer control lowers the front of the drill frame along with the stabilizer.

c00ic148h.eps

To stop, move to center.

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Controls - 24 JT5 Operator’s Manual

Anchor Console

1. Left rotation control

2. Left thrust control

Item Description Notes

1. Left rotation control To drive anchor, push down.

To remove anchor, pull up.

3. Right rotation control

4. Right thrust control

IMPORTANT: Stand on platform when operating anchor controls.

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JT5 Operator’s Manual Controls - 25

Anchor Console

Item Description Notes

2. Left thrust control To move anchor down, push

down. To move anchor up, pull up.

3. Right rotation control To drive anchor, push down.

To remove anchor, pull up.

4. Right thrust control To move anchor down, push

down.

IMPORTANT: Stand on platform when operating anchor controls.

To move anchor up, pull up.

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Controls - 26 JT5 Operator’s Manual

Operator’s Station

Gauges and Indicators

1. Hydraulic fluid sight glass

2. Hourmeter

3. Cold start wait (glow plug) indicator

Item Description Notes

1. Hydraulic fluid sight glass

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Displays level of hydraulic fluid.

4. Engine oil pressure indicator

5. Engine temperature indicator

6. Drilling fluid pressure gauge

Maintain level in center of glass.

JT5 Operator’s Manual Controls - 27

Operator’s Station

Item Description Notes

2. Hourmeter Displays engine operating

time.

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

heater (glow plug) is operating.

Wait until light goes off before starting engine.

4. Engine oil pressure indicator

Lights when oil pressure is too low. Light will come on briefly when engine is started.

Use engine operating times to schedule service.

See “Start Unit” on page 64.

If light remains on:

• Stop engine.

• Check oil level.

5. Engine temperature indicator

Lights when engine temperature is too high.

• Check for leaks before starting engine.

• If pressure is still low, consult engine manual.

If light remains on:

• Stop engine and let it cool.

• Check fan belt tension.

• Check for low engine oil level.

• Check cooling fins for dirt and debris.

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Controls - 28 JT5 Operator’s Manual

Operator’s Station

Item Description Notes

6. Drilling fluid pressure gauge

Displays drilling fluid pressure supplied by drilling fluid pump.

• Yellow: low pressure

• Green: optimum pressure

• Red: high pressure

If pressure is too high, check if nozzle is plugged.

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JT5 Operator’s Manual Controls - 29

Operator’s Station

Controls

1. Ignition switch

2. Engine throttle control

3. Fluid flow control

4. Carriage control

Item Description Notes

1. Ignition switch To start engine, insert key and

turn clockwise. To stop engine, turn key

counterclockwise.

5. Wrench control

6. Pipe lubricator control

7. Auxiliary outlet

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+ 131 hidden pages