Ditch Witch JT9 User Manual

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JT9

Operator’s Manual

CMW

Issue 1.0

Original Instruction

053-2747

JT9 Operator’s Manual Overview - 1

Overview

Chapter Contents

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

Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 JT9 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

JT9 Operator’s Manual Overview - 3

Intended Use

The JT9 is a self-contained horizontal directional drilling unit designed to install buried cable and pipe at distances to 300’ (90 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 JT9 can be used with Ditch Witch operated, serviced, and repaired only by persons familiar with its particular characteristics and acquainted with the relevant safety procedures.

drilling fluid units and Ditch Witch locating equipment. It should be

Equipment Modification

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

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Overview - 4 JT9 Operator’s Manual

Unit Components

1. Operator’s station

2. Spindle

3. Carriage

4. Set up

5. Drill pipe box

6. Stabilizer

7. Drill frame

8. Tracks

9. Vise wrenches

10. Anchoring system

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JT9 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 JT9 Operator’s Manual

About This Manual

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JT9 Operator’s Manual Foreword - 7

Foreword

This manual is an important part of your equipment. It provides safety information and operation

instructions to help you use and maintain your Ditch Witch Read this manual before using your equipment. Keep it with the equipment at all times for future reference.

If you sell your equipment, be sure to give this manual to the new owner. If you need a replacement copy, contact your Ditch Witch dealer. If you need assistance in locating a

dealer, visit our website at www.ditchwitch.com or write to the following address:

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

The descriptions and specifications in this manual are subject to change without notice. The Charles

Machine Works, Inc. reserves the right to improve equipment. Some product improvements may have taken place after this manual was published. For the latest information on Ditch Witch equipment, see your Ditch Witch dealer.

equipment.

Thank you for buying and using Ditch Witch equipment.

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Foreword - 8 JT9 Operator’s Manual

JT9

Operator’s Manual

This manual covers the following models: JT9 Tier 4i, JT9 Tier 4.

Issue number 1.0/OM-04/14

Part number 053-2747

by The Charles Machine Works, Inc.

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

registered trademarks of The Charles Machine Works, Inc.

This product is covered by one or more of the following patents:

U.S. B1 5,684,466; 5,794,719; 5,880,680; 6,085,852; 6,109,371; 6,179,065; 6,250,403; 6,250,404; 6,290,606; 6,311,790; 6,543,551; 6,550,547; 6,808,210; 6,871,712; 7,011,166; 7,392,858; AU 689,533; 718,034; 755,862; DE 197 12 641; 669 42 993; 695 29 634;

FR 674,093; GB 2,312,006; UK0674093; UK0984132; other U.S. and foreign patents pending.

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JT9 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

119

125

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Contents - 10 JT9 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

155

159

163

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JT9 Operator’s Manual Safety - 11

Safety

Chapter Contents

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

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

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

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

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

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

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

Safety Alert Classifications . . . . . . . . . . . . . . . . . . 17

Machine Safety Alerts . . . . . . . . . . . . . . . . . . . . . . 18

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Safety - 12 JT9 Operator’s Manual

Guidelines

Follow these guidelines before operating any jobsite equipment:

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

• Contact your local One-Call (811 in USA) or the One-Call referral number (888-258-0808 in USA and Canada) to have underground utilities located before digging. Also contact any utilities that do not participate in the One-Call service. Mark proposed path with white paint prior to contacting One-Call or utilities.

• Classify jobsite based on its hazards and use correct tools and machinery , safety equipment, and work methods for jobsite.

• Mark jobsite clearly and keep spectators away.

• Wear personal protective equipment.

• Review jobsite hazards, safety and emergency procedures, and individual responsibilities with all personnel before work begins. Safety videos are available from your Ditch Witch

• Replace missing or damaged safety shields and safety signs.

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

dealer.

• Do not operate unit where flammable gas may be present.

• Contact your Ditch Witch dealer if you have any question about operation, maintenance, or equipment use.

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

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JT9 Operator’s Manual Safety - 13

Emergency Procedures

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

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

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

Electric Strike Description

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

Know location of lines and stay away.

When working near electric cables, remember the following:

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

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

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

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

• power outage

• smoke

• explosion

• popping noises

• arcing electricity

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

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Safety - 14 JT9 Operator’s Manual

Emergency Procedures

If an Electric Line is Damaged

If you suspect an electric line has been damaged and you are on drilling unit or bonded equipment, DO NOT MOVE. Remain on drilling machine and take the following actions. The order and degree of action will depend on the situation.

• Warn people nearby that an electric strike has occurred.

• Have someone contact electric company.

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

• Press electric strike system self test button.

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

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

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

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

where you are until electric company shuts off power.

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

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

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

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JT9 Operator’s Manual Safety - 15

Emergency Procedures

If a Gas Line is Damaged

Fire or explosion possible. Fumes could ignite and cause

burns. No smoking, no flame, no spark.

Explosion possible. Serious injury or equipment damage could occur.

Follow directions carefully.

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

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

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

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

• Leave jobsite as quickly as possible.

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

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

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

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Safety - 16 JT9 Operator’s Manual

Emergency Procedures

If a Fiber Optic Cable is Damaged

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

If Machine Catches on Fire

Perform emergency shutdown procedure and then take the following actions. The order and degree of action will depend on the situation.

• Immediately move battery disconnect switch (if equipped and accessible) to disconnect position.

• If fire is small and fire extinguisher is available, attempt to extinguish fire.

• If fire cannot be extinguished, leave area as quickly as possible and contact emergency personnel.

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JT9 Operator’s Manual Safety - 17

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 - 18 JT9 Operator’s Manual

Machine Safety Alerts

Tiedown location. See Transport chapter for more information.

Read operator’s manual. Know how to use all

controls before operating machine. When you see this sign on the machine or in the manual, read it and use caution. Your safety is at stake.

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

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JT9 Operator’s Manual Safety - 19

Machine Safety Alerts

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

away.

Do not park machine on slope unless chocked or

blocked.

Electric shock will cause death or serious injury.

Stay away.

Moving tools will kill or injure. Never use pipe

wrenches on drill string.

Fire or explosion possible. Do not use starter fluid.

Hot parts may cause burns. Do not touch until cool

or wear gloves.

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Safety - 20 JT9 Operator’s Manual

Machine Safety Alerts

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JT9 Operator’s Manual Controls - 21

Controls

Chapter Contents

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

Left Control Console . . . . . . . . . . . . . . . . . . . . . . . 25

Gauge Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Right Control Console . . . . . . . . . . . . . . . . . . . . . . 32

Anchoring System Console . . . . . . . . . . . . . . . . . 34

Seat/Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

ESID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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Controls - 22 JT9 Operator’s Manual

Set-Up Console

1. Left track control

2. Right track control

3. Stabilizer and frame tilt control

4. Tracker control key

5. Engine throttle control

6. Engine stop

Item Description Notes

1. Left track control To move forward, push.

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

c00ic147h.eps

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JT9 Operator’s Manual Controls - 23

Set-Up Console

Item Description Notes

2. Right track control To move forward, push.

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

c00ic148h.eps

3. Stabilizer and frame tilt control

To raise stabilizer and increase frame tilt, push.

To lower stabilizer and decrease frame tilt, pull.

4. 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).

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

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

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Controls - 24 JT9 Operator’s Manual

Set-Up Console

Item Description Notes

5. Engine throttle control (Tier 4i)

To increase engine speed, push up.

To decrease engine speed, pull down.

Engine throttle control

To increase speed, press top.

(Tier 4)

To decrease speed, press bottom.

To further increase or decrease speed, press additional times.

c00ic243h.eps

6. Engine stop To stop engine, press. NOTICE:

• 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.

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

JT9 Operator’s Manual Controls - 25

Left Control Console

Drilling/Operation Controls

1. Auxiliary outlet

2. Ignition switch

3. Engine throttle control

4. Cold start

Item Description Notes

1. Auxiliary outlet Provides power for other

equipment.

5. Wrench control

6. Rear home/front home switch

7. Fluid flow control

Power output is 12V, 5A.

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Controls - 26 JT9 Operator’s Manual

Left Control Console

Item Description Notes

2. Ignition switch T o start engine, insert key and

turn clockwise. To stop engine, turn key

counterclockwise.

3. Engine throttle control (Tier 4i)

To increase engine speed, push up.

To decrease engine speed, pull down.

Engine throttle control

To increase speed, press top.

(Tier 4)

To decrease speed, press bottom.

To further increase or decrease speed, press additional times.

c00ic243h.eps

4. Cold start To start cold engine when

temperature is below 32°F (0°C):

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• Turn ignition switch to on position.

• Press top and release.

Start engine.

JT9 Operator’s Manual Controls - 27

Left Control Console

Item Description Notes

5. Wrench control To clamp front wrench and

shut off drilling fluid, move toward pipe box.

To unclamp front wrench, move away from pipebox.

To clamp and rotate rear (rotating) wrench, move toward engine compartment.

To unclamp rear (rotating) wrench, move toward seat.

6. Rear home/ front home switch

7. Fluid flow control To increase flow, turn

To move carriage to front of drill frame, press top.

To move carriage to rear of drill frame, press bottom.

counterclockwise. To decrease flow, turn

clockwise. To stop flow, turn all the way

clockwise.

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Controls - 28 JT9 Operator’s Manual

Left Control Console

Engine Display

1. Hydraulic fluid temperature indicator

2. Hydraulic filter service indicator

3. Hourmeter

4. Cold start wait indicator

5. High temperature indicator

6. Engine shutdown indicator (Tier 4i) Diagnostic message indicator (Tier 4)

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7. Engine temperature indicator

8. Engine oil pressure indicator

9. Diagnostics menu indicator

10. Settings menu indicator

11. Voltmeter display

12. Fuel gauge

JT9 Operator’s Manual Controls - 29

Left Control Console

Item Description Notes

1. Hydraulic fluid temperature indicator

2. Hydraulic filter service indicator

3. Hourmeter Displays engine operating

Indicates hydraulic fluid is overheating.

Indicates hydraulic fluid filter needs replacing.

time.

• Check hydraulic fluid level.

• Check cooler for debris. See page 140.

Change filter when indicator lights continuously and as indicated on page 147.

Use engine operating times to schedule service.

4. Cold start wait indicator Lights when intake air preheater is operating.

Wait until light goes off before starting engine.

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Controls - 30 JT9 Operator’s Manual

Left Control Console

Item Description Notes

5. High temperature

indicator

c00ic232h.eps

6. Engine shutdown

indicator (Tier 4i) Diagnostic message

indicator (Tier 4)

Indicates engine is overheating.

Tier 4i: Indicates the engine shutdown relay has been activated due to low engine oil pressure.

Tier 4: Indicates a Diagnostic Trouble Code.

IMPORTANT: Alarms will sound when engine overheats.

Stop engine and service unit.

7. Engine temperature

indicator

c00ic004w.eps

8. Engine oil pressure

indicator

Lights when engine coolant temperature is too high.

Indicates engine oil pressure is too low.

Tier 4i: Will flash when temperature is over 275°F (135°C).

Tier 4: Will flash when temperature is over 230°F (110°C).

Stop engine and service unit.

IMPORTANT: Alarms will sound when engine oil pressure is too low.

Stop engine and check oil level.

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JT9 Operator’s Manual Controls - 31

Left Control Console

Item Description Notes

9. Diagnostics menu

indicator

Use soft key directly below icon to access diagnostics menu.

10. Settings menu indicator Use soft key directly below icon to access main menu.

11. Voltmeter display Shows system voltage.

c00ic008w.eps

12. Fuel gauge Displays fuel level in tank. NOTICE: Use low sulfur or ultra low

sulfur fuel only. Refer to engine operator’s manual for

cold weather fuel recommendations.

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

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Controls - 32 JT9 Operator’s Manual

Right Control Console

1. Carriage control

2. Pipe lubricator button (optional)

3. Drilling fluid pressure gauge

Item Description Notes

1. Carriage control To move carriage forward,

push. To move carriage backward,

pull. To rotate spindle

counterclockwise (breakout), move right.

To rotate spindle clockwise (makeup), move left.

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4. Thrust pressure gauge

5. Rotation pressure gauge

JT9 Operator’s Manual Controls - 33

Right Control Console

Item Description Notes

2. Pipe lubricator button

(optional)

To apply joint compound to threads at wrenches, press button.

3. Drilling fluid pressure

gauge

Displays drilling fluid pressure supplied by drilling fluid pump.

c00ic157h.eps

4. Thrust pressure gauge Displays hydraulic fluid pressure to thrust motor during thrust and pullback.

Estimates thrust and pullback force on lines outside gauge.

5. Rotation pressure

gauge

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

Estimates rotational torque on lines outside gauge.

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Controls - 34 JT9 Operator’s Manual

Anchoring System 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.

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3. Right rotation control

4. Right thrust control

IMPORTANT: Stand on platform when operating anchor controls.

JT9 Operator’s Manual Controls - 35

Anchoring System 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 - 36 JT9 Operator’s Manual

Seat/Armrest

1. Seat tilt latch 2. Seat leveling wheel

Item Description Notes

1. Seat tilt latch To tilt seat forward for

transport, push knob. To lower seat for operation,

pull knob.

2. Seat leveling wheel To level seat when the unit is set up on a side slope, turn wheel.

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JT9 Operator’s Manual Controls - 37

Battery

1. Battery disconnect switch

Item Description Notes

1. Battery disconnect

switch

To disable battery power, move switch to the disconnect position.

To enable battery power, move switch to the connect position.

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Controls - 38 JT9 Operator’s Manual

ESID

j07om042h.eps

1. Alphanumeric display

2. Strike indicator

3. Alarm interrupt button

4. Voltage problem indicator

Item Description Notes

1. Alphanumeric display Display amount of current

and voltage being detected as a percentage of strike condition.

5. Current problem indicator

6. OK indicator

7. Electrical power supply indicator

8. Self test button

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.

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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.

JT9 Operator’s Manual Controls - 39

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

Blinking red light indicates a voltage indicator problem.

Blinking red light indicates a current indicator problem.

self test detected no problems.

See “Troubleshoot Strike System” on page 95.

Strike system is ready to operate.

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Controls - 40 JT9 Operator’s Manual

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.

NOTICE: See “If an Electric Line is Damaged” on page 14.

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JT9 Operator’s Manual Operation Overview - 41

Operation Overview

Chapter Contents

Planning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Setting Up at Jobsite . . . . . . . . . . . . . . . . . . . . . . . 42

Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Backreaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Leaving Jobsite. . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Storing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 43

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Operation Overview - 42 JT9 Operator’s Manual

Planning

1. Gather information about jobsite. See page 47.

2. Inspect jobsite. See page 48.

3. Classify jobsite. See page 50.

4. Plan bore path. See page 53.

5. Check supplies and prepare equipment. See page 59.

6. Load equipment. See page 66.

Setting Up at Jobsite

1. Prepare jobsite. See page 58.

2. Unload drilling unit from trailer. See page 69.

3. Position drilling unit and frame. See page 73.

4. Assemble strike system. See page 93.

5. Anchor drilling unit. See page 93.

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

Drilling

1. Start system. See page 73.

2. Prime drilling fluid pump. See page 73.

3. Engage tracker control if desired. See page 104.

4. Assemble drill string. See page 77.

5. Drill first pipe. See page 80.

6. Record bore path. See page 83.

7. Add pipe. See page 81.

8. Drill remaining pipes in pipe box.

• Correct direction. See page 82.

9. Surface drill head. See page 84.

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JT9 Operator’s Manual Operation Overview - 43

Backreaming

1. Assemble backream string. See page 85.

2. Start drilling unit and adjust throttle.

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

4. Remove pipe from bore. See page 87.

5. Remove pullback device. See page 88.

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. See page 88.

2. Remove anchors. See page 92.

3. Rinse unit and downhole tools. See page 121.

4. Disassemble strike system and disconnect from fluid system. See page 123.

5. Stow tools. See page 123.

6. Load unit onto trailer. See page 66.

Storing Equipment

1. For cold weather storage, antifreeze drilling unit. See page 120.

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

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Operation Overview - 44 JT9 Operator’s Manual

Storing Equipment

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JT9 Operator’s Manual Prepare - 45

Prepare

Chapter Contents

Gather Information . . . . . . . . . . . . . . . . . . . . . . . . . 47

• Review Job Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

• Notify One-Call Services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

• Examine Pullback Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

• Arrange for Traffic Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

• Plan for Emergency Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Inspect Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

• Identify Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

• Select Start and End Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Classify Jobsite. . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

• Inspect Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

• Select a Classification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

• Apply Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Plan Bore Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

• Recommended Bend Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

• Entry Pitch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

• Minimum Setback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

• Minimum Depth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

• Bore Path Calculator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

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Prepare - 46 JT9 Operator’s Manual

Prepare Jobsite. . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

• Mark Bore Path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

• Prepare Entry Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Check Supplies and Prepare Equipment . . . . . . . 59

• Check Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

• Prepare Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

• Assemble Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

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JT9 Operator’s Manual Prepare - 47

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.

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.

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Prepare - 48 JT9 Operator’s 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 50.)

• traffic

• access

• soil type and condition

• water supply

• sources of locator 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 50.

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

NOTICE:

• 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.

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JT9 Operator’s Manual Prepare - 49

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 56.

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.

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Prepare - 50 JT9 Operator’s 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 bore 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

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JT9 Operator’s Manual Prepare - 51

Classify Jobsite

Apply Precautions

Once classified, precautions appropriate for jobsite must be taken.

Electric Jobsite Precautions

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

Know location of lines and stay away.

In addition to using a directional drilling system with an electric strike system, use one or both of these methods.

• Expose line by careful hand digging or soft excavation. Use beacon to track bore path. Have someone observe clearance between drill head and backreamer when crossing a line.

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

Natural Gas Jobsite Precautions

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.

In addition to using a directional drilling system and positioning equipment upwind from gas lines, use one or both of these methods.

• Expose lines by careful hand digging or soft excavation. Use beacon to track bore path. Have someone observe clearance between drill head and backreamer when crossing a line.

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

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Prepare - 52 JT9 Operator’s Manual

Classify Jobsite

Crystalline Silica (Quartz) Dust Precautions

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.

Follow OSHA or other guidelines for exposure to crystalline silica when trenching, sawing or drilling through material that might produce dust containing crystalline silica (quartz).

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.

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JT9 Operator’s Manual Prepare - 53

Plan Bore Path

Plan the bore path, from entry to end, before drilling begins. The Ditch Witch® T rac Management System Plus is available for planning your bore path. This special software can be run in the field using a laptop

computer equipped with Windows® 95 or higher operating system. See your Ditch Witch dealer for details. If not using Trac Management System Plus, 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 Trac Management System Plus, see “Bore Path Calculator” on page 57 and use these measurements to help plan your bore.

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Prepare - 54 JT9 Operator’s Manual

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. For JT922 drill pipe, make sure pitch (A) changes no more than 6% 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 remote display on the operator’s console.

Bend Radius

JT922 drill pipes have a tested minimum bend radius of 105’ (32 m). This means that a 90-degree bend in the bore path:

• has a radius (A) of 105’ (32 m)

• requires approximately 165’ (50 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.

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JT9 Operator’s Manual Prepare - 55

Plan Bore Path

Pipe-By-Pipe Bend Limits

Pipe

(C)

1 6 ft 0 in (1.8 m) 0 ft 2 in (0.1 m) 15 79 ft 5 in (24.3 m) 36 ft 3 in (11.1 m) 2 12 ft 0 in (3.7 m) 0 ft 8 in (0.2 m) 16 83 ft 2 in (25.4 m) 40 ft 11 in (12.5 m) 3 17 ft 11 in (5.5 m) 1 ft 6 in (0.5 m) 17 86 ft 8 in (26.2m) 45 ft 9 in (13.9 m) 4 23 ft 9 in (7.2 m) 2 ft 9 in (0.8 m) 18 89 ft 11 in (27.4m) 50 ft 10 in (15.5 m) 5 29 ft 7 in (9 m) 4 ft 3 in (1.3 m) 19 92 ft 11 in (28.3m) 56 ft 0 in (17 m) 6 35 ft 4 in (10.8 m) 6 ft 1 in (1.8 m) 20 95 ft 6 in (29.2m) 61 ft 5 in (18.7 m) 7 40 ft 11 in (12.5 m) 8 ft 3 in (2.5 m) 21 97 ft 10 in (29.9m) 66 ft 11 in (20.4 m) 8 46 ft 4 in (14.1 m) 10 ft 9 in (3.2 m) 22 99 ft 11 in (30.5m) 72 ft 7 in (22.2 m) 9 51 ft 8 in (15.7 m) 13 ft 7 in (4.2 m) 23 101 ft 7 in (31m) 78 ft 4 in (23.9 m) 10 56 ft 9 in (17.3 m) 16 ft 8 in (5.1 m) 24 102 ft 11 in (31.4m) 84 ft 2 in (25.7 m) 11 61 ft 9 in (18.8 m) 20 ft 1 in (6.2 m) 25 103 ft 11 in (31.7m) 90 ft 1 in (27.5 m) 12 66 ft 6 in (20.3 m) 23 ft 9 in (7.2 m) 26 104 ft 7 in (31.9m) 96 ft 1 in (29.4 m) 13 71 ft 0 in (21.6 m) 27 ft 8 in (8.4 m) 27 105 ft 0 in (32m) 102 ft 1 in (31.2 m) 14 75 ft 4 in (23 m) 31 ft 10 in (9.8 m) 27.5 105 ft 0 in (32m) 105 ft 0 in (32 m)

Forward (B) Deflection (A) Pipe

(C)

Forward (B) Deflection (A)

Pipe 14 is illustrated.

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Prepare - 56 JT9 Operator’s Manual

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 bore path 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.

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JT9 Operator’s Manual Prepare - 57

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)

2 ft 9 in (0.8 m) -18% 24 ft 6 in (7.5 m) 1 ft 1 in (0.33 m) 3 ft 3 in (1.0 m) -20% 26 ft 6 in (8.1 m) 1 ft 2 in (0.36 m) 3 ft 9 in (1.1 m) -22% 28 ft 5 in (8.7 m) 1 ft 3 in (0.38 m) 4 ft 4 in (1.3 m) -24% 30 ft 4 in (9.2 m) 1 ft 5 in (0.43 m) 4 ft 7 in (1.4 m) -25% 31 ft 3 in (9.5 m) 1 ft 5 in (0.43 m)

IMPORTANT: Numbers in table based on 105’ (32 m) minimum bend radius, beacon housing, EZConnect, connector, transition sub, and 1/3 of first drill pipe (L, totalling 8’ [2.4 m]) in the ground before steering.

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Prepare - 58 JT9 Operator’s Manual

Prepare Jobsite

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

NOTICE:

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

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

• All vegetation near operator’s station must be removed. 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.

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.

To prevent bending or straining pipe, position drilling

unit for straight entry.

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JT9 Operator’s Manual Prepare - 59

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 112)

• transition sub

• anchoring equipment and accessories

• bits, screens, nozzles (see page 107)

• adapters, pipe, beacon housings

• marking flags or paint

• water and additional hoses

• fuel (Use low sulfur or ultra low sulfur fuel only.)

• drilling fluid additives (see page 99)

• spare fuses

• keys

• backreamers, swivels, pulling devices (see page 107)

• wash down hose and spray gun

• duct tape

• spray lubricant

• tool joint compound (see page 128)

• electrically insulating boots and gloves

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

• notepad and pencil

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Prepare - 60 JT9 Operator’s Manual

Prepare Equipment

Fluid Levels

• fuel (Use low sulfur or ultra low sulfur fuel only.)

• hydraulic fluid

• 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.

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JT9 Operator’s Manual Drive - 61

Drive

Chapter Contents

Start Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Steer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Shut Down Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

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Drive - 62 JT9 Operator’s Manual

Start Unit

1. Insert key.

2. Turn key clockwise. See page 26 for more information.

3. Run engine at low throttle for 5 minutes.

Steer Unit

To steer drilling unit, follow instructions for type of steering desired. See page 22 for more information.

To steer while moving forward, move one control slightly more than the other to turn in the desired direction. Drilling unit will gradually turn to left or right.

To steer while moving backward, move one control slightly more than the other to turn in the desired direction. Drilling unit will gradually turn to left or right.

For tight steering at low speed, one control to reverse and one control to forward to turn in the desired direction. Tracks will counter-rotate and turn drilling unit in a tight circle.

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 152.)

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

• Driving on slopes.

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

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JT9 Operator’s Manual Drive - 63

Shut Down Unit

1. Stop track movement.

2. Lower drill frame and stabilizer to the ground.

IMPORTANT: If frame and stabilizer cannot be lowered, use cylinder locks, chocks (shown), or other suitable material to block the tracks. Remove cylinder locks or chocks before driving unit.

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

4. Turn key to STOP.

5. Remove key.

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Drive - 64 JT9 Operator’s Manual

Shut Down Unit

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JT9 Operator’s Manual Transport - 65

Transport

Chapter Contents

Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Haul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

• Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

• Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

• Unload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Tow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

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Transport - 66 JT9 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.

Haul

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:

• Load and unload trailer on level ground.

• Verify that trailer wheels are blocked.

• Incorrect loading can cause trailer swaying.

• Attach trailer to vehicle before loading or unloading.

• Ten to fifteen percent of total vehicle weight (equipment plus trailer) must be on tongue to help prevent trailer sway.

1. Start drilling unit engine.

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

3. Slow engine to low throttle and slowly drive unit onto trailer.

4. Lower stabilizer and drill frame to trailer floor.

5. Stop engine when unit is safely positioned on trailer bed.

6. Attach tiedowns to drilling unit where indicated on page 67.

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JT9 Operator’s Manual Transport - 67

Haul

Tie Down

Points

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

points is unsafe and can damage machinery.

Procedure

Read operator’s manual. Know how to use all controls before operating

machine. When you see this sign on the machine or in the manual, read it and use caution. Your safety is at stake.

To help avoid injury:

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.

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Transport - 68 JT9 Operator’s Manual

Haul

Attach chains at front and rear tie-down points (shown). Make sure chains are tight before transporting

unit.

IMPORTANT: Drill frame must be lowered to trailer floor before attaching chains.

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JT9 Operator’s Manual Transport - 69

Haul

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:

• Load and unload trailer on level ground.

• Ensure trailer wheels are blocked.

• Attach trailer to vehicle before loading or unloading.

1. Lower ramps.

2. Remove tiedowns.

3. Start drilling unit engine.

4. Raise stabilizers.

5. Raise drill frame.

6. Slow engine to low throttle and slowly back unit down trailer or ramps.

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Transport - 70 JT9 Operator’s Manual

Tow

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

• Tow for short distances at less than 1 mph (1.6 kph).

• Attach chains to indicated tow points facing towing vehicle.

• Use maximum towing force of 1.5 times unit weight.

• disengage power to tracks.

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

To disengage track hydraulics:

1. Loosen locknut (B).

2. Turn screw (A) on each counterbalance valve clockwise until it stops.

IMPORTANT: Be sure to count number of turns.

3. Repeat on other track.

To engage track hydraulics:

1. Turn screw (A) on counterbalance exactly same number of turns counterclockwise.

2. Tighten locknut (B).

3. Repeat on other track.

To attach chains to tow points, determine which points are facing towing vehicle.

Loop chains around crossmember (either front or back) on drill frame.

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JT9 Operator’s Manual Conduct a Bore - 71

Conduct a Bore

Chapter Contents

Position Equipment . . . . . . . . . . . . . . . . . . . . . . . . 73

Start System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Prime Drilling Fluid Pump . . . . . . . . . . . . . . . . . . . 73

Operate Carriage Control . . . . . . . . . . . . . . . . . . . 75

Clamp Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Assemble Drill String . . . . . . . . . . . . . . . . . . . . . . . 77

• Prepare Beacon Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

• Attach Transition Sub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

• Connect Drill Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Drill First Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Add Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Correct Direction . . . . . . . . . . . . . . . . . . . . . . . . . . 82

• Basic Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

• Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

• Drill Head Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

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Conduct a Bore - 72 JT9 Operator’s Manual

Record Bore Path . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Surface Drill Head . . . . . . . . . . . . . . . . . . . . . . . . . 84

Assemble Backream String . . . . . . . . . . . . . . . . . . 85

Remove Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Remove Pullback Device . . . . . . . . . . . . . . . . . . . . 88

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JT9 Operator’s Manual Conduct a Bore - 73

Position Equipment

1. Review bore plan and select drilling unit position and fluid unit position. See “Select Start and End Points” on page 49.

NOTICE: Do not connect to a public or private water system while drilling on an electrical job site.

2. Move equipment into selected positions.

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.

2. Enable tracker control mode if desired. See “Tracker Control” on page 104.

3. Set engine to full throttle.

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

Prime Drilling Fluid Pump

Read operator’s manual. Know how to use all controls

before operating machine. When you see this sign on the machine or in the manual, read it and use caution. Your safety is at stake.

To help avoid injury:

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.

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Conduct a Bore - 74 JT9 Operator’s Manual

Prime Drilling Fluid Pump

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.

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JT9 Operator’s Manual Conduct a Bore - 75

Operate Carriage Control

The thrust/rotation control has eight positions which allow the four basic

functions to be combined. The chart below summarizes functions that occur when control is put at a combined position. Operator must be in seat for control to function.

Carriage Movement Rotation Direction

forward clockwise (makeup)

reverse counterclockwise (breakout)

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Conduct a Bore - 76 JT9 Operator’s Manual

Clamp Pipe

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

To help avoid injury:

Clamping anywhere else on the pipe will weaken the pipe. Pipe can later

break, even when operating under normal loads.

Read operator’s manual. Know how to use all controls

before operating machine. When you see this sign on the machine or in the manual, read it and use caution. Your safety is at stake.

To help avoid injury:

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 centered between wrenches (1 and 2). Always clamp on the larger diameter areas on either side of the tool joint face.

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JT9 Operator’s Manual Conduct a Bore - 77

Assemble Drill String

Prepare Beacon Housing

1. Select nozzles and bit.

IMPORTANT: A variety of nozzles and bits are available to suit your particular job conditions. See “Downhole Tools” on page 107 for more information, or contact your Ditch Witch® dealer.

2. Insert nozzle into beacon housing.

3. Attach bit (2) to beacon housing (1).

4. Install beacon, following beacon instructions for:

• battery replacement

• beacon positioning

5. Install beacon housing lid. See “Beacon Housings” on page 108.

6. Follow beacon instructions to check beacon operation.

7. Follow tracker instructions to calibrate beacon.

Attach Transition Sub

Use either machine torque or quick wrench to attach transition sub (3) to beacon housing (1).

Machine Torque

1. Pull transition sub into front wrench.

2. Close wrench.

3. Lube joints.

4. Slowly make up joint.

5. Use full machine torque to tighten joint fully.

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Conduct a Bore - 78 JT9 Operator’s Manual

Assemble Drill String

Quick Wrench

Moving tools will kill or injure. Never use pipe wrenches

on drill string.

1. Lube joints with TJC.

2. Attach quick wrench to the joint in the join position and tighten joint. See “Quick Wrench” on page 112.

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JT9 Operator’s Manual Conduct a Bore - 79

Assemble Drill String

Connect Drill Pipe

1. Start drilling unit engine.

2. Align transition sub (3) in front wrench.

3. Clamp tool in front wrench. See “Clamp Pipe” on page 76.

4. Lift pipe box latches.

NOTICE: If drilling unit is set up in a side-slope, the rear pipe box latch should be left latched to help ensure that upper rows of drill pipe do not fall.

5. Load pipe (4).

• Lubricate upper pipe threads.

• Move pipe to spindle. Move pin end of pipe into saver sub and release pipe to rest on rear wrench.

Lubricate lower threads.

6. Connect pipe.

• Move carriage forward until saver sub nears male pipe thread.

• Slowly rotate spindle clockwise. Carriage will move forward as threads screw together.

• Slowly move carriage forward until pipe end touches end of transition sub.

• To screw pipes together and fully torque joint, slowly rotate drill pipe until spindle stops turning.

• Open wrench.

NOTICE: Do not handle pipe while rotating.

7. Close guides.

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Conduct a Bore - 80 JT9 Operator’s Manual

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 rod or pipe slowly. Forcing can bend string. Do not use bent rod or 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. See “Prepare Entry Point” on page 58.

4. Slowly move carriage forward. See “Prepare Entry Point” on page 58. Take care to steer to drill straight in line with drilling unit. Drill in downhole tools and 1/3 of first pipe before steering.

5. Monitor gauges.

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JT9 Operator’s Manual Conduct a Bore - 81

Add Pipe

1. Set engine throttle to full speed.

2. Clamp pipe joint. See “Clamp Pipe” on page 76.

3. Locate drill head.

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

5. Slowly rotate spindle counterclockwise. Move carriage back as threads unscrew.

6. After threads are fully unscrewed, stop rotation and move carriage to back of frame, slowing down as carriage approaches rear end.

7. Connect Pipe. See “Connect Drill Pipe” on page 79.

8. Ensure that pipe fills and fluid pressure begins to rise.

9. Rotate spindle.

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

11. Monitor gauges.

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

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Conduct a Bore - 82 JT9 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

To track progress and make corrections, one crew member locates 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

• 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 54.

• 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.

dealer.

• Do not push an entire piece of drill pipe into ground without rotation. This can exceed bend radius and cause pipe failure.

Procedure

1. Locate drill head. Take readings available with your beacon and locating 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. Push in drill pipe as needed to change direction.

5. Rotate in remaining length of drill pipe.

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JT9 Operator’s Manual Conduct a Bore - 83

Record Bore Path

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 locator 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:

Rotate pipe into ground.

Record Bore Path

Locate drill head every half-length of pipe. As the job is completed, record the actual data for each drill pipe. List pitch and depth of each joint and a brief description of the procedure. In addition, draw a simple sketch of the site and record depth and rough location of pullback.

The Trac Management System Plus is also available for plotting and tracking your bore path. It utilizes the

tracking system, a tracking beacon, and special software. The tracking display can store jobs in its memory or the system can be run in the field using a laptop computer. See your Ditch Witch® dealer for details.

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Conduct a Bore - 84 JT9 Operator’s Manual

Surface Drill Head

Moving tools will kill or injure. Never use pipe wrenches

on drill string.

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

To help avoid injury:

• Tracker operator and drill operator should maintain two-way communication.

• Keep everyone clear of the exposed drill string.

• No one should enter pit until clear communication is given by the drill operator that the drill unit is shut down. If using tracker control, do not enter pit until tracker control is turned off and green light on drill unit is lit.

• Drill operator should be instructed to discontinue drill string rotation as soon as drill bit exits the bore. Use thrust only to extend drill string beyond exit hole.

1. Guide drill head to target pit or up through surface. Make all bends gradual. See “Recommended Bend Limits” on page 54.

2. Clean area around exit point.

3. If using tracker control mode, tracker operator turns off tracker to disable drilling unit thrust/pullback and rotation hydraulics. Tracker operator waits for green light to enter pit and change tools.

If not using tracker control mode, tracker operator signals to drilling unit operator to stop engine before changing downhole tools.

4. Turn fluid flow control to off position as soon as drill head emerges.

5. Clean drill head especially around threads.

6. Disconnect EZ-Connect joint or use quick wrench to remove drill head. Keep threads clean. See “Quick Wrench” on page 112.

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JT9 Operator’s Manual Conduct a Bore - 85

Assemble Backream String

Sometimes it is necessary to enlarge the pilot hole to accommodate larger product. As a general rule, the final hole should be 1.5 times larger than the diameter of the product being installed. The number of passes needed depends on soil conditions. Do not try to increase hole size too much in one pass. Several passes using successively larger reamers will save wear on machine.

Moving tools will kill or injure. 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.

To help avoid injury:

Continue to use strike system during backreaming.

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

To help avoid injury:

• Maintain two-way communication with tracker operator.

• Begin backream only when tracker operator has communicated that everyone is clear of the exposed backream string or has disabled thrust and rotation hydraulics using tracker control.

• Do not allow anyone to stand to the side of the exposed drill string. Drill string and backreamer can move sideways suddenly if rotated while away from the exit hole.

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Conduct a Bore - 86 JT9 Operator’s Manual

Assemble Backream String

1. Select backreaming devices. See “Backreamers” on page 109.

2. Determine fluid rate requirements and install appropriate nozzles to provide sufficient flow. See “Backream Fluid Requirements” on page 110 and “Nozzles” on page 107.

3. Attach backreamer to backream beacon housing if tracking backream.

4. Install beacon, following beacon instructions for:

• battery replacement

• beacon positioning

5. Install beacon housing lid. See “Beacon Housings” on page 108.

6. Follow beacon instructions to check beacon operation.

7. Follow tracker instructions to calibrate beacon.

8. Connect EZ-Connect joint or use quick wrench to attach backreamer/beacon housing assembly to transition sub. See “Quick Wrench” on page 112.

9. Attach swivel and additional pullback devices or product to end of backreamer/beacon housing assembly.

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JT9 Operator’s Manual Conduct a Bore - 87

Remove Pipe

NOTICE: If engine is shut off during backreaming, drill pipe clamped by wrenches but not connected to saver sub can be pulled downhole as vise wrenches loosen.

1. Stop carriage when pipes are aligned in wrenches.

2. Clamp pipe in front wrench. See page 76.

3. Clamp and rotate rear wrench to break front joint. See “Wrench control” on page 27.

4. Disengage rear wrench.

5. Unscrew front joint.

• Slowly rotate spindle counterclockwise to unscrew pipe. Move carriage back slowly until threads

unscrew.

• Move carriage back until pipe is properly positioned in rear wrench.

6. Break rear joint.

• Engage rear wrench.

• Slowly rotate spindle counterclockwise until joint is loosened. Do not fully unscrew joint.

• Disengage rear wrench.

• Move carriage back, move seat toward pipe and grip pipe with both hands.

• Pull pin end of pipe clear of saver sub, lift pipe and stow it in box.

7. Lube front threads.

8. Attach saver sub to next pipe.

• Move carriage forward until saver sub touches pipe.

• Rotate spindle to screw onto pipe. Slowly tighten joint to full machine torque.

9. Disengage front wrench to release pipe.

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Conduct a Bore - 88 JT9 Operator’s Manual

Remove Pullback Device

The pullback device can be removed when the last pipe is on the frame. It can also be removed when a

target pit along the bore path has been reached. Remaining pipe is then pulled back and removed.

Moving tools will kill or injure. Never use pipe wrenches

on drill string.

1. Turn off drilling fluid.

2. Move engine throttle to low speed.

3. Turn drilling unit engine off.

4. Use tracker control to verify that unit is turned off.

5. Clean pullback device.

6. Use quick wrench to remove pullback device. See “Quick Wrench” on page 112.

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JT9 Operator’s Manual Systems and Equipment - 89

Systems and Equipment

Chapter Contents

Anchor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

• Drive Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

• Remove Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Electric Strike System . . . . . . . . . . . . . . . . . . . . . . 93

• FCC Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

• Assemble Voltage Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

• Test Strike System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

• Troubleshoot Strike System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

• Use Electric Strike Simulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Drilling Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

• Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

• Polymer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

• Bentonite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

• Mixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

• Basic Fluid Recipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

• Drilling Fluid Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

• Funnel Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Tracker Control . . . . . . . . . . . . . . . . . . . . . . . . . . 104

• Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

• Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

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Systems and Equipment - 90 JT9 Operator’s Manual

Downhole Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 107

• Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

• Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

• Beacon Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

• Backreamers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

• Backream Fluid Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110

Quick Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Drill Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

• Perform Regular Drill Pipe Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

• Use Drill Pipe Correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116

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JT9 Operator’s Manual Systems and Equipment - 91

Anchor System

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:

• Drive anchors properly before drilling.

• Stand on platform when operating anchor controls.

• Wear high-top protective boots with legs of pants completely tucked inside.

• Wear protective gloves.

• If you are not driving two anchors to full depth, drive optional ground rod into soil away from drilling unit and connect ground rod to drilling unit.

Electric shock. Contacting electric lines will cause death or serious

injury. Know location of lines and stay away.

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

To help avoid injury:

Do not replace anchor collar bolt with one longer than original. Clothing could catch on turning shaft.

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Systems and Equipment - 92 JT9 Operator’s Manual

Anchor System

Drive Anchors

IMPORTANT: Carefully time anchor rotation

with anchor movement. Properly driven anchors should thread into soil and should not auger up soil.

1. Use anchor rotation and thrust controls to drive anchor into ground.

2. Anchor is set when cap top plate (1) rests firmly on centering tube (2).

3. Repeat process for other anchor.

Remove Anchors

1. Use anchor rotation and thrust controls to slowly remove anchor shaft from ground.

2. Repeat process for other anchor.

NOTICE: If anchors are not being driven to full depth, additional grounding is needed.

• Remove paint from surface and attach cable to machine where shown.

• Drive rod into ground away from machine.

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JT9 Operator’s Manual Systems and Equipment - 93

Electric Strike System

Any time you drill in an electric jobsite, electric strike system must be properly set up, tested, and used. You must wear protective boots and gloves meeting the following standards:

• Boots must have high tops and meet the electric hazard protection requirements of ASTM F2413 or ASTM F1117 when tested at 14,000 volts. Tuck legs of pants completely inside boots.

• Gloves must have 17,000 AC maximum use voltage, according to ASTM specification D120.

If working around higher voltage, use gloves and boots with appropriately higher ratings.

NOTICE: The strike system does not prevent electric strikes or detect strikes before they occur. If alarms are activated, a strike has already occurred and equipment is electrified.

Read and follow “Electric Jobsite Precautions” on page 55. Review safety procedures before each job.

FCC Statement

The Electric Strike System has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the

FCC rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, can cause harmful interference to radio communications. Operation of this equipment in a residential area could cause harmful interference which the user will be required to correct at his own expense.

Changes or modifications not expressly approved in writing by The Charles Machine Works, Inc. may void the user's authority to operate this equipment.

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Systems and Equipment - 94 JT9 Operator’s Manual

Electric Strike System

Assemble Voltage Detector

1. Drive voltage stake into ground at least 6’ (2 m) away from any part of system.

2. Clip voltage limiter to voltage stake.

Test Strike System

If system fails any part of this test, see “Troubleshoot Strike System” on page 95 on the following page. Do not drill until test is completed successfully.

1. Turn on drilling unit.

2. ESID control module will perform internal tests which check everything but alarms and strobe.

3. If green OK indicator and electrical power supply indicator lights remain on, press self test button to perform total test of strike system. During this test:

• All lights should glow.

• Alphanumeric readout should display numbers.

• Alarms and strobes on all connected units should sound.

4. If this test is successful, OK indicator and electrical power supply indicator lights will remain on.

5. Use Electric Strike Simulator to test voltage and current sensors. See page 97.

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JT9 Operator’s Manual Systems and Equipment - 95

Electric Strike System

Troubleshoot Strike System

When strike system detects a problem, an error code will be displayed. Anytime this happens, press self test button to retest. If error code is still displayed and does not appear in this chart, have control module checked or replaced.

Other problem situations and their possible causes and solutions are listed in the chart below.

Problem Possible cause Possible solution

No lights or readings showing after drilling unit key has been on at least one minute

Screen is blank Strike system is not getting

Information on screen is visible during self test but not after test is complete

Problems in startup Push self test button. If problem goes

No power to strike system control module

Defective control module Have control module checked or

adequate power from drilling unit

Defective control module Have control module checked or

LCD contrast is not set properly

away, retest strike system Check drilling unit electric system Check that harness from drilling unit

to control module is connected Check that cable from drilling unit

carries more than 10V

replaced Check drilling unit electric system Check that harness from drilling unit

to control module is connected Check that harness from drilling unit

carries more than 10V

replaced Contact your Ditch Witch® dealer to

adjust contrast

OK indicator is on, but electrical power supply indicator is off

Electrical power supply indicator is on, but OK indicator is off

Strike system is not getting adequate power from drilling unit

Defective control module Have control module checked or

Problem detected during test Check for error code and have control

Defective control module Have control module checked or

Check drilling unit electric system Check that harness from drilling unit

to control module is connected Check that harness from drilling unit

carries more than 10V

replaced

module checked or replaced

replaced

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Systems and Equipment - 96 JT9 Operator’s Manual

Electric Strike System

Problem Possible cause Possible solution

Strobe light on drilling unit does not work during total test

Alarm on drilling unit does

not work during total test

Strobe light and alarm on drilling unit do not work during total test

Improper connections with control module

Defective strobe light 1. Disconnect strobe and connect to

Defective control module Have control module checked or

Improper connections with control module

Defective alarm 1. Disconnect strobe and connect to

Defective control module Have control module checked or

Improper connections with control module

Defective control module Have control module checked or

Check connections and wiring harness

external 12V power source.

2. If strobe does not work, replace it.

replaced Check connections and wiring

harness

external 12V power source.

2. If strobe does not work, replace it.

replaced Check connections and wiring

harness

replaced

EC2 code displays and current problem indicator is on

EV1 code displays and voltage problem indicator is on

Improper connections with control module

Defective current transformer 1. Disconnect current transformer.

Defective current transformer cable

Defective control module Have control module checked or

Improper connection of voltage limiter to ground stake

Defective voltage limiter Have voltage limiter checked or

Check cable connections on control module and current transformer

2. Check for 20-40 ohms from pin 1 to pin 4, 20-40 ohms from pin 1 to pin 2, and less than 1 ohm from pin 2 to pin 4.

1. Disconnect cable from transformer and control module.

2. Check continuity of cable.

3. If continuity is zero or cable is damaged, replace.

replaced Check voltage limiter connection to

ground stake and verify that ground stake is driven into the ground

replaced

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Defective control module Have control module checked or

replaced

JT9 Operator’s Manual Systems and Equipment - 97

Electric Strike System

Problem Possible cause Possible solution

EV2 code displays and voltage problem indicator is on

Improper connections with control module

Defective voltage limiter Have voltage limiter checked or

Defective control module Have control module checked or

Check cable connection on control module

replaced

Use Electric Strike Simulator

Use the Electric Strike Simulator (p/n 259-506) to test voltage and current sensors on ESID. If readings are less than indicated here, replace 9V battery in simulator and retest.

Current Test

To test for current at normal levels:

1. Thread one lead wire through current transformer.

2. Clip ends of lead wires together to make one loop.

3. Move simulator switch to "current" and press test button.

4. Watch screen and lights above display on strike system.

• Three or four lights should turn on.

• Current "A" should show 30-50% in display.

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Systems and Equipment - 98 JT9 Operator’s Manual

Electric Strike System

To test for current at strike levels:

1. Put two or three loops through current transformer.

2. Follow steps above to test.

3. Display should show the following:

• All lights should turn on.

• Alarm and strobe should turn on. With two loops,

• Current "A" should be 80-110%.

• Strike indication might go on and off. With three loops,

• Current should be 130-160%.

• Strike indication should be continuous.

Voltage Test

1. Place voltage limiter on something insulated from ground and drilling unit (such as dry board or tire), but near frame of drilling unit.

2. Clip one lead to frame.

3. Clip other lead to one voltage limiter mount.

4. Move simulator switch to "voltage" and press test button.

5. Watch screen and lights above display on strike system.

• All lights should turn on.

• Alarm and strobe should turn on.

• Voltage "V" should show 90-110%.

It is normal for simulator voltage levels to drift below strike level. When this happens, light in triangle should go off and alarm and strobe should stop working. If the level drifts above strike level again, light, alarm, and strobe should be turned on again.

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JT9 Operator’s Manual Systems and Equipment - 99

Drilling Fluid

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).

For productive drilling and equipment protection, use these recommended Baroid® products, available from your Ditch Witch® dealer.

• Soda ash

• Quik-Gel® dry powder bentonite (p/n 259-804)

• E-Z Mud™ liquid polymer (p/n 259-805)

• Liqui-Trol™ liquid polymer suspension (p/n 259-808)

• Quik-Trol® dry powder polymer (p/n 259-809)

• Bore-Gel® drilling fluid (p/n 259-807)

• Con-Det™ water-soluble cleaning solution (p/n 259-810)

Guidelines

Match drilling fluid to soil type. This chart is meant as a guideline only . See your local Ditch Witch dealer for soil conditions and drilling fluid recommendations for your area. Also see our interactive Drilling Fluid Formulator at www.ditchwitch.com.

Soil type Drilling fluid recommendation

smooth, flowing sand bentonite or Bore-Gel + medium chain polymer coarse sand or light soil bentonite or Bore-Gel heavy clay long chain polymer + Con-Det swelling clay long chain polymer + Con-Det rock Bore-Gel

Polymer

This drilling fluid additive provides excellent lubrication and increases viscosity in average soils and heavy

clay. In swelling clay, polymer can reduce swelling that traps pipe in the bore.

There are two types of polymer:

• long chain such as Baroid EZ-Mud

• medium chain such as Baroid Quik-Trol

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Ditch Witch JT9 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

“Continued” Indicators

Foreword

Contents

Safety

Guidelines

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

Safety Alert Classifications

Machine Safety Alerts

Controls

Set-Up Console

Left Control Console

Drilling/Operation Controls

Engine Display

Right Control Console

Anchoring System Console

Seat/Armrest

Battery

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

Tips to Reduce Track Wear

Shut Down Unit

Transport

Lift

Haul

Load