Ditch Witch JT9 User Manual

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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+ 135 hidden pages