Ditch Witch JT100 Operator'S Manual Download Page 190

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JT100/JT100 All Terrain Operator’s

Manual

Service - 189

Service

Chapter Contents

Service Precautions . . . . . . . . . . . . . . . . . . . . . . . 190

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Welding Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190

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Washing Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190

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Working Under Drilling Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191

Service and Lubrication Overview . . . . . . . . . . . 192

Recommended Lubricants/Service Key . . . . . . . 193

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Approved Coolants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194

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Approved Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194

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Diesel Exhaust Fluid (DEF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195

Each Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Startup/10 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . 199

25 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

100 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

200 Hour. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

250 Hour. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

500 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

1000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

2000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

4500 Hour. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

As Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

Summary of Contents for JT100

Page 1: ...JT100 JT100 All Terrain Tier 4 Issue 2 1 Original Instruction Operator s Manual 053 2814...

Page 2: ...1 Overview Chapter Contents Serial Number Location 2 Intended Use 3 Equipment Modification 3 Unit Components 4 FCC Statement Internal Transmitter 5 RF Exposure Statement 5 Operator Orientation 6 Abou...

Page 3: ...er Location Serial Number Location Record serial numbers and date of purchase in spaces provided Drilling unit serial number is located as shown Item date of manufacture date of purchase drilling unit...

Page 4: ...intended use The unit can be used with Ditch Witch drilling fluid units and Subsite Electronics tracking equipment It should be operated serviced and repaired only by persons familiar with its partic...

Page 5: ...nts 1 Driver loader attachment optional 2 Pipeloader 3 Front and rear wrenches 4 Spindle 5 Rotation carriage 6 Thrust carriage 7 Front and rear stabilizers 8 Tracks 9 Operator s station 10 Drill frame...

Page 6: ...requirements during normal operation this device must be held in front of the body horizontally The antenna must be vertical in line with the body with at least 4 100 mm separation distance from the...

Page 7: ...ee 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 import...

Page 8: ...acement 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 Ma...

Page 9: ...OM 08 16 Part number 053 2814 Copyright 2016 by The Charles Machine Works Inc and Ditch Witch Subsite Electronics Power Pipe SaverLok DrillLok and Rockmaster are registered trademarks of The Charles...

Page 10: ...lling product and restoring the jobsite with cross references to detailed procedures 75 Prepare procedures for inspecting and classifying the jobsite planning the installation path and preparing the j...

Page 11: ...ghts measurements power ratings and fluid capacities 247 Support the warranty policy for this machine and procedures for obtaining warranty consideration and training 255 Service Record a record of ma...

Page 12: ...65 Warning 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 D...

Page 13: ...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...

Page 14: ...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 no...

Page 15: ...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 w...

Page 16: ...y 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 I...

Page 17: ...chine 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...

Page 18: ...Follow all local regulations for inspections Transportation Always store auxiliary stabilizer before moving unit Always store driver loader properly for transportation Never drive with load suspended...

Page 19: ...lified or unauthorized person shall be allowed to operate the loader driver Always comply with load chart capacities Weight of heavy load can create enough tipping momentum to overturn drilling unit O...

Page 20: ...or pulling a load sideways Keep load directly under boom point at all times Boom can fail far below its rated capacity if the driver loader is side loaded Always walk around unit and check for obstru...

Page 21: ...ing on the driver loader lower boom to the ground turn driver loader controls off and relieve hydraulic pressure from circuits Never weld modify or use unauthorized components on driver loader attachm...

Page 22: ...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...

Page 23: ...Safety 22 JT100 JT100 All Terrrain Operator s Manual Machine Safety Alerts Machine Safety Alerts...

Page 24: ...275 197 4 Read operator s manual Know how to use all controls Your safety is at stake 273 475 5 Jobsite hazards could cause death or serious injury Use correct equipment and work methods Use and maint...

Page 25: ...Crushing weight could cause death or serious injury Stay away 275 326 11 Pressurized fluid or air could pierce skin and cause severe injury Refer to operator s manual for proper use 270 6035 12 Fire o...

Page 26: ...ader Attachment 1 Riding on boom or load will result in death or serious injury No riders Keep off 274 962 2 Moving parts could cut off hand Stay away 274 965 3 Do not get boom near power lines Death...

Page 27: ...erator s Manual Attachment Safety Alerts 4 Auxiliary stabilizer must be properly installed with contact on firm surface before operating pipebox loader on the engine side of the unit Working loads sho...

Page 28: ...head Console 35 Left Control Console 37 Pipeloading Controls 37 JT Drilling Controls 40 AT Drilling Controls 42 Operation Controls 45 Climate Controls 47 Right Control Console 49 Engine Display 49 Sta...

Page 29: ...Controls 28 JT100 JT100 All Terrain Operator s Manual Miscellaneous Controls 67 Engine Diagnostic Connector 70 Battery 71 ESID 72...

Page 30: ...izer control 5 Right rear stabilizer control 6 Left front stabilizer control 7 Right front stabilizer control 8 Auxiliary hydraulic pressure gauge Item Description Notes 1 Engine throttle switch To in...

Page 31: ...periods of time Battery discharge can occur If wrenches are engaged when remote stop is pressed wrenches will remain engaged but could gradually open 3 Auxiliary light switch To turn on press To turn...

Page 32: ...ually 7 Right front stabilizer control To lower push To raise pull Lower both front stabilizers to the ground together and then adjust individually 8 Auxiliary hydraulic pressure gauge Displays hydrau...

Page 33: ...control switch 5 Extension control switch 6 Driver Loader arm swing control switch 7 Outer boom control switch 8 Inner boom control switch 9 Speed control IMPORTANT Tethered driver loader controller...

Page 34: ...h to right 3 Auxiliary control switch Not used This switch is reserved for future auxiliary functions 4 Anchor driver control switch To drive anchor rotate clockwise push up and press speed control To...

Page 35: ...unterclockwise push to left and press speed control To swing clockwise push to right and press speed control To stop release switch or speed control IMPORTANT Arm will not swing more than 360 8 Extens...

Page 36: ...er windshield wiper switch 3 Lower windshield wiper switch 4 Cab pivot control switch Item Description Notes 1 Light switch To turn on press To turn off press 2 Upper windshield wiper switch To spray...

Page 37: ...er fluid on windshield press To start wiper blade move to center To stop wiper blade press 4 Cab pivot control switch To move cab into drilling position disengage cab pivot lock and press To move cab...

Page 38: ...tilt switch 7 Back frame tilt switch 8 Pipe lubricator switch 9 Front wrench clamp switch 10 Rear wrench clamp switch 11 Rear wrench rotation switch Item Description Notes 1 Shuttle stop switch To low...

Page 39: ...ipe gripper switch To close press To open press 5 Pipe shuttle switch To move toward pipe box press To move toward spindle press IMPORTANT Shuttles will not function unless shuttle guard bar on outsid...

Page 40: ...anual Controls 39 Left Control Console 10 Rear wrench clamp switch To unclamp press To clamp press 11 Rear wrench rotation switch To rotate counterclockwise press To rotate clockwise press To stop rot...

Page 41: ...tachometer Item Description Notes 1 Spindle brake switch To engage press To disengage press IMPORTANT Use when making directional change 2 Set resume switch To resume operation or increase operation...

Page 42: ...l Terrain Operator s Manual Controls 41 Left Control Console 3 Rotation speed control To increase turn clockwise To decrease turn counterclockwise 4 Rotation tachometer Displays spindle speed Item Des...

Page 43: ...hometer 6 Inner rotation pressure gauge 7 Inner rotation speed control 8 Manual inner rotation switch 9 Inner spindle switch Item Description Notes 1 Outer spindle brake switch To engage press To dise...

Page 44: ...f switch To set operating conditions or reduce operation levels press white part of switch See Cruise Control on page 174 3 Outer rotation speed control To increase turn clockwise To decrease turn cou...

Page 45: ...ounterclockwise move switch to left To rotate clockwise move switch to right IMPORTANT Inner spindle switch must be in manual position 9 Inner spindle switch To turn on press top To turn off move to c...

Page 46: ...Item Description Notes 1 Cab pivot lock To move cab into drilling position press down and pivot cab into position Lock automatically engages when cab moves into drive position See Cab pivot control s...

Page 47: ...ontrol Console 3 Horn To sound horn press 4 Fluid flow control To increase flow turn clockwise To decrease flow turn counterclockwise 5 Drill drive selector To drill press To set parking brake move to...

Page 48: ...ctor 3 Heater temperature control 4 Air conditioner temperature control Item Description Notes 1 Climate control fan speed selector To select high fan speed press To select medium speed move to center...

Page 49: ...t Control Console 3 Heater temperature control To make air warmer turn clockwise To make air cooler turn counterclockwise 4 Air conditioner temperature control To make air cooler turn clockwise To mak...

Page 50: ...ant temperature gauge 5 Engine oil pressure gauge 6 Main menu key 7 Day Night mode key 8 Voltmeter display 9 Diesel exhaust fluid DEF gauge and indicator 10 Fuel gauge Item Description Notes 1 Tachome...

Page 51: ...ges to select main menu 7 Day Night mode key Press from main screen gauges to toggle between day and night modes 8 Voltmeter display Shows system voltage Normal voltage is 13 14V with engine running 9...

Page 52: ...s under Tier 4 menu Diagnostic information is only available to dealer technicians 2 User settings key Press to select user settings menu User settings menu allows user to change the language and unit...

Page 53: ...erator s Manual Right Control Console Status Indicators Indicators Exhaust cleaning inhibited High hydraulic temperature Engine stop Exhaust cleaning Hydraulic filter restriction Engine caution High e...

Page 54: ...gine display Item Description Notes 1 Drilling fluid pressure gauge Displays discharge pressure of drilling fluid pump IMPORTANT Monitor this gauge and drilling fluid flowmeter carefully to see if val...

Page 55: ...ion pressure gauge Displays hydraulic fluid pressure to rotation motor when spindle is turning 4 Engine display Displays engine speed engine data and diagnostic codes See Diagnostic Codes on page 178...

Page 56: ...home status light 6 Front wrench status light 7 Drilling fluid pump status light Item Description Notes 1 Control cycle light green If nothing is being controlled light is off If system is waiting for...

Page 57: ...Diagnostic Codes on page 178 3 Shuttle home status light If shuttle is retracted light is on If shuttle is extended light is off IMPORTANT This light indicates the shuttle is under the pipe box and o...

Page 58: ...l Console 6 Front wrench status light If front wrench is closed and pressured up light is on If front wrench is open or pressure has dropped light is off 7 Drilling fluid pump status light If pump is...

Page 59: ...tch 4 Track and carriage control 5 Shutdown override switch 6 Ignition switch 7 Remote engine stop switch Item Description Notes 1 Dual speed carriage control To increase carriage travel speed push an...

Page 60: ...d push To move backward pull To steer move right or left while moving Carriage control To move carriage forward push To move carriage backward pull To rotate spindle counterclockwise breakout move rig...

Page 61: ...e insert key and turn clockwise To stop engine turn key counterclockwise IMPORTANT Restart engine with ignition switch after it has been turned off with remote engine stop switch 7 Remote engine stop...

Page 62: ...Operator s Manual Controls 61 Fluid Pump Fluid Pump 1 Light switch 2 Wash wand switch 3 Fluid pressure gauge Item Description Notes 1 Light switch To turn on press To turn off press Controls light at...

Page 63: ...00 JT100 All Terrain Operator s Manual Fluid Pump 2 Wash wand switch To spray press To turn off press 3 Fluid pressure gauge Displays drilling fluid pressure supplied to the pump Item Description Note...

Page 64: ...move to center To select JT mode press right Use AT or AT DIRT drilling mode when using AT pipe with inner shaft Use JT drilling mode when using JT pipe without inner shaft IMPORTANT See Prepare Dril...

Page 65: ...t slide control 2 Seat recline control Item Description Notes 1 Seat slide control To slide forward or backward move left To lock seat in position move right 2 Seat recline control To recline or raise...

Page 66: ...erride switch 5 Rotation or left track override switch Item Description Notes 1 Drive override connector Allows drive function override when box is attached Use switches 4 and 5 to control tracks 2 Dr...

Page 67: ...ve down Connect to drill connector 2 to control thrust pullback Connect to drive connector 1 to control right track 5 Rotation or left track override switch For counterclockwise rotation or to move tr...

Page 68: ...xiliary outlets Supplies power to work lights or other 12V devices Outlet has power only when ignition switch is on 2 Auxiliary outlet Supplies power to 12V devices 3 Driver Loader enable switch To en...

Page 69: ...r to stop thrust and rotation move key to enable position up To override DrillLok mode move key to override position right IMPORTANT Remove key and keep in tracker operator s possession Top icon is sh...

Page 70: ...reline restricted operating mode switches To slow rotation and thrust press top To allow normal rotation and thrust press bottom Used when adding pipe and when making wireline connections A display in...

Page 71: ...ntrols 70 JT100 JT100 All Terrain Operator s Manual Engine Diagnostic Connector Engine Diagnostic Connector Item Description Notes Engine diagnostic connector Connects diagnostic test equipment to uni...

Page 72: ...sconnect switch To connect move switch so that indicator points right To disconnect move switch so that indicator points left Use when servicing unit and during long term storage IMPORTANT Wait 2 minu...

Page 73: ...entage of strike condition The line with the V shows voltage reading and the line with the A shows current reading 2 Strike indicator Red lights come on as values in display increase Light in triangle...

Page 74: ...tage problem indicator Red light indicates a voltage indicator problem See Troubleshoot Strike System on page 153 5 Current problem indicator Red light indicates a current indicator problem See Troubl...

Page 75: ...fficient electrical power for operation Strike system is operating if OK indicator is also on 8 Self test button To start manual self test press To reset system after a strike has been detected press...

Page 76: ...100 JT100 All Terrain Operator s Manual Operation Overview 75 Operation Overview Chapter Contents Planning 76 Setting Up at Jobsite 76 Drilling 77 Backreaming 78 Leaving Jobsite 78 Storing Equipment 7...

Page 77: ...quipment See page 98 6 Load equipment See page 111 Setting Up at Jobsite 1 Prepare jobsite See page 97 2 Unload drilling unit from trailer See page 113 3 Assemble drill string See page 121 4 Position...

Page 78: ...he hole to remove cuttings AT mode only See page 125 5 Record bore path See page 130 6 Enable automated pipeloader system See page 125 7 Add pipe See page 126 8 Drill remaining pipes in pipe box Corre...

Page 79: ...ial 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 informat...

Page 80: ...ervices 81 Examine Pullback Material 81 Arrange for Traffic Control 81 Plan for Emergency Services 81 Inspect Site 82 Select Start and End Points 83 Classify Jobsite 84 Select a Classification 84 Appl...

Page 81: ...Operator s Manual Prepare Jobsite 97 Mark Bore Path 97 Prepare Entry Point 97 Check Supplies and Prepare Equipment 98 Check Supplies 98 Prepare Equipment 99 Select Drilling Mode 100 Prepare Drilling...

Page 82: ...ed before working In the US or Canada call 811 US or 888 258 0808 US and Canada Also contact any local utilities that do not participate in the One Call service In countries that do not have a One Cal...

Page 83: ...s utility facilities without overhead lines gas or water meters junction boxes drop boxes light poles manhole covers sunken ground traffic access soil type and condition water supply sources of locato...

Page 84: ...ng 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 a...

Page 85: ...ted before working Comply with all utility notification regulations before digging or drilling Verify location of previously marked underground hazards Mark jobsite clearly and keep spectators away Re...

Page 86: ...e tracker operator s possession Have service shut down while work is in progress Have electric company test lines before returning them to service Natural Gas Jobsite Precautions In addition to using...

Page 87: ...its 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 precau...

Page 88: ...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...

Page 89: ...the full length of each pipe For JT100 Power Pipe Forged drill pipe make sure pitch A changes no more than 7 6 over the full length of each pipe For JT100 All Terrain drill pipe make sure pitch A chan...

Page 90: ...end in the bore path has a radius A of 197 60 m requires approximately 310 94 5 m of drill pipe B JT100 All Terrain drill pipes have a tested minimum bend radius of 205 62 5 This means that a 90 bend...

Page 91: ...8 ft 5 in 2 6 m 15 180 ft 10 in 55 1 m 108 ft 5 in 33 1 m 5 72 ft 3 in 22 m 13 ft 2 in 4 0 m 16 187 ft 4 in 57 1 m 121 ft 8 in 37 1 m 6 85 ft 10 in 26 2 m 18 ft 10 in 5 7 m 17 192 ft 10 in 58 8 in 13...

Page 92: ...in 16 6 m 135 ft 11 in 41 4 m 21 197 ft 0 in 60 m 197 ft 0 in 60 m 11 65 ft 2 in 19 9 m 146 ft 4 5 in 44 6 m Pipe C Forward B Deflection A Pipe C Forward B Deflection A 1 14 ft 1 in 4 3 m 0 ft 6 in 0...

Page 93: ...ame 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...

Page 94: ...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...

Page 95: ...ft 6 in 16 61 m 2 ft 10 in 0 86 m 7 ft 11 in 2 41 m 12 4 22 58 ft 3 in 17 75 m 3 ft 2 in 0 97 m 9 ft 1 in 2 77 m 13 5 24 62 ft 0 in 18 90 m 3 ft 5 in 1 04 m 10 ft 3 in 3 12 m 14 6 26 65 ft 8 in 20 02...

Page 96: ...18 46 ft 10 in 14 27 m 2 ft 3 in 0 69 m 6 ft 0 in 1 83 m 10 8 19 49 ft 8 in 15 14 m 2 ft 5 in 0 74 m 6 ft 8 in 2 03 m 11 7 21 52 ft 5 in 15 98 m 2 ft 8 in 0 81 m 7 ft 6 in 2 29 m 12 5 22 55 ft 2 in 1...

Page 97: ...1 3 20 53 ft 4 in 16 26 m 2 ft 7 in 0 79 m 7 ft 8 in 2 34 m 12 4 22 57 ft 1 in 17 40 m 2 ft 10 in 0 86 m 8 ft 9 in 2 67 m 13 5 24 60 ft 10 in 18 54 m 3 ft 1 in 0 94 m 10 ft 0 in 3 05 m 14 6 26 64 ft 6...

Page 98: ...prevent bending or straining pipe position drilling unit for straight entry Jobsite hazards could cause death or serious injury Use correct equipment and work methods Use and maintain proper safety e...

Page 99: ...sories bits screens nozzles see Downhole Tools on page 163 adapters pipe beacon housings marking flags or paint water and additional hoses fuel drilling fluid additives see Drilling Fluid on page 157...

Page 100: ...luid engine coolant battery charge engine oil Condition and Function all controls filters air oil hydraulic fluid pump couplers tires and tracks pumps and motors drilling fluid mixer hoses and valves...

Page 101: ...ny other situation with difficult steering because of hard soil conditions All Terrain drill pipe Rockmaster tool 70 000 lb 311 kN of thrust dither inner rotation AT dirt When one bore out of several...

Page 102: ...opriate anchors for jobsite conditions Load All Terrain pipe and pipe box onto unit Move mode selector switch to AT position AT Dirt Mode Verify unit has not been converted to JT mode Ensure All Terra...

Page 103: ...onto unit Move mode selector switch to JT position Assemble Accessories Fire Extinguisher Identify location shown for fire extinguisher Mount a fire extinguisher near the power unit but away from poss...

Page 104: ...JT100 JT100 All Terrain Operator s Manual Prepare 103 Lighting Kit If you will need additional light plug lighting kit into provided outlet Contact your Ditch Witch dealer for further information...

Page 105: ...Prepare 104 JT100 JT100 All Terrain Operator s Manual...

Page 106: ...JT100 JT100 All Terrain Operator s Manual Drive 105 Drive Chapter Contents Start Unit 106 Steer Unit 106 Safe Slope Operation 107 Shut Down Unit 108...

Page 107: ...steer while moving forward push forward toward F and then move to left or right Drilling unit will gradually turn to left or right To steer while moving backward pull back toward R and then move to le...

Page 108: ...ngine angle and braking performance are two absolute limits which must never be exceeded These maximums are stated below since they are design limits These design limits usually exceed the operating l...

Page 109: ...rain Operator s Manual Shut Down Unit Shut Down Unit 1 Stop track movement 2 Move drill drive selector to center position to engage parking brake 3 Run engine at low throttle for 3 minutes to cool 4 T...

Page 110: ...JT100 JT100 All Terrain Operator s Manual Transport 109 Transport Chapter Contents Lift 110 Pipe Box Lifting Procedure 110 Haul 111 Load 111 Tie Down 112 Unload 113 Retrieve 114...

Page 111: ...fications on page 247 for weight of machine Pipe Box Lifting Procedure Pipe box lifting points are identified by lifting decals Lifting at other points is unsafe and can damage machinery Pipe Box Use...

Page 112: ...t onto trailer 9 Lower stabilizers to trailer floor 10 Lower drill frame to trailer floor 11 Stop engine when unit is safely positioned on trailer bed 12 Attach tiedowns to drilling unit where tiedown...

Page 113: ...river loader is in stowed position and stow strap 2 is tight Ensure anchor drive motor is in stowed position 1 Loop tiedowns around unit at tiedown points Make sure tiedowns are tight before transport...

Page 114: ...Remove tiedowns 5 Raise drill frame 6 Raise stabilizers 7 Slow engine to low throttle and slowly back unit down trailer or ramps Crushing weight could cause death or serious injury Use proper procedu...

Page 115: ...tow for short distances at less than 1 mph 1 6 km h attach chains to indicated tow points facing towing vehicle use maximum towing force of 1 5 times unit weight disengage track planetaries To disenga...

Page 116: ...rate Carriage Control 119 Clamp Pipe 120 Assemble Drill String 121 Prepare Beacon Housing 121 Attach Transition Sub 122 Connect Drill Pipe 123 Drill First Pipe 124 JT Mode AT Dirt Mode 124 AT Mode 124...

Page 117: ...Conduct a Bore 116 JT100 JT100 All Terrain Operator s Manual Backream 132 Assemble Backream String 133 Remove Pipe 134 Remove Pullback Device 136...

Page 118: ...To prevent pump cavitation hose must provide 30 psi 2 bar of continuous pressure at the drilling fluid pump inlet 2 Install y strainer between mixing unit and drilling fluid pump Position strainer so...

Page 119: ...eturn mixing transfer pump to normal operating speed and continue the bore Check gauge to ensure at least 30 gpm 113 5 L min of flow 4 If drilling fluid pressure surges are observed repeat step 2 IMPO...

Page 120: ...at 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 IMPORTANT On units equipped with assi...

Page 121: ...e tool joint face Read operator s manual Know how to use all controls Your safety is at stake 273 475 To help avoid injury Ensure that any downhole tool or pipe in wrenches is attached to spindle or r...

Page 122: ...w beacon instructions to check beacon operation 7 Follow tracker instructions to calibrate beacon JT mode AT dirt mode AT mode 1 beacon housing 2 bit 3 transition sub 4 JT100 drill pipe 1 beacon housi...

Page 123: ...chine 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 Quick Wrench 1 Lube joints with tool joint com...

Page 124: ...Lubricate threads on transition sub Move pipe to spindle Raise pipe in box 5 Connect pipe Move carriage forward until SaverLok body nears male pipe thread Slowly rotate spindle clockwise Carriage will...

Page 125: ...pindle brake 4 Rotate inner spindle clockwise 5 Slowly move carriage forward Drill first pipe as straight as possible 6 Monitor gauges If inner rotation pressure approaches 1600 psi 110 bar slow carri...

Page 126: ...ll frame open front wrench and retract shuttles for add pipe function to work 3 Press top front of add pipe manual remove pipe switch 4 Green control cycle light will come on grippers will open pipe w...

Page 127: ...of frame Clamp pipe joint See Clamp Pipe on page 120 Locate drill head Engage front wrench until pipe is clamped and pressure develops Slowly rotate spindle counterclockwise Carriage will move back au...

Page 128: ...every half length of pipe IMPORTANT Always rotate clockwise unless breaking pipe joint Rotating counterclockwise will unscrew joints Manual Pipeloader Controls Automated Pipeloader Control Slowly move...

Page 129: ...rotation All corrections should be made as gradually as possible See Recommended Bend Limits on page 88 Over correcting will cause snaking This can damage pipe and will make drilling and pullback mor...

Page 130: ...l Head Position The drill head position is determined by reading beacon roll Roll is displayed as a clock face position 1 Read beacon roll 2 Slowly rotate pipe until tracker displays desired beacon ro...

Page 131: ...he procedure In addition draw a simple sketch of the site and record depth and rough location of pullback Subsite Electronics bore tracking software is also available for plotting and tracking your bo...

Page 132: ...ion as soon as drill head emerges 5 Clean drill head especially around threads 6 Disconnect EZ Connect joint or use Hydratong wrenches to remove drill head Keep threads clean See Hydratong Wrenches on...

Page 133: ...ds could cause death or serious injury Use correct equipment and work methods Use and maintain proper safety equipment 274 050 274 724 2P To help avoid injury Continue to use strike system during back...

Page 134: ...heck beacon operation 7 Follow tracker instructions to calibrate beacon 8 Use quick wrenches to attach transition sub to drill pipe string See Hydratong Wrenches on page 168 9 Use quick wrenches to at...

Page 135: ...tinue tracking when the backream string is no longer visible Remove Pipe 1 Enable automated pipeloader system automated pipeloader control only See page 125 2 Stop carriage when pipes are aligned in w...

Page 136: ...h Move carriage back until front end of pipe is positioned inside front end of pipe box Stop rotation and grip pipe Rotate spindle counterclockwise until saver sub is unscrewed from pipe Move carriage...

Page 137: ...g the bore path has been reached Remaining pipe is then pulled back and removed 1 Press bottom of drilling unit throttle switch until engine is at low throttle 2 Turn off drilling fluid 3 Turn drillin...

Page 138: ...ctric Strike System 151 FCC Statement 151 Assemble Voltage Detector 152 Test Strike System 152 Troubleshoot Strike System 153 Use Electric Strike Simulator 155 Drilling Fluid 157 Guidelines 157 Polyme...

Page 139: ...orm Regular Drill Pipe Care 171 Use Drill Pipe Correctly 173 Cruise Control 174 Engage 174 Adjust Settings 175 Override 175 Disengage 175 Resume 175 Wireline Tracking 176 Operation 176 Diagnostic Code...

Page 140: ...f 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...

Page 141: ...until it rests on ground 2 Remove pull pins 1 3 Ensure that anchor driver is attached to loader driver and slowly swing loader driver boom to front of drilling unit 4 Attach anchor driver to auger sh...

Page 142: ...9 Detach anchor driver from auger shaft 10 Lower nut driver onto auger shaft and over nut 11 Attach anchor driver to nut driver 12 Use loader driver rotation and boom controls to slowly rotate nut dri...

Page 143: ...tation and boom controls to slowly remove auger from ground Electric shock will cause death or serious injury Stay away 274 049 To help avoid injury Maintain minimum clearance of 10 3 m between loader...

Page 144: ...r caps 6 Detach anchor driver from auger shaft and raise loader driver to safe position 7 Insert pull pins to connect ratchet binders to drill frame 8 Rotate ratchet binders to fully raise anchor plat...

Page 145: ...d unit and check for obstructions before moving load Keep objects and personnel clear of loader driver path during operation Do not take your eyes off moving load Always look in the direction load is...

Page 146: ...f the load 4 Release loader driver stow strap 5 Using loader driver remote control module slowly swing loader driver arm to pipe box Pipe Box Step Use the pipe box step when loading and unloading pipe...

Page 147: ...ver boom and extension controls to lift and move one pipe box 6 Return loader driver to stow position and secure with stow strap before transporting NOTICE Lift only one pipe box at a time Before lift...

Page 148: ...ve box 5 Insert pins shown into ends of box and lock AT pins into position 6 Detach loader driver shackle and chains before drilling 7 Lift pipes and remove pins under pipe at each end of pipe box NOT...

Page 149: ...on Turn on loader driver enable switch Main relief valve setting too low or not working properly Check and adjust Poor loader driver performance Pump speed Check pump size and engine speed for proper...

Page 150: ...ft Overload Remove overload Holding valve relief set too low Replace as required Damaged cylinder Repair Dirt in holding or check valve Cycle under no load to reset clean and or replace Air in hydraul...

Page 151: ...sted properly Check amplifier setup and output Trigger potentiometer voltage output not changing Check trigger voltage output Power relay not operating correctly Check relay wiring Loader Driver opera...

Page 152: ...mmediately contact your local Ditch Witch dealer to have the electric strike system tested FCC Statement The Electric Strike System has been tested and found to comply with the limits for a Class A di...

Page 153: ...sfully 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 remai...

Page 154: ...more than 10V Defective control module Have control module checked or replaced Defective CAN bus connection Ensure CAN cable from drilling unit to ESID control module is connected dc513 Test Wire sho...

Page 155: ...4 20 40 ohms from pin 1 to pin 2 and less than 1 ohm from pin 2 to pin 4 Defective current transformer cable 1 Disconnect cable from transformer and control module 2 Check continuity of cable 3 If co...

Page 156: ...ead 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 syst...

Page 157: ...ne 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 Vol...

Page 158: ...Ditch Witch dealer for soil conditions and drilling fluid recommendations for your area Polymer This drilling fluid additive provides excellent lubrication and increases viscosity in average soils and...

Page 159: ...For information on measuring funnel viscosity see Funnel Viscosity on page 161 Mixtures Bentonite does not mix well in water containing polymer To use both mix bentonite first then add polymer When ad...

Page 160: ...to reduce loss of returns sand gravel clay or shale 35 40 lb 16 18 kg Bore Gel 5 pt 235 mL EZ Mud 5 gal 2 L Con Det Vary mixture according to percentage of sand and clay clay 5 lb 225 g Poly Bore 5 ga...

Page 161: ...availability Drilling fluid Water supply If more water than can be carried with the unit will be needed arrange to transport additional water Bentonite and or polymer 3 Check water quality Use meter...

Page 162: ...ner take a fresh sample of drilling fluid The sample must be at least 1 5 qt 1 4 L 2 With finger over bottom of funnel fill with fluid from the container through the screen until fluid reaches the bot...

Page 163: ...mode any time you change downhole tools or during other times when the drill string is exposed If you are not using DrillLok mode turn off drilling unit before changing downhole tools NOTICE This mode...

Page 164: ...These charts are meant as a guideline only No one bit works well in all conditions See your Ditch Witch dealer for soil conditions and bit recommendations for your area 1 best 2 good 3 fair 4 not rec...

Page 165: ...n is installed correctly in housing see beacon information Soil Description sandy soil sugar sand blow sand or other soils where sand is the predominant component soft soil sandy loam medium soil loam...

Page 166: ...1 best 2 good 3 fair 4 not recommended Backreamer Sandy Soil Soft Soil Medium Soil Hard Soil Rocky Soil Soft Rock Hard Rock Beavertail 3 1 1 1 3 4 4 Three Wing 4 3 3 2 1 1 4 Water Wing 4 3 2 1 2 2 4...

Page 167: ...sful Instructions Example 1 Find amount of fluid needed for your size of backreamer See the table on the next page U S A 6 backreamer requires at least 1 47 gal ft Metric A 152 mm backreamer requires...

Page 168: ...18 in 457 mm 13 22 164 17 5 5 in 139 mm 1 23 15 33 18 5 in 470 mm 13 96 173 42 6 in 152 mm 1 47 18 24 19 in 483 mm 14 73 182 92 6 5 in 165 mm 1 72 21 41 19 5 in 495 mm 15 51 192 68 7 in 178 mm 2 00 24...

Page 169: ...th pipe diameter 4 1 2 in to 5 in 11 43 cm to 12 7 cm To accommodate 3 5 8 in to 4 3 8 in 9 2 cm to 11 1 cm pipe remove one chain link Read operator s manual Know how to use all controls Your safety i...

Page 170: ...Method on page 170 6 Connect Hydratong power pack to cylinder 7 To tighten or loosen joint move shuttle valve handle 2 shown toward the A position on pump and press power switch 1 shown to extend cyl...

Page 171: ...ing line A 2 To join scribe second line B on moveable side of joint in the opposite direction of tightening action Refer to table for correct dimension Connection Dimension transition sub to JT100 pip...

Page 172: ...ghten joint 3 Break joint 4 Move pipe back to box Lubricate Joints Before Each Use Lubricate threads and shoulders of male joints with copper base tool joint compound This prevents rust and reduces we...

Page 173: ...place SaverLok body any time when its thread condition is not better than thread condition of your drill pipe Failing to replace SaverLok body will result in damaged drill pipe See Change Auto Lubrica...

Page 174: ...nt Clamp Pipe Correctly Clamp on pipe when joint is between wrenches but as near front wrench as possible Clamp only on the tool joint of the drill pipe as shown This portion of the drill pipe is desi...

Page 175: ...threads fully separate Do not Overwork the Pipe Never exceed the bend radius for your pipe See Plan Bore Path on page 87 Do not oversteer Cruise Control During the bore you can set the desired thrust...

Page 176: ...f carriage travel Green control cycle light will go off Resume 1 Position joystick out of neutral in direction of carriage travel 2 Press resume Green control cycle light will come on Setting Instruct...

Page 177: ...line tracking specialist s activity at the front and rear of the machine Operation IMPORTANT This section is intended as an overview for the JT100 drilling unit operator During most bores a wireline t...

Page 178: ...pipe Insert the other end rear of machine through the spindle gearbox and water swivel 5 Use the pipeloading controls to move the new pipe into position and makeup the joint 6 The wireline tracking sp...

Page 179: ...two levels of severity A non essential code affects non essential functions of the unit If the system detects a non essential problem a diagnostic code will be recorded and the diagnostic light will...

Page 180: ...ht red begins to flash approximately 2 seconds IMPORTANT Do not turn off ignition Diagnostic codes are cleared each time ignition is turned off View All Codes View Codes Individually 1 Ensure that eng...

Page 181: ...sume switch until the Control Cycle light green turns on and the Diagnostic light red begins to flash approximately 2 seconds 2 Count the flashes as described above The first time will flash code 12 w...

Page 182: ...p solenoid add pipe or remove pipe is aborted and code is stored non essential 042 PIPE RELEASE no continuity to pipe release solenoid add pipe or remove pipe is aborted and code is stored non essenti...

Page 183: ...NNER ROT SPD inner rotation position sensor not changing dither compensation is blocked non essential 234 ADDP REMP SW add pipe and remove pipe inputs both on add pipe and remove pipe are blocked non...

Page 184: ...lay may not be able to reset ESID 515 STR VOLT strike voltage input error 516 STR COIL strike current input error 517 POST AC V self test ac voltage input error self test of ac voltage stake failed 51...

Page 185: ...T100 All Terrain Operator s Manual Diagnostic Codes 588 EEP WRITE EEProm write error ESID may not be able to record strike history 589 MISC CODE invalid error report entry software error report Code D...

Page 186: ...JT100 All Terrain Operator s Manual Complete the Job 185 Complete the Job Chapter Contents Antifreeze Drilling Unit 186 Rinse Equipment 187 Disconnect 188 Stow Tools 188 Prepare Drilling Unit to Load...

Page 187: ...en antifreeze tank and drilling fluid pump 4 Open valves under water pressure gauges in cab 1 and on fluid pump 2 5 Turn drilling fluid potentiometer counterclockwise to zero position 6 Start unit and...

Page 188: ...controls Your safety is at stake 273 475 To help avoid injury Never use high flow when using washwand Prime the drilling fluid pump before operating washwand Failure to prime the drilling fluid pump...

Page 189: ...rame 4 Disconnect and store the following hoses and cables if used electric cable electric strike system voltage stake fluid hose Stow Tools Make sure all wrenches bits pullback devices and other tool...

Page 190: ...190 Working Under Drilling Unit 191 Service and Lubrication Overview 192 Recommended Lubricants Service Key 193 Approved Coolants 194 Approved Fuel 194 Diesel Exhaust Fluid DEF 195 Each Use 197 Startu...

Page 191: ...currents can damage electronic components Always disconnect the ECU ground connection from the frame harness connections to the ECU and other electronic components prior to welding on machine or atta...

Page 192: ...y a cylinder make sure drilling unit is parked on hard surface 1 Remove cylinder locks from storage at rear of pipe box and place over extended cylinder rods shown with curved ends toward stabilizer s...

Page 193: ...Service 192 JT100 JT100 All Terrain Operator s Manual Service and Lubrication Overview Service and Lubrication Overview...

Page 194: ...n Automobile Manufacturer s Association DEF Diesel exhaust fluid DEF meeting ISO 22241 1 or DIN 70070 DEAC Diesel engine antifreeze coolant meeting CES 14603 See Approved Coolant on page 194 PTF Power...

Page 195: ...quality fuel meeting ASTM D975 No 2D EN590 or equivalent At temperatures below 32 F 0 C winter fuel blends are acceptable See the engine operation manual for more information Biodiesel blends up to 5...

Page 196: ...ited shelf life In ideal conditions minimum expected shelf life is 18 months At temperatures higher than 90 F 32 C DEF will degrade more rapidly Do not store in direct sunlight Storage and transfer eq...

Page 197: ...ey on page 51 for the duration of the job and return to automatic cleaning when the job is finished The exhaust cleaning inhibited icon will light and remain on until the system is returned to automat...

Page 198: ...Each Use Drilling Unit Lube Water Swivel Lube water swivel with 5 6 pumps before first use and every 4 hours JT two zerks shown AT two zerks shown Location Task Notes DRILLING UNIT Lube water swivel M...

Page 199: ...zerk 2 Inject WRG into zerk 3 Continue pumping until grease seeps into gap between tool body and the bit 4 Remove grease gun and step away Communicate to drill operator to rotate bit 5 Repeat steps 2...

Page 200: ...ILLING UNIT Check fuel filter water separator Check engine oil level DEO Check fluid pump piston seals Check engine coolant level Check hydraulic hoses Check hydraulic fluid level Check fluid pump oil...

Page 201: ...before startup and every 10 hours of operation Check with unit on level surface Add DEO at fill 1 as necessary to keep oil level at highest line on dipstick Check Fluid Pump Piston Seals Check piston...

Page 202: ...s If low add approved coolant at fill 1 according to instructions on page 229 Contents under pressure Relieve pressure before opening Death or injury could occur To help avoid injury Do not remove the...

Page 203: ...hands to search for leaks Wear protective clothing including gloves and eye protection Before disconnecting a hydraulic line turn engine off and operate all controls to relieve pressure Lower block or...

Page 204: ...ass shown when unit is on level ground engine is off and fluid is cool Add THF at hydraulic fluid fill as needed Check Fluid Pump Oil Level Check fluid pump oil level at sight glass 2 before startup a...

Page 205: ...artup and every 10 hours of operation and clean or replace as needed 1 Pipe guard switch 2 Front home switch 3 Shuttle home switch 4 Rear home switch 5 Rear stop switch To test 1 Turn ignition switch...

Page 206: ...eck Pipe Auto Lubricator Level Check pipe auto lubricator TJC level before startup and every 10 hours of operation Change pail as needed See Change Auto Lubricator Pail on page 235 for procedure NOTIC...

Page 207: ...y 10 hours of operation Ensure that strainer is free of debris Check JT Fluid Pump Liner Wash Level Check fluid level at petcock 2 before startup and every 10 hours of operation Add antifreeze and fre...

Page 208: ...pty dust ejector valve shown before startup and every 10 hours of operation Ensure that valve is not inverted damaged plugged or cracked 25 Hour Drilling Unit Lube Rear Wrench Lube two fittings one on...

Page 209: ...p oil Initial service PTF Check radiator Change hydraulic filters Initial service Change remote charge filter Initial service Check ground drive gearbox oil level 2 gearboxes MPL Check rotation gearbo...

Page 210: ...ge Hydraulic Filters Initial Service Change hydraulic filter after first 50 hours Replace filter every 500 hours thereafter Change filter more often if indicated by filter indicator Change Remote Char...

Page 211: ...ery 50 hours Park unit on level surface and move carriage down drill frame until it is even with cab Swing cab out for access to gearbox Add MPL as needed 1 Remove barbed fitting from port on right si...

Page 212: ...r has drained tighten plug Check Anchor Driver Gearbox Oil Level Check anchor driver gearboxes oil level every 50 hours To check Lay anchor driver on its side Oil should be level with plug 1 Add MPL a...

Page 213: ...stub 1 and spring 2 off of drive shaft 3 Check condition of hex stub 3 and replace if needed 4 Check o ring on inner water swivel seal kit and replace if needed 5 Install new spring and hex stub 6 Ins...

Page 214: ...ivel shown to separate water swivel casing 4 inspect inner parts for damage See Change Water Swivel Components on page 239 5 Replace water swivel screws 6 Install water swivel in the gear box using ni...

Page 215: ...ckmaster Tool Rebuild downhole tool every 50 hours as measured by inner rotation hourmeter Use kits indicated by the chart below to rebuild downhole tool Kits are available at your Ditch Witch dealer...

Page 216: ...Check Track Sprocket Bolts Check track sprocket bolts shown every 100 hours Tighten to 350 ft lb 475 N m Apply Loctite 242 any time bolts are removed Location Task Notes DRILLING UNIT Lube stabilizer...

Page 217: ...5 N m Apply Loctite 242 any time bolts are removed Loader Driver Lube Rotation Bearing Lube zerk with MPG every 100 hours of loader driver operation To access zerk remove cover from side of unit If ze...

Page 218: ...your Ditch Witch dealer for parts 250 Hour Drilling Unit Change JT Drilling Fluid Planetary Oil Change every 250 hours Remove oil at fill 1 Add MPL until oil comes out level plug 2 Replace plugs Loca...

Page 219: ...intake piping 1 for cracked hoses loose clamps or punctures 2 Inspect seal 2 for damage 3 Verify a positive seal to door 4 Tighten or replace parts as necessary Loader Driver Check Swing Drive Gearbox...

Page 220: ...lace plug 2 Remove filter 3 and replace with new filter each time oil is changed 3 Add DEO at fill 1 Change Fuel Filters Replace filters every 500 hours Location Task Notes DRILLING UNIT Change engine...

Page 221: ...Service 220 JT100 JT100 All Terrain Operator s Manual 500 Hour Loader Driver Change Swing Drive Gearbox Oil Drain oil at plug 2 every 500 hours Add MPL at fill plug 1 until oil is level with plug...

Page 222: ...earbox oil 2 gearboxes MPL Change AT rotation gearbox oil 2 gearboxes MPL Change thrust drive gearbox oil 2 gearboxes MPL Change spindle brake oil THF Change AT fluid pump oil PTF Lube AT SaverLok wre...

Page 223: ...itial Service on page 209 3 Add THF at fill 1 until level is at halfway point on sight glass 2 IMPORTANT If ambient temperature exceeds 100 F 37 C for 50 of time change oil and filter every 500 hours...

Page 224: ...g 3 and remove plugs 1 and 2 4 Add MPL at plug 1 until oil comes out plug 2 5 Install plugs 1 and 2 Change JT Rotation Gearbox Oil Move carriage down drill frame until it is even with cab Swing cab ou...

Page 225: ...ive Gearbox Oil Change thrust drive gearbox oil every 1000 hours Capacity is 26 oz 0 77 L of MPL per gearbox To change 1 Ensure that drill frame is level 2 Remove six plugs 1 and drain oil from each g...

Page 226: ...apacity is 5 oz 148 mL Change AT Fluid Pump Oil Change oil after first 50 hours and every 1000 hours thereafter Maintain fluid level at halfway point on sight glass or at petcock level 2 Drain at plug...

Page 227: ...and debris 5 Install new belt Change Diesel Exhaust Fluid DEF Tank Filter Change DEF filter shown every 1000 hours Contact your Ditch Witch dealer for more detailed information 1 Remove multifunction...

Page 228: ...JT100 JT100 All Terrain Operator s Manual Service 227 1000 Hour Loader Driver Grease Loader Driver Swivel Lube loader driver swivel zerk with MPG every 100 hours of loader driver operation...

Page 229: ...lug 3 Ensure that the drain plug is cleaned of debris before reinstalling 2 Add 12 qt 11 3 L of PTF at fill 1 until oil level is at middle of sight tube 2 Location Task Notes DRILLING UNIT Change JT f...

Page 230: ...ur To help avoid injury Do not remove the pressure cap from a hot engine Wait until the coolant temperature is below 122 F 50 C before removing pressure cap Do not stand near or over the expansion tan...

Page 231: ...9 With the pressure cap removed start the engine and increase the speed to high throttle 10 Let the engine run until the thermostat opens approximately 10 minutes 11 Shut engine off and allow it to co...

Page 232: ...1 Disconnect crankcase ventilation hose 2 Turn breather housing cover knob counterclockwise and remove securing screws 3 Remove filter element shown 4 Install the new filter element either end up in...

Page 233: ...it is not cut frayed or showing signs of extreme or unusual wear Check the area near the buckle and latch and anywhere the seat belt has contact with equipment or seat Retractor Check that the retrac...

Page 234: ...ement 3 using disposable service tool 4 To install 1 Slide DEF filter equalizing element 2 into the DEF filter cartridge 3 2 Insert filter equalizing element and filter cartridge assembly into the DEF...

Page 235: ...nytime system is opened Check pipeloader inserts Check front pipe guard inserts Check fluid pump ball valve Check wrench jaw inserts Change air filter Check SaverLok body TJC Clean crankcase breather...

Page 236: ...Press firmly on follower plate until TJC comes up in center opening 4 Remove empty pail from TJC pail holder 5 Install new pail into TJC pail holder 6 Insert pump dip tube through hole in follower pla...

Page 237: ...for replacement parts Check Front Pipe Guide Inserts Check front pipe guide inserts 2 for wear Rotate inserts for longer wear or replace as needed To replace 1 Remove lynch pins 1 and open pipe guide...

Page 238: ...k Fluid Pump Ball Valve Check ball valve for leaks Tighten stem packing as needed See your Ditch Witch dealer for replacement packing Check Wrench Jaw Inserts Check front and rear inserts and hardware...

Page 239: ...on of primary filter is as shown 5 Close air filter case Check SaverLok Body Check SaverLok body and replace as needed See your Ditch Witch dealer for replacement parts To replace 1 Remove nine bolts...

Page 240: ...ws from the water swivel shown to separate water swivel casing 4 Remove damaged parts 5 Replace internal parts with a packing set 500 2810 and seals only with a seal kit 500 2811 6 Lightly coat seals...

Page 241: ...increases dramatically or after rebuild Check maximum pump flow by capping saver sub to deadhead drilling fluid flow and measuring pressure Reading should be no more than 6450 50 psi 445 3 bar Adjust...

Page 242: ...nd recoil stop bars 3 Clean track cylinder zerk 1 4 Use 7 8 button head coupler on grease gun 5 Add MPG to increase track tension until recoil stop bars 4 can be removed 6 Re insert recoil stop bars 7...

Page 243: ...le clamps carefully negative cable first 4 Clean cable clamps and terminals to remove dull glaze 5 Check for signs of internal corrosion in cables 6 Connect battery cable clamps positive cable first 7...

Page 244: ...llow directions carefully To help avoid injury Use a single 12V maximum source for charging Do not connect to rapid chargers or dual batteries Use caution and wear personal protective equipment such a...

Page 245: ...the engine or frame ground on the disabled vehicle at least 12 305 mm from the failed battery as shown 7 Operate service vehicle engine at 1500 2000 rpm for a few minutes to build an electrical charg...

Page 246: ...JT100 JT100 All Terrain Operator s Manual Service 245 As Needed Driver Loader Lube Boom Extensions Lube top and bottom of entire length of boom extensions with MPG as needed for smooth operation...

Page 247: ...Service 246 JT100 JT100 All Terrain Operator s Manual As Needed...

Page 248: ...machine width per SAE J2022 101 in 2 57 m H overall machine height per SAE J2022 110 in 2 79 m Entry angle per SAE J2022 10 15 10 15 Angle of approach 13 13 Angle of approach with cab step removed 18...

Page 249: ...Minimum bend radius 205 ft 63 m Weight per SAE J2022 229 lb 104 kg Weight 12 drill pipe and box 3760 lb 1710 kg All Terrain Pipe U S Metric Length without inner pipe per SAE J2022 169 5 in 4 3 m Joint...

Page 250: ...00 lb 311 kN actual JT and AT dirt modes per SAE J2022 70 000 lb 311 kN Pullback force 100 000 lb 445 kN Carriage thrust travel speed per SAE J2022 150 fpm 46 m min Carriage pullback travel speed per...

Page 251: ...88 in 124 mm Power manufacturer s gross power rating SAE J1995 260 hp 194 kW estimated net power rating per SAE J1349 257 hp 192 kW rated speed 2200 rpm 2200 rpm peak gross power at 2000rpm 270 HP 20...

Page 252: ...ic Fuel tank 97 gal 370 L Hydraulic reservoir 47 gal 180 L Engine oil including filter 19 qt 18 L Engine cooling system 14 3 gal 53 L Fluid pump liner wash tank 3 5 gal 13 L Antifreeze tank 27 gal 102...

Page 253: ...l Ditch Witch XXXX Type machine type Engine Power xxx kW Serial Number CMWXXXXXXXXXXXXXX Conforms to the requirements of 2006 42 EC Machinery Directive 2004 108 EC Electromagnetic Compatibility Direct...

Page 254: ...JT100 JT100 All Terrain Operator s Manual Service Record 253 Service Record Service Performed Date Hours...

Page 255: ...Service Record 254 JT100 JT100 All Terrain Operator s Manual Service Performed Date Hours...

Page 256: ...of purchase Return damaged parts to dealer for inspection and warranty consideration if in warranty time frame Order genuine Ditch Witch replacement or repair parts from your authorized Ditch Witch d...

Page 257: ...ARTICULAR PURPOSE AND MERCHANTABILITY IF THE PRODUCTS ARE PURCHASED FOR COMMERCIAL PURPOSES AS DEFINED BY THE UNIFORM COMMERCIAL CODE THEN THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE FACE HEREOF A...

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Page 260: ...JT100 JT100 All Terrain Operator s Manual Appendix 259 Appendix Chapter Contents Engine Diagnostic Codes...

Page 261: ...Crankcase Pressure Data valid but above normal operational range Most Severe Level X X 101 2 1942 Crankcase Pressure Data erratic intermittent or incorrect X X 101 3 1843 Crankcase Pressure Circuit Vo...

Page 262: ...X 411 3 2273 Exhaust Gas Recirculation Differential Pressure Sensor Circuit Voltage above normal or shorted to high source X X 411 4 2274 Exhaust Gas Recirculation Differential Pressure Sensor Circuit...

Page 263: ...or 1 Circuit Voltage above normal or shorted to high source X X 974 4 134 Remote Accelerator Pedal or Lever Position Sensor 1 Circuit Voltage below normal or shorted to low source X X 974 19 288 SAE J...

Page 264: ...ntroller Out of Calibration X X 2791 15 1961 EGR Valve Control Circuit Over Temperature Data Valid But Above Normal Operating Range Least Severe Level X X 3031 2 1679 Aftertreatment 1 Diesel Exhaust F...

Page 265: ...rmal or shorted to high source X X 3513 4 1696 Sensor Supply 5 Voltage below normal or shorted to low source X X 3514 3 515 Sensor Supply 6 Circuit Voltage above normal or shorted to high source X X 3...

Page 266: ...X 4376 3 3577 Aftertreatment Diesel Exhaust Fluid Return Valve Voltage above normal or shorted to high source X X 4376 4 3578 Aftertreatment Diesel Exhaust Fluid Return Valve Voltage below normal or...

Page 267: ...treatment Selective Catalytic Reduction Temperature Sensor Module Voltage below normal or Shorted to low source X X 5743 9 4152 Aftertreatment Selective Catalytic Reduction Temperature Sensor Module A...

Page 268: ...itch Position Sensor Circuit Voltage Below Normal or Shorted to Low Source X X 520784 5 5185 Fan Blade Pitch Mechanical system not responding or out of adjustment X X 520808 31 5291 Engine Emergency S...

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