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Ditch Witch JT40, Operator'S Manual

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Ditch Witch JT40 Operator'S Manual Download Page 204

JT40/JT40 All Terrain Operator’s Manual

Service - 203

Recommended Lubricants/Service Key

Proper lubrication and maintenance protects Ditch Witch

®

 equipment from damage and failure. Service 

intervals listed are for minimum requirements. In extreme conditions, service machine more frequently. 
Use only genuine Ditch Witch parts, filters, approved lubricants, TJC, and approved coolants to maintain 
warranty. Fill to capacities listed in “Specifications” on page 241. 

For more information on engine lubrication and maintenance, see your engine manual. 

Approved Coolant

This unit was filled with coolant meeting Cummins

®

CES 14603 

(

blue

 in color) before shipment from 

factory. Add or replace only with coolant meeting this specification, such as Fleetguard

®

 ES Compleat

™

coolant. This coolant is available, pre-diluted, from your Ditch Witch dealer as part number 255-1055. 
Contact your Cummins service partner for a full list of approved coolants meeting 

CES 14603

. In an 

emergency, non-Cummins approved, heavy duty diesel engine coolant meeting ASTM D6210 may be 
used. Change to 

CES 14603

 coolant as soon as practical.   

IMPORTANT: 

 Use the “Service Record” on page 251 to record all required service to your machine.

NOTICE:

•

Use only pre-diluted coolant or concentrated coolant mixed with distilled water. Do not use tap 
water. 

•

Do not use water or high-silicate automotive-type coolant. This will lead to engine damage or 
premature engine failure. 

•

Do not mix heavy-duty diesel engine coolant and automotive-type coolants. This will lead to coolant 
breakdown and engine damage. 

Summary of Contents for JT40

Page 1: ...JT40 JT40 All Terrain HRC and LRC Issue 1 0 Original Instruction Operator s Manual 053 2966 ...

Page 2: ... 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 About This Manual 6 Bulleted Lists 6 Numbered Lists 6 Continued Indicators 6 ...

Page 3: ...al Number 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 serial number engine serial number j59om059w eps ...

Page 4: ...d contrary to the intended use The JT40 JT40 All Terrain should be used with genuine Ditch Witch drilling fluid units and Subsite Electronics tracking equipment It should be operated serviced and repaired only by persons familiar with its particular characteristics and acquainted with the relevant safety procedures Equipment Modification This equipment was designed and built in accordance with app...

Page 5: ...it Components 1 Operator s station 2 Spindle 3 Carriage 4 Drill frame 5 Stabilizer 6 Tracks 7 Pipeloader 8 Vise wrenches 9 Anchoring system 10 DrillLok light green 11 Wireless remote control light clear 12 ESID strobe light amber 1 2 3 4 5 6 7 8 9 12 10 11 j59om060w eps ...

Page 6: ...y with RF exposure 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 body This equipment has been tested and found to comply with the limits for a Class B digital device pursuant to Part 15 of the FCC rules These limits are designed to provide reasona...

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 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 IMP...

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 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...

Page 9: ...4 16 Part number 053 2966 Copyright 2017 by The Charles Machine Works Inc Subsite Jet Trac Fluid Miser Power Pipe Rockmaster SaverLok SaverLok System and DrillLok are registered trademarks of The Charles Machine Works Inc This product and its use may be covered by one or more patents at http patents charlesmachine works ...

Page 10: ...lling product and restoring the jobsite with cross references to detailed procedures 79 Prepare procedures for inspecting and classifying the jobsite planning the installation path and preparing the jobsite for work 83 Drive procedures for startup cold start driving and shutdown 107 Transport procedures for lifting hauling and towing 113 Conduct a Bore procedures for drilling and backreaming 119 S...

Page 11: ...ghts measurements power ratings and fluid capacities 241 Support the warranty policy for this machine and procedures for obtaining warranty consideration and training 247 Service Record a record of major service performed on the machine 251 Appendix additional information about Ditch Witch equipment 253 ...

Page 12: ...nes 12 California Proposition 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 Safety Alert Classification 17 Machine Safety Alerts 18 ...

Page 13: ...al protective equipment Review jobsite hazards safety and emergency procedures and individual responsibilities with all personnel before work begins Safety videos are available from your Ditch Witch dealer or at www ditchwitch com safe Safety Data Sheets SDS are available at www ditchwitch com support Fully inspect equipment before operating Repair or replace any worn or damaged parts Replace miss...

Page 14: ... 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 Jobsite hazards could cause death or serious injury Use ...

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 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 of...

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 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 Fire or explosion possible Fumes could ignit...

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 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 cont...

Page 18: ...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 moderat...

Page 19: ...Safety Alerts Machine Safety Alerts 1 DANGER stripe decal See Parts Manual for replacement part numbers 2 Tiedown location See Transport chapter for more information 274 318 3 Crushing weight Place cylinder lock on extended cylinder and secure 273 231 273 413 ...

Page 20: ...se all controls Your safety is at stake 273 475 7 Electric shock will cause death or serious injury Stay away 274 049 8 Turning shaft will kill you or crush arm or leg Stay away 274 187 9 Moving parts Crushing could cause death or severe injury Use correct procedures and equipment Stay away from moving parts and their range of movement 274 204 10 Moving parts could cut off hand or foot Stay away 2...

Page 21: ... and work methods Use and maintain proper safety equipment 14 Pressurized fluid or air could pierce skin and cause severe injury Refer to operator s manual for proper use 270 6035 15 Emergency exit Pull pin and lift rear window to exit cab in case of emergency 270 6859 16 Lift point See Transport chapter for more information 274 442 17 Crushing weight could cause death or serious injury Stay away ...

Page 22: ... Console 31 Pipeloading Controls 31 Drilling Operation Controls 35 Miscellaneous Controls 42 Right Control Console 44 Lower Display 47 Upper Display 50 Open Station Seat 63 Cab Optional 64 Controls 64 Seat 67 Engine Compartment 69 Auxiliary Pipeloading 72 Wireline Optional 74 Controls 74 Wireline Restricted Operating Mode ROM 75 Battery Disconnect 77 ...

Page 23: ...icator 2 Ignition switch 3 Engine shutdown override switch 4 Wash wand switch 5 Left track switch 6 Right track switch Item Description Notes 1 Cold start wait indicator Lights when intake air pre heater is operating NOTICE If indicator is on wait until it goes out before starting engine j59om001w eps 1 2 3 4 5 6 ...

Page 24: ...gine shutdown for 30 seconds This control allows a temporary override of engine shutdown NOTICE After 30 seconds engine will again shut down unless fault condition has been corrected IMPORTANT See Electronic Controlled Engine Overview on page 191 4 Wash wand switch To turn wash wand on press top To turn wash wand off press bottom 5 Left track switch To move forward press top To move backward press...

Page 25: ...dicator 2 Power status indicator 3 Power start horn switch 4 Right multifunction joystick 5 Operator presence switches 6 Engine stop 7 Drive mode switch 8 Left multifunction joystick 9 Throttle switch 10 Menu select switch 11 LCD display IMPORTANT Operator station must be empty to operate wireless ground drive control ...

Page 26: ...blinks green Release switch Wireless remote control light page 4 will shine To start operation hold switch up with joystick controls in neutral position until horn sounds Release switch To use horn move switch up Release switch to stop horn To turn power off hold switch down until LED indicators go off Transmitter shuts off and yellow LED indicator blinks after 1 minute of inactivity Hold switch u...

Page 27: ...speed move up To decrease engine speed move down Release switch to stop speed adjustment IMPORTANT Switch only works when controller is in the ready mode green LED blinking and at least one operator presence switch is pressed 10 Menu select switch To move up through the modes on the transmitter move up To move down through the modes on the transmitter move down Release switch to stop moving throug...

Page 28: ...witch must be pressed and operator seat must be empty for control to work See Steer Unit on page 108 for more information 2 Right stabilizer control To raise push up To lower pull down IMPORTANT Lower left and right stabilizers to the ground together then adjust individually 3 Back frame tilt control To raise push up To lower push down IMPORTANT To ensure a stable platform for drilling use front a...

Page 29: ...rol To raise push up To lower push down 7 Dual joystick ground drive control To move right track forward move lever forward To move right track backward move lever back Operator presence switch must be pressed and operator seat must be empty for control to work See Steer Unit on page 108 for more information Item Description Notes c00ic209w eps c00ic210w eps c00ic229w eps ...

Page 30: ... Steer Unit on page 108 for more information 2 Left stabilizer control To raise push up To lower pull down IMPORTANT Lower left and right stabilizers to the ground together then adjust individually 3 Front frame tilt control To raise push up To lower push down IMPORTANT To ensure a stable platform for drilling use front and back tilt controls together to set frame at desired pitch without raising ...

Page 31: ...ntrols 30 JT40 JT40 All Terrain Operator s Manual Set Up Console 5 Right anchor dual joystick control To rotate counterclockwise push up To rotate clockwise push down Item Description Notes c00ic210w eps ...

Page 32: ...ing Controls 1 Remove pipe control 2 Select previous row control 3 Select next row control 4 Add pipe control 5 Pipe gripper switch 6 Pipe shuttle switch 7 Pipe lift switch 8 Wrench control 9 Pipe lubricator switch 10 Set Resume switch 11 Rear wrench rotation switch j59om004w eps 5 6 7 8 9 10 11 2 1 3 4 ...

Page 33: ... move shuttle to previous row in pipe box press IMPORTANT See Row Select on page 177 3 Select next row control To move shuttle to next row in pipe box press IMPORTANT See Row Select on page 177 4 Add pipe control To select automated add pipe pipeloader function press To use manual pipeloader controls press again See Enable Automated Pipeloader System on page 130 5 Pipe gripper switch To close pres...

Page 34: ...es release 7 Pipe lift switch To raise press top To lower press bottom To stop release 8 Wrench control To clamp rear wrench push forward To unclamp rear wrench pull back To clamp front wrench move to right To unclamp front wrench move to left 9 Pipe lubricator switch To apply joint compound press Applies joint compound to threads at wrenches Item Description Notes c00ic612h eps ...

Page 35: ... press top To set operating conditions or reduce operation levels press bottom See Cruise Control on page 186 See AutoCarve control on page 37 See Pipeloader on page 175 11 Rear wrench rotation switch To rotate counterclockwise press top To rotate clockwise press bottom To stop rotation release Item Description Notes RESUME SET c00ic113h eps ...

Page 36: ...g counterclockwise control AT only 5 AutoCarve control JT and AT Dirt modes 6 Two speed rotation control 7 Engine throttle down control 8 Autothrottle control 9 Remote engine start control 10 Rotary operation control 11 Inner spindle selector AT Rock mode 12 Fluid flow selector 13 Carve window selector JT and AT Dirt modes 14 Outer spindle brake control JT only Optional j59om005w eps 5 8 9 10 11 1...

Page 37: ...ated inner spindle control To turn on press To turn off to manually control inner rotation speed and direction press again Then use manual inner spindle control as needed See Manual inner spindle control on page 36 IMPORTANT To control inner spindle speed drilling mode switch must be in AT position See Engine Compartment on page 69 Use rotary operation control to control inner rotation See Rotary ...

Page 38: ... control to adjust carve window See Carve window selector on page 40 Two speed thrust is not allowed in autocarve mode Cruise control is not available in autocarve mode Autocarve is disabled while front wrench is closed 6 Two speed rotation control To rotate in high speed press To rotate in low speed press again 7 Engine throttle down control To decrease engine speed press Engine speed will be dec...

Page 39: ... involving thrust rotation drilling fluid flow or pipeloader functions To return to high speed activate thrust rotation drilling fluid or an add remove pipe cycle 9 Remote engine start control To start engine from operator s station push button Release when engine starts IMPORTANT This button works only when key in set up console is on operator is in seat and battery disconnect switch is closed It...

Page 40: ...rn counterclockwise Automated inner spindle speed control To increase rotation speed turn clockwise To decrease rotation speed turn counterclockwise Fluid flow control To increase flow turn clockwise To decrease flow turn counterclockwise Carve window control To increase carve window range turn clockwise To decrease carve window range turn counterclockwise See Manual inner spindle control on page ...

Page 41: ...ress To turn off press again IMPORTANT To control drilling fluid flow drilling fluid pump must be switched on See Right Control Console on page 44 Use rotary operation control to adjust fluid flow See Rotary operation control on page 39 13 Carve window selector To turn on press To turn off press again IMPORTANT To adjust carve window AutoCarve control must be on See AutoCarve control on page 37 Us...

Page 42: ...ole 14 Outer spindle brake control To engage press To disengage press again Prevents outer spindle from rotating when inner spindle or mud motor are in use Brake is temporarily released when front wrench is closed to allow pipe change Item Description Notes c00ic188w eps ...

Page 43: ...tes 1 ESID alarm interrupt self test switch To turn off strike alarm at drilling unit press top To start manual self test press bottom To reset system after a strike has been detected press bottom IMPORTANT Self test checks all systems and circuits except voltage limiter See Voltage Test on page 157 See If an Electric Line is Damaged on page 14 j59om076w eps 2 1 ...

Page 44: ...JT40 JT40 All Terrain Operator s Manual Controls 43 Left Control Console 2 Horn Press and hold to sound horn Item Description Notes c00ic194w eps ...

Page 45: ...se button 6 USB port 7 Lower Remote display 8 Upper display 9 Auxiliary outlet See tracker manual Item Description Notes 1 Carriage control joystick To move carriage forward push To move carriage backward pull To rotate spindle counterclockwise breakout move right To rotate spindle clockwise makeup move left IMPORTANT See Operate Carriage Control on page 123 for more information j59om003w eps 5 1 ...

Page 46: ...periods of time Battery discharge can occur If wrenches are engaged when remote stop is pressed wrenches will remain engaged but could gradually open 4 Drilling fluid pump switch To turn on press once To turn off press once IMPORTANT Use rotary operation control to control drilling fluid flow See Rotary operation control on page 39 Drilling fluid pump switch and fluid flow selector must be ON befo...

Page 47: ...tem information from the tracker is also displayed For more information see Lower Display on page 47 See tracking system operator s manual for more information 8 Upper display Displays graphic symbols for indicators and conditions For more information see Upper Display on page 50 9 Auxiliary outlet Provides power for other equipment Power output is 12VDC 5A Item Description Notes c00ic179h eps ...

Page 48: ...nt temperature indicator numeric display 4 Hydraulic fluid temperature indicator numeric display 5 Voltmeter display 6 Fuel gauge 7 DEF indicator tank level percentage 8 Exhaust cleaning indicator 9 High exhaust temperature indicator 10 Hydraulic fluid filter indicator Hydraulic fluid temperature indicator 11 Engine warning stop indicator 12 Engine load display 13 Hourmeter HRC units only j59om077...

Page 49: ...ashes yellow when fuel level reaches 10 See Approved Fuel on page 204 7 DEF indicator tank level percentage Displays amount of diesel exhaust fluid DEF remaining in tank Icon flashes yellow every one second if level is lower than 10 but higher than 2 5 Icon flashes yellow every half second if level is less than 2 5 Icon flashes yellow every two seconds if quality of DEF is poor See Diesel Exhaust ...

Page 50: ...ht Control Console 11 Engine warning stop indicator Lights when engine needs attention Lights when operator needs to stop engine 12 Engine load display Displays engine load 13 Hourmeter Displays number of hours engine has been running Item Description Notes ...

Page 51: ...e mode indicator 5 Operation messages 6 Front home stop indicator 7 Front wrench indicator 8 Rear wrench indicator 9 Exception messages 10 Rear home stop indicator 11 Carriage indicator 12 Tool joint position indicator j59om063w eps R F 9 9 15 9 22000 4000 ft lb psi ft lb rpm gpm rpm 225 1500 50 8000 400 fpm ft 0 5 10 15 lbs 0 6 5 3 EXCEPTION MESSAGES 1 2 3 4 5 7 6 8 9 10 11 12 12 ...

Page 52: ...ode Drive mode 4 Cruise mode indicator Indicates when cruise mode is enabled 5 Operation messages Displays messages for overall operation of the machine 6 Front home stop indicator Indicates when the carriage has reached the rear home stop indicator Yellow background Carriage is approaching the rear home position Green background Carriage has reached the rear home position Red background Carriage ...

Page 53: ... Carriage is approaching the rear home position Green background Carriage has reached the rear home position Red background Carriage is in the rear stop position 11 Carriage indicator Animated display of the movement of the carriage and outer and inner AT only pipe 12 Tool joint position indicator Displays the current position of the SaverLok and pipe tool joints Item Description Notes R ...

Page 54: ...tation pressure gauge AT only 7 Inner rotation hour meter 8 Day Night mode key 9 Inner rotation hour reset key AT only 10 ESID status display key 11 Force exhaust cleaning key HRC only 12 Main menu key 13 Carve window JT and AT Dirt mode only 14 Thrust pressure gauge 15 Carriage distance display 16 Carriage speed display IMPORTANT Press any key to activate menu buttons Item Description Notes 1 Out...

Page 55: ...anual reset See Inner rotation hour reset key AT only on page 53 8 Day Night mode key Press from main screen to toggle between day and night modes 9 Inner rotation hour reset key Press and hold for five seconds to reset inner rotation hours 10 ESID status display key Displays when unit detects an error with ESID system 11 Stationary exhaust cleaning key Press from main screen gauges to force stati...

Page 56: ...window set by operator IMPORTANT This gauge replaces the inner rotation speed pressure gauge when the carve function is selected See Use AutoCarve on page 138 14 Thrust pressure gauge Numerically and graphically displays thrust pressure 15 Carriage distance display Numerically displays distance of the carriage 16 Carriage speed display Numerically displays speed of the carriage Item Description No...

Page 57: ...Exhaust cleaning activation key HRC only 5 Engine diagnostics key 6 User settings key 7 Not used 8 Drill set up menu key 9 Not used 10 Return key Item Description Notes 1 Information menu key Press to display information about raw values and rotation hours 2 System settings key Press to display software version information 3 ESID history menu key Press to select the ESID history menu Displays past...

Page 58: ...ss 5 Engine diagnostics key Press to display engine diagnostic codes if any IMPORTANT If diagnostic codes are displayed contact your Ditch Witch dealer 6 User settings key Press to customize settings Real time clock brightness and language can be adjusted in this screen 7 Not used 8 Drill set up menu key Press to access menu used to adjust cab anchors stabilizers and frame tilt using the carriage ...

Page 59: ...m with current coil circuit 3 ESID voltage indicator ESID has detected a non specific problem with voltage limiter circuit 4 ESID test indicator Self test is being conducted 5 ESID horn active indicator 6 ESID strobe active indicator 7 ESID coil strike percentage 8 ESID volt strike percentage 9 Return key Press to return to main screen gauges 10 ESID history menu key Displays past ESID codes j59om...

Page 60: ...ween voltage limiter and unit 30 volts will display as 100 3 Current indicator Indicates percentage of current being detected at the current transformer 300 milliamps will display as 100 4 Strike condition indicator Indicates the total combined percentage of detected voltage and current and displays it graphically An alarm condition occurs when the total combined percentage is equal to or greater ...

Page 61: ...agnostics error message information display Displays detailed information about the error messages 3 Next error message key Press to display next active error message in list 4 Previous error message key Press to display previous active error message in list Diagnostic Message 3 of 5 Gearbox ground oil temperature Short circuit to SPN 523618 FMI 4 0 DID j59om075w eps 1 2 3 4 ...

Page 62: ... indicator 2 Set up controls 3 Previous system set up display key 4 Next system set up display key 5 Return key Item Description 1 System set up indicator Visually indicates which system is being set up Adjust cab anchors stabilizers and frame tilt using the carriage control joystick j59om120w eps 1 2 3 4 5 ...

Page 63: ...o raise front frame tilt move joystick backward and to the left To lower front frame tilt move joystick backward and to the left To raise left stabilizer move joystick forward and to the left To lower left stabilizer move joystick backward and to the left To raise right stabilizer move joystick forward and to the right To lower right stabilizer move joystick backward and to the right Functions can...

Page 64: ... Station Seat 1 Slide control 2 Recline control Item Description Notes 1 Slide control To slide forward or backward pull then adjust seat To lock seat in position release 2 Recline control To recline seatback rotate backward To raise seatback rotate forward j59om085w eps 1 2 ...

Page 65: ...ional Controls EMERGENCY EXIT Pull pin and lift rear window to exit cab in case of emergency 1 Door wiper switch 2 Left wiper switch 3 Air temperature dial 4 Fan speed dial 5 Washer fluid switch 6 Work light switch 7 Air conditioner on off switch j59om007w eps 1 5 6 7 2 3 4 ...

Page 66: ...off press bottom 2 Left wiper switch To turn on press top To turn off press bottom 3 Air temperature dial To adjust air temperature turn dial 4 Fan speed dial To adjust fan speed turn dial 5 Washer fluid switch To turn on press top To turn off press bottom c00ic214w eps F c00ic212w eps L c00ic211w eps 0 1 2 3 c00ic205w eps c00ic213w eps ...

Page 67: ...Manual Cab Optional 6 Work light switch To turn on press top To turn off press bottom 7 Air conditioner on off switch To turn air conditioner on press left To turn air conditioner off press right Item Description Notes c00ic048w eps c00ic205w eps ...

Page 68: ... EDT diagnostic port cab controller 6 Recline control Item Description Notes 1 Heat switch To turn seat heat on high press top To turn lumbar heat off press middle To turn seat heat on low press bottom 2 Lumbar lever Push lever down to engage lumbar support Push lever up to disengage lumbar support j59om006w eps 2 1 3 4 6 5 c00ic215w eps ...

Page 69: ... lock seat in position release 4 Suspension control Adjust dial to approximate body weight for additional comfort 5 EDT diagnostic port cab controller For use only by qualified Ditch Witch technicians 6 Recline control To recline seatback rotate backward To raise seatback rotate forward Item Description Notes c00ic216w eps ...

Page 70: ...speed switch 5 EDT diagnostic port remote control receiver 6 EDT diagnostic port main controller 7 DrillLok key 8 Hydraulic fluid and temperature sightglass Item Description Notes 1 Air intake restriction indicator Shows air intake restriction on LRC units only Replace the air filter elements when the indicator reaches the red zone See Change Air Filter on page 233 j59om008w eps 1 2 3 4 5 7 6 8 ...

Page 71: ...T Rock mode when using AT pipe with inner rod and rock drilling bits Use AT Dirt mode when using AT pipe with inner rod and adapter to use dirt tool head Use JT drilling mode when using JT pipe without inner rod 4 Fan speed switch For high speed press top For automatic speed press bottom IMPORTANT If switch is on high speed fan will run at full speed all the time If switch is on auto speed fan spe...

Page 72: ...to override position right IMPORTANT Remove key and keep in tracker operator s possession Top icon is shown when operating with Subsite Electronics tracker Bottom icon is shown when operating without Subsite Electronics tracker 8 Hydraulic fluid and temperature sightglass Displays hydraulic fluid level and temperature Normal coolant temperature is less than 175 F 79 C Item Description Notes c00ic1...

Page 73: ...gle Pipe on page 179 1 Auxiliary pipe shuttle switch 2 Auxiliary pipe load restricted operating mode switch 3 Auxiliary pipe lifter switch Item Description Notes 1 Auxiliary pipe shuttle switch To move toward pipe box press top To move toward spindle press bottom To stop shuttles release j59om009w eps 1 2 3 c00ic200w eps ...

Page 74: ...cted operating mode switch To override drill operator control of shuttles and lifters press right To enable drill operator control of shuttles and lifter press left 3 Auxiliary pipe lifter switch To raise press top To lower press bottom To stop release Item Description Notes c00ic202w eps c00ic201w eps ...

Page 75: ...n or press top of wireline restricted operating mode switch 2 To disable wireline restricted operating mode move wireline restricted operating mode platform switch to the downright position or press bottom of wireline restricted operating mode switch Green light will indicate when wireline restricted operating mode is active IMPORTANT Wireline restricted operating mode is enabled after wireline re...

Page 76: ...s on Indicates ROM error See your Ditch Witch dealer 2 ROM message boundary Green boundary indicates ROM mode is on Yellow and red boundary indicate error conditions See your Ditch Witch dealer Turn off wireline ROM switch page 74 Do not use ROM until error is fixed 3 ROM switch status indicator Indicates switch is on Indicates an error See Wireline restricted operating mode switch on page 74 j59o...

Page 77: ...All Terrain Operator s Manual Wireline Optional 4 ROM platform switch status indicator Indicates switch is on Indicates an error See Wireline restricted operating mode platform switch on page 74 Item Description Notes ON R R ...

Page 78: ...y disconnect switch Item Description Notes Battery disconnect switch To connect move right To disconnect move left NOTICE Do not operate battery switch with engine running To avoid equipment damage wait two minutes after turning engine off before disconnecting battery j59om086w eps c00ic156w eps _ ...

Page 79: ...Controls 78 JT40 JT40 All Terrain Operator s Manual Battery Disconnect ...

Page 80: ...JT40 JT40 All Terrain Operator s Manual Operation Overview 79 Operation Overview Chapter Contents Planning 80 Setting Up at Jobsite 80 Drilling 81 Backreaming 81 Leaving Jobsite 82 Storing Equipment 82 ...

Page 81: ... 6 Load equipment See page 114 Setting Up at Jobsite 1 Prepare jobsite See page 100 2 Mix drilling fluid See page 158 3 Unload drilling unit from trailer See page 116 4 Assemble drill string See page 125 5 Position drilling unit and drill frame See page 121 6 Assemble strike system See page 152 7 Anchor drilling unit See page 149 8 Connect fluid system See page 121 9 Calibrate tracker with beacon ...

Page 82: ...g 1 Assemble backream string See page 142 2 Start drilling unit and adjust throttle 3 Set drilling fluid flow Check that fluid flows through all nozzles 4 Remove extra drill pipe from pipe box see page 182 to complete backream 5 Remove remaining pipe to complete backream 6 Remove pullback device See page 145 Backreaming Tips Plan backreaming job before drilling Plan bore path as straight as possib...

Page 83: ...ee page 150 3 Rinse unit and downhole tools See page 196 4 Disassemble strike system and disconnect from fluid system See page 152 5 Stow tools See page 197 6 Load unit onto trailer See page 114 Storing Equipment 1 For cold weather storage antifreeze drilling unit see page 194 2 For long term storage disconnect battery disconnect switch ...

Page 84: ... Examine Pullback Material 85 Arrange for Traffic Control 85 Plan for Emergency Services 85 Inspect Site 86 Identify Hazards 86 Select Start and End Points 87 Classify Jobsite 88 Select a Classification 88 Apply Precautions 89 Plan Bore Path 91 Recommended Bend Limits 92 Entry Pitch 96 Minimum Setback 96 Minimum Depth 97 Bore Path Calculator 97 ...

Page 85: ...erator s Manual Prepare Jobsite 100 Mark Bore Path 100 Prepare Entry Point 100 Check Supplies and Prepare Equipment 101 Check Supplies 101 Prepare Equipment 102 Select Drilling Mode 103 Prepare Drilling Mode 103 Assemble Accessories 105 ...

Page 86: ...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 Call service contact all local utility companies to have underground utilities located Examine Pullback Material Ask for a sample of the material you will be pulling back Check its weight and stiffness C...

Page 87: ...y 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 locator interference rebar railroad tracks etc Have an experienced locating equipment operator sweep area within 20 6 m to each side of bore path to verify previously marked line and cable locations Mark location o...

Page 88: ...ach slope to determine if factors affecting risks create an unsafe condition for drilling 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 96 Check that there is enough space to work and to set u...

Page 89: ...efore 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 Remember jobsite is classified by hazards in place not by line being installed 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...

Page 90: ...with the DrillLok key in the 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 Position equipment upwind from gas lines and use one or both of these methods Expose lines by careful hand digging or soft excavation Use beacon to track bore path If utility must be crossed tra...

Page 91: ...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 precautions should be taken or if job should be attempted Breathing crystalline silica dust may cause lung disease Cutting drilling or working materials such as concrete sand or rock containing quartz may r...

Page 92: ...rd 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...

Page 93: ...t pitch Make sure pitch A changes no more than the following percentages over the full length of each pipe Monitor the pitch of each pipe with the tracker remote display on the operator s console See tracking system operation instructions IMPORTANT Consider recommended bend limits during any bend not just during bore entry JT Power Pipe HD JT HIWS1 AT pipe 10 3 10 4 8 9 NOTICE Bending drill pipe m...

Page 94: ...n the bore path has a radius A of 145 44 2 m requires approximately 228 69 5 m of drill pipe B AT JT40 All Terrain drill pipes have a tested minimum bend radius of 170 51 8 m This means that a 90 degree bend in the bore path has a radius A of 170 51 8 m requires approximately 267 81 4 m of drill pipe B NOTICE Bending drill pipe more sharply than recommended will damage the pipe and cause failure o...

Page 95: ...3 0 9 0 94 m 10 124 11 5 38 10 m 70 6 3 21 50 m 3 44 3 5 13 50 m 6 10 6 2 10 m 11 132 0 5 40 25 m 83 8 8 25 52 m 4 58 3 9 17 78 m 12 1 9 3 71 m 12 137 8 8 30 72 m 97 9 3 29 80 m 5 71 8 9 21 87 m 18 10 2 5 75 m 13 141 11 6 41 98 m 111 11 9 34 14 m 6 84 4 9 25 73 m 26 10 5 8 19 m 14 144 8 4 44 10 m 126 8 8 38 63 m 7 96 2 1 29 31 m 36 2 0 11 02 m 15 145 10 9 44 47 m 141 8 2 43 19 m 8 106 11 2 32 59 m...

Page 96: ...2 0 11 02 m 15 145 10 9 44 47 m 141 8 2 43 19 m 8 106 11 2 32 59 m 46 7 3 14 21 m 16 146 0 0 44 50 m 146 0 0 44 50 m Pipe C Forward B Deflection A Pipe C Forward B Deflection A 1 14 11 8 4 57 m 0 7 9 0 20 m 10 131 3 4 40 02 m 61 11 9 15 85 m 2 29 10 1 9 10 m 2 7 7 0 81 m 11 140 3 4 34 8 m 73 11 8 22 55 m 3 44 5 7 13 56 m 5 11 1 1 81 m 12 148 2 4 45 17 m 86 8 6 26 43 m 4 58 9 1 17 91 m 10 5 7 3 19 ...

Page 97: ...e 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 Minimum Setback Setback is the distance from the entry point to where pipe becomes horizontal B1 IMPORTANT A shallow entry pitch A1 allows you to reach h...

Page 98: ...o 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 JT40 Power Pipe HD Minimum depth D Entry pitch A Setback B Depth to begin steering S 4 4 1 32 m 18 10 0 37 3 11 35 m 2 2 0 66 m 5 5 1 65 m 21 11 6 41 2 12 55 m 2 6 0 76 m 6 8 2 03 m 23 13 2 45 1 13 74 m 2 9 0 84 m 7 11 2 41 m 26 14 8 49 0 14 94 m 3 1 0 94 m 9 5 2 ...

Page 99: ...11 6 41 2 12 55 m 2 6 0 76 m 6 8 2 03 m 23 13 2 45 1 13 74 m 2 9 0 84 m 8 0 2 44 m 26 14 8 49 0 14 94 m 3 1 0 94 m 9 4 2 84 m 29 16 4 52 10 16 10 m 3 5 1 04 m 10 11 3 33 m 32 18 0 56 7 17 25 m 3 9 1 14 m IMPORTANT Numbers in table based on 145 44 2 m minimum bend radius and beacon housing EZ Connect connector transition sub and 1 3 of first drill pipe L totaling 12 1 3 68 m in the ground before st...

Page 100: ...5 4 1 63 m 21 11 6 43 3 13 18 m 1 11 0 58 m 6 8 2 03 m 23 13 2 47 10 14 58 m 2 2 0 66 m 7 11 2 41 m 26 14 8 52 4 15 95 m 2 5 0 74 m 9 7 2 92 m 29 16 4 56 10 17 32 m 2 8 0 81 m 11 2 3 40 m 32 18 0 61 4 18 69 m 2 11 0 89 m IMPORTANT Numbers in table based on 170 51 8 m minimum bend radius and beacon housing and 1 3 of first drill pipe L totaling 9 2 2 79 m in the ground before steering ...

Page 101: ...tend to move in easiest direction toward surface when rotated near the surface To 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 equipment 274 050 274 724 2P To help avoid injury If jobsite classification is in question or is the possibility of unma...

Page 102: ...ng equipment and accessories bits screens nozzles see page 163 adapters pipe beacon housings marking flags or paint water and additional hoses fuel drilling fluid additives see page 161 spare fuses keys backreamers swivels pulling devices see page 166 wash down hose and spray gun duct tape spray lubricant tool joint compound see page 202 electrically insulating boots and gloves Boots must have hig...

Page 103: ...ulic fluid engine coolant battery charge engine oil Condition and Function all controls filters air oil hydraulic fluid pump couplers tracks pumps and motors drilling fluid mixer hoses and valves water tanks Improper control function could cause death or serious injury If control does not work as described in instructions stop machine and have it serviced ...

Page 104: ...e conditions Load All Terrain pipe and pipe box onto unit Move mode selector switch to AT position Mode Situation used Downhole tools Capabilities AT Rock soft rock other non compressible soils Any other situation with difficult steering because of hard soil conditions All Terrain drill pipe Rockmaster tool 40 000 lb 178 kN of thrust inner rotation AT dirt When one bore out of several can be bette...

Page 105: ...chors for jobsite conditions Load All Terrain pipe and pipe box onto unit Move mode selector switch to AT DIRT position JT Mode Install SaverLok body pipe loader accessories pipe guides and wrench inserts for JT pipe Use standard transition sub and beacon housing Select soil bit based on jobsite conditions Use auger type anchors Load JT pipe and pipe box onto unit Move mode selector switch to JT p...

Page 106: ... points of ignition The fire extinguisher should always be classified for both oil and electric fires It should meet legal and regulatory requirements Covers and Canopy Open Station Only 1 Remove canopy from storage position under console cover 2 Remove fiberglass rod from storage position and slide through front pocket of canopy 3 Insert fiberglass rod into top of operator station grab rails show...

Page 107: ...sition as shown 5 Remove pin 1 and lift and lower display cover as shown 6 Secure canopy to operator station grab rails with snaps 1 and buckles 2 7 To disassemble repeat steps in reverse order IMPORTANT Optional canopy has buckles that connect at the bottom of the operator station instead of snaps 1 j59om113w eps 1 j59om114w eps 1 2 2 j59om117w eps ...

Page 108: ...in Operator s Manual Drive 107 Drive Chapter Contents Start Unit 108 Steer Unit 108 Single Joystick Ground Drive 108 Dual Joystick Ground Drive 108 Tips to Reduce Track Wear 109 Safe Slope Operation 110 Shut Down Unit 111 ...

Page 109: ...For tight steering in low speed move control to center position and then to a corner Tracks will counter rotate and turn drilling unit in a tight circle Dual Joystick Ground Drive 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 mor...

Page 110: ...jects 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 208 To prevent premature wear avoid the following Spinning tracks under heavy load Turning on sharp objects such as stones stumps and de...

Page 111: ...ation accordingly Maximum engine 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 limits and must never be used alone to establish safe operating angle for variable conditions HRC Maximum engine lubrication angle 45 LRC Maximum engine lubrication angle 45 ...

Page 112: ...t Down Unit Shut Down Unit 1 Stop track movement 2 Lower drill frame and stabilizers to the ground 3 Run engine at high throttle with no load for one minute then low throttle with no load for two minutes to cool 4 Turn ignition switch to STOP 5 Remove key ...

Page 113: ...Drive 112 JT40 JT40 All Terrain Operator s Manual Shut Down Unit ...

Page 114: ...JT40 JT40 All Terrain Operator s Manual Transport 113 Transport Chapter Contents Lift 114 Pipe Box Lifting Procedure 114 Load 114 Tie Down 115 Unload 116 Tow 116 ...

Page 115: ...and align with ramps 4 Slowly drive unit onto trailer 5 Lower stabilizers to trailer floor 6 Lower drill frame to trailer floor 7 Stop engine when unit is safely positioned on trailer bed for proper tongue weight 8 Attach tiedowns to drilling unit where indicated on page 115 9 Ensure that all covers are properly secured NOTICE Machine should be loaded using wireless remote controller See Wireless ...

Page 116: ...iedown ends Make sure tiedowns are tight before transporting NOTICE Wrenches can open after engine shutdown Ensure that any downhole tool or pipe in wrenches is attached to spindle or removed before transport Use Grade 7 3 8 18 7 cm transport chain to secure drilling unit IMPORTANT If hauling unit without pipe box remove remaining pipe in drill frame chute Distance U S Metric A greater than 18 gre...

Page 117: ...ight use towing chains appropriately rated for maximum towing force attach chains to indicated tow points facing towing vehicle shown disengage track planetaries Loop chain 1 through each tow point and bring them together to a central pull point Arrange chains so that angle A is always less than 120 NOTICE Machine should be unloaded using wireless remote controller See Wireless Remote Controller o...

Page 118: ...ansport 117 Retrieve To disengage track planetaries reverse small cover plate in center of planetary on each track drive A Normal operation B Towing IMPORTANT When planetaries are disengaged unit has no brakes j59om083w eps 1 j59om011w eps A B ...

Page 119: ...Transport 118 JT40 JT40 All Terrain Operator s Manual Retrieve ...

Page 120: ...ng Fluid Pump 122 Operate Carriage Control 123 Drilling 123 Assisted Makeup 123 Clamp Pipe 124 Assemble Drill String 125 AT Mode AT Pipe 125 AT Dirt Mode AT Pipe 126 JT Mode 126 Connect Drill Pipe 128 Drill First Pipe 129 AT Mode 129 AT Dirt JT Mode 129 Swab the Hole 130 Enable Automated Pipeloader System 130 Add Pipe 131 AT Mode 131 JT Mode 134 Correct Direction 136 ...

Page 121: ...0 JT40 All Terrain Operator s Manual Basic Rules 136 Procedure 137 Drill Head Position 137 Use Carve Mode 138 Operation 138 Record Bore Path 139 Surface Drill Head 140 Backream 141 Remove Pipe 143 Remove Pullback Device 145 ...

Page 122: ... to drilling fluid pump A 2 0 50 8 mm or larger non collable hose is required 2 Install y strainer between mixing unit and drilling fluid pump Position strainer so that drilling fluid flows in the direction of the arrow In most cases positioning strainer at outlet of mixing unit gives best results Electric shock will cause death or serious injury Stay away 274 049 To help avoid injury Do not conne...

Page 123: ...hose and connect hose to unit 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 IMPORTANT Ensure that mixture of drilling fluid matches drilling conditions See Drilling Fluid on page 158 Read operator s manual Know how ...

Page 124: ...verse thrust with clockwise rotation Assisted Makeup During pipe change operations when front wrench is closed and carriage is on front or rear home the thrust rotation joystick only controls the speed and direction of rotation The machine controller manages thrust and matches the speed and direction of rotation to smoothly thread or unthread pipe sections Push joystick toward 1A or 1B for clockwi...

Page 125: ... leg Stay away To help avoid injury Only clamp pipe at reinforced end Clamping anywhere else on the pipe will weaken the pipe Pipe can later break even when operating under normal loads NOTICE Ensure that any downhole tool or pipe in tool joint vises is attached to spindle or removed before transport Wrenches can open after engine shutdown NOTICE Clamping pipes on top of female end threads can dam...

Page 126: ... procedures 3 Ensure that Rockmaster tool is properly lubricated from last usage If using Rockmaster tool for the first time lubricate the tool Remove rear plug from tool Install zerk Remove front plug Rotate the tool by hand while pumping tool with WRG until grease comes out rear port Reinstall front plug and add 1 5 pumps WRG Remove zerk Reinstall rear plug 4 Install beacon following beacon inst...

Page 127: ...se wrench 4 Use machine torque to tighten joint fully Quick Wrenches 1 Lube joints with TJC tool joint compound 2 Attach quick wrenches to the joint in the join position and tighten joint AT Dirt Mode AT Pipe 1 bit 2 beacon housing 3 adapter 4 collar 5 transition sub 6 JT40 AT drill pipe JT Mode 1 bit 2 beacon housing 3 adapter 4 collar 5 transition sub 6 JT40 drill pipe Power Pipe HD or HIWS1 Pip...

Page 128: ...con operation 7 Follow tracker instructions to calibrate beacon Attach Transition Sub 1 Remove blocks from pipe guides 2 Pull transition sub into front wrench 3 Close wrench 4 Lube joints 5 Use machine torque to tighten joint fully Attach Beacon Housing Use machine torque to attach beacon housing 1 Pull beacon housing into front wrench 2 Close wrench 3 Use machine torque to tighten joint fully IMP...

Page 129: ...ar stop switch 8 Load pipe Ensure shuttle stop is positioned correctly Open grippers or make sure they are open Grippers open as pipe is lowered Close grippers around pipe Lubricate pipe threads at front wrench Move pipe to spindle Raise pipe lifters 9 Connect pipe Move carriage forward until spindle meets back end of pipe joint Rotate spindle clockwise until pipe begins to spin Relax grippers sli...

Page 130: ...ls stop carriage thrust If inner rotation does not resume pull pipe back AT Dirt JT Mode 1 Turn on drilling fluid 2 Visually check for drilling fluid flow 3 Turn drill bit to starting position 4 Slowly move carriage forward Drill first pipe as straight as possible 5 Monitor gauges Turning shaft will kill you or crush arm or leg Stay away To help avoid injury Keep everyone at least 10 3 m away from...

Page 131: ...ilable then lowered into shuttles If no pipe is detected the operator is instructed to move the pipe box before continuing 1 Ensure pipe box is properly positioned 2 Open front wrench 3 Retract shuttles 4 Adjust engine to full throttle for remove pipe function to work 5 Press bottom of remove pipe control If any steps are skipped the upper display will inform the operator which steps to take to co...

Page 132: ...hes See Clamp Pipe on page 124 If spindle brake is set disengage it rotate outer pipe to 3 o clock and close front wrench Locate drill head Rotate spindle counterclockwise Carriage moves back slowly as threads separate After threads are fully separated stop rotation and move carriage to back of frame until rear stop indicator is lit in right console While carriage is moving grippers will grip pipe...

Page 133: ... threads onto pipe Press RESUME Grippers will relax Manual Pipeloader Controls Automated Pipeloader Control Slowly move carriage forward to allow inner rod to match up and rotate spindle clockwise until pipe threads together To fully tighten joint slowly rotate pipe until spindle stops turning Open wrench Open grippers fully Retract shuttles Lower pipe lifters Slowly move carriage forward to allow...

Page 134: ...ording to bit size and soil conditions 12 Engage and set cruise control as desired See Cruise Control on page 186 13 Monitor gauges If inner rotation stalls stop carriage travel If inner rotation does not resume pull pipe back 14 Locate drill head with tracker at least every half length of pipe 15 Engage spindle brake if desired and drill rest of pipe IMPORTANT To improve accuracy of depth estimat...

Page 135: ...See Clamp Pipe on page 124 Locate drill head Rotate pipe to 12 o clock position Close front wrench Rotate spindle counterclockwise Carriage moves back slowly as threads separate After threads are fully separated stop rotation and move carriage to back of frame until rear stop indicator is lit in right console While carriage is moving grippers will grip pipe is lubed and upper display shows corresp...

Page 136: ...o pipe Relax grippers IMPORTANT Always rotate clockwise unless breaking pipe joint Rotating counterclockwise will separate joints Move carriage forward until saver sub meets pipe Rotate spindle clockwise until saver sub threads onto pipe Press RESUME Grippers will relax Manual Pipeloader Controls Automated Pipeloader Control Slowly move carriage forward until new pipe meets pipe in wrench Rotate s...

Page 137: ...zle 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 92 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 JT Mode Do not push an entire piece of drill pipe into ground w...

Page 138: ...lock face position 1 Read beacon roll 2 Slowly rotate pipe until tracking equipment displays desired beacon roll To change direction To move forward without changing direction IMPORTANT In AT mode depth estimate improves if drill head is at 3 o clock position A rather than horizontal B JT mode AT mode 1 Rotate pipe to clock position you intend to travel 2 Push pipe into ground 1 Rotate outer pipe ...

Page 139: ...tion control to full clockwise rotation Press the Set Resume switch to decrease increase rotation speed Adjust as needed while carving Movement Description alternating clockwise and counterclockwise rotation Enables the downhole tool to carve tough soil formations Rotation speed can be adjusted during autocarving NOTICE To reduce the chance of unthreading pipe sections downhole rotation pressure i...

Page 140: ...st and rotation settings are retained until the unit is shut down 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 Subsite Electronics bore tracking sof...

Page 141: ...Disconnect EZ Connect joint or use quick wrench to remove drill head Keep threads clean See Hydratong Wrenches on page 169 Moving tools will kill or injure Never use pipe wrenches on drill string 273 278 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 st...

Page 142: ... kill or injure Never use pipe wrenches on drill string 273 278 Jobsite hazards 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 backreaming Turning shaft will kill you or crush arm or leg Stay away To help avoid injury Maintain two way communication with ...

Page 143: ...enches to attach backreamer beacon housing assembly to transition sub 10 Attach additional pullback devices or product to end of backreamer beacon housing assembly Begin Backream 1 After backream assembly is attached to pipe tracker operator should leave pit and stand away from the exposed drill string if using DrillLok system turn on tracker to enable drilling unit thrust pullback and rotation if...

Page 144: ...nal position 5 Grip pipe 6 Separate front joint Manual Pipeloader Controls Automated Pipeloader Control Lift pipe out of shuttles Grippers will open as pipe is lifted Extend shuttles to spindle position Close grippers Relax grippers to allow pipe to rotate Lower lifters Press RESUME Display reads Extending Shuttles and shuttles extend grippers grip fully then relax open and pipe lifters lower Disp...

Page 145: ...tate spindle counterclockwise until joint is loosened at saver sub Do not fully unthread joint Open rear wrench Move carriage back until the front end of the pipe clears the front face of the wrench mount plate shown Press RESUME Grippers close Rotate spindle counterclockwise until saver sub is separated from pipe Move carriage to back of frame until rear stop indicator is lit in right console Man...

Page 146: ...n pullback device 5 Disconnect pullback material 6 Use quick wrenches to remove pullback device Manual Pipeloader Controls Automated Pipeloader Control Move carriage forward until saver sub touches pipe Rotate spindle to thread saver sub onto pipe Carriage moves forward slowly as pipe threads together Slowly tighten joint to full machine torque Move carriage forward until saver sub touches pipe Ro...

Page 147: ...Conduct a Bore 146 JT40 JT40 All Terrain Operator s Manual Remove Pullback Device ...

Page 148: ...tem 152 FCC Statement 152 Assemble Voltage Detector 153 Test Strike System 153 Troubleshoot Strike System 154 Use Electric Strike Simulator 156 Drilling Fluid 158 Guidelines 158 Polymer 158 Bentonite 159 Mixtures 159 Basic Fluid Recipes 160 Drilling Fluid Requirements 161 Funnel Viscosity 161 DrillLok System 162 Downhole Tools 163 Nozzles 163 Bits 163 Beacon Housings 164 Backreamers 166 Backream F...

Page 149: ...rrect Dropped Pipe 178 Correct Misaligned or Jammed Pipe 178 Rotate Drill Pipe Order 178 Add Remove Single Pipe 179 Wireless Remote Controller 184 Before each Use 184 Operation 184 Troubleshooting 185 Cruise Control 186 Engage 186 Adjust Settings 187 Override 187 Disengage 187 Resume 187 Wireline Operation 188 Diagnostic Codes 191 Electronic Controlled Engine Overview 191 Machine Diagnostic System...

Page 150: ...hors properly and or tie off unit before drilling Stand on platform when operating anchor controls Wear high top protective boots with legs of pants completely tucked inside Wear protective gloves Only swing cab after setup is complete 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 ...

Page 151: ...ger shaft flange 3 rests firmly on centering cap 1 4 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 Anchor type Situation used rock bit hard soft rock asphalt concrete cobble auger bit soft soil to hard soil soft rock IMPORTANT Do not attempt to operate anchor controls while drill ...

Page 152: ...ght back from machine 2 Use rings located on front of anchor frame 2 to anchor machine when drilling out Connect a chain to each ear and run straight forward from machine 3 Connect ground rod included in grounding kit to drill frame as shown NOTICE If using remote tie offs instead of anchors additional grounding of the machine will need to be done using kit 100 794 Avoid drill string when implemen...

Page 153: ...immediately 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 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 Th...

Page 154: ...ing page Do not drill until test is completed successfully 1 Turn on drilling unit 2 To test alarms and strobe press the test button on the left console See ESID alarm interrupt self test switch on page 42 3 Press the ESID soft key to view test results and historical data stored in the upper display This data includes ESID bar graph alphanumeric readout showing volts and amps current diagnostic co...

Page 155: ...ontrol module Have control module checked or replaced Defective CAN bus connection Ensure CAN cable from drilling unit to ESID control module is connected SPN521513 FMI31 DID224 shows on upper display Test wire not connected Check that test wire is connected to ESID control module Check that test wire is connected to upper display Have ESID control module checked or replaced Strobe light on drilli...

Page 156: ...pin 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 continuity is zero or cable is damaged replace Defective control module Have control module checked or replaced Red ESID voltage icon shows on upper display No code is displayed Improper connection o...

Page 157: ...ead one lead wire through current transformer 2 Clip ends of lead wires together to make one loop 3 Select ESID menu on upper display 4 Move simulator switch to current and press test button 5 Watch display on upper display ESID bar graph should show 1 2 scale on display ESID and Current AMPS should show 30 or higher in display To test for current at strike levels 1 Put two or three loops through ...

Page 158: ...Clip other lead to one voltage limiter mount 4 Move simulator switch to voltage and press test button 5 Watch display screen Alarm and strobe should turn on ESID and voltage volts should show 90 or higher It is normal for simulator voltage levels to drift below strike level When this happens ESID bar should show less than full and alarm and strobe should stop working If the level drifts above stri...

Page 159: ...local 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 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 Improper handling o...

Page 160: ...ormation 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 adding other products follow the order listed below General mixing order 1 Soda ash 2 Bentonite 3 Polymer 4 Con Det The Bore Gel system contains premixed bentonite polymer and soda ash Use approximately 15 lb ...

Page 161: ...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 gal 2 L Con Det Flow rate should be 3 5 parts fluid to 1 part soil May use 25 5 gal 1 2 L of Penetrol instead of Con Det swelling sticky clay 75 1 lb 340 450 g Poly Bore 5 1 gal 2 4 L Con Det Flow rate ...

Page 162: ...resistance of a fluid to flow the greater the resistance the higher the viscosity Viscosity of drilling fluids must be controlled To determine viscosity you will need a Marsh funnel p n 259 267 and a measuring cup available from your Ditch Witch dealer 1 Using wash hose and a clean container 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...

Page 163: ... you change downhole tools or during other times when the drill string is exposed If you are not using DrillLok system turn off drilling unit and keep key in tracker operator s possession before changing downhole tools NOTICE This mode does not disable thrust and rotation immediately Functions are disabled within 16 seconds If thrust and rotation are not enabled check whether the green DrillLok li...

Page 164: ...dations Bits Selection These charts are meant as a guideline only No one bit works well in all conditions See your dealer for soil conditions and bit recommendations for your area 1 best 2 good 3 fair 4 not recommended Bit Sandy Soil Soft Soil Medium Soil Hard Soil Rocky Soil Soft Rock Hard Rock Sand bit 1 2 3 4 4 4 4 Tornado bit 2 2 2 1 1 3 4 Tuff bit 3 2 1 1 3 1 4 Steep Taper Tuff bit 2 2 1 1 2 ...

Page 165: ...n bolts to 60 70 ft lb 81 95 N m 4 Repeat tightening sequence Soil Description sandy soil sugar sand blow sand or other soils where sand is the predominant component soft soil sandy loam medium soil loams loamy clays hard soil packed clays gumbo all compacted soils cobble rock chunk rock glacial till cobble gravel soft rock sandstone shale coral caliche chaulk medium rock limestone caliche sandsto...

Page 166: ...n 1 Clean all threads bolt holes and mating surfaces 2 Use removable thread locker Loctite 242 or equivalent if desired 3 Place lid on trough and install bolts 1 4 Use punch holder 3 to drive roll pins 2 from direction shown Lid Removal 1 Use punch holder 3 with bolt pin driver 4 to drive out pins 2 2 Remove bolts 3 Remove lid ...

Page 167: ...are meant as a guideline only See your local Ditch Witch dealer for soil conditions and backreamer recommendations for your area 1 best 2 good 3 fair 4 not recommended Backreamer Sandy Soil Soft Soil Medium Soil Hard Soil Rocky Soil Soft Rock Hard Rock Compact Fluted HD 3 3 1 2 Kodiak TM HD 3 2 1 2 Beavertail HD 2 1 1 1 WarthogTM HD Rockmaster 4 4 4 4 3 1 1 IMPORTANT For soil definitions see the c...

Page 168: ...ssful 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 at least 18 24 L m 2 Multiply this number by distance per minute you plan to backream The answer is an estimate of amount of fluid you will need for each minute of backreaming U S 1 5 gal x 2 ft min ...

Page 169: ...18 in 457 mm 13 22 164 17 5 5 in 140 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 83 20 in 508 mm 16 32 202 68 7 5 in 191 mm 2 29 28 50 20 5 in 521 mm 17 15 212 94 8 in 203 mm 2 61 32 43 21 in 533 mm 17 99 223 46 8 5 in 216 mm 2 95 36 61 21 5 in 546 mm 18 86 234 23 9 in 229 mm 3 3...

Page 170: ...work with pipe diameter 4 5 to 5 11 43 cm to 12 7 cm To accommodate 3 5 8 to 4 3 8 9 2 cm to 11 1 cm pipe remove one chain link Read operator s manual Know how to use all controls Your safety is at stake 273 475 To help avoid injury Ensure only chain tongs and chain are in contact with pipe shown and that chain is correctly wrapped Do not use Hydratong with chain bushing pin touching pipe shown St...

Page 171: ... Method on page 171 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 cylinder 8 To reposition chain tongs and continue tightening or loosening joint move handle to the B position and then press power switch to retract cylinder 9 Monitor gauge 3 shown and refer to decal on...

Page 172: ...line A 2 To join scribe second line B on movable side of joint in the opposite direction of tightening action Refer to table for correct dimension Connection Dimension transition sub to JT40 Power Pipe HD 5 16 8 0 mm transition sub to beacon housing 1 2 13 mm transition sub to All Terrain pipe 1 4 6 4 mm transition sub to JT40 HIWS1 pipe 5 16 8 0 mm j07om071h eps A A A A B B ...

Page 173: ...r recommended lubricant Clean the Threads Clean the threads as needed with high pressure water and detergent Replace Worn SaverLok Body Because each pipe comes in contact with the SaverLok body check SaverLok body regularly for wear Compare condition of SaverLok body threads to condition of your drill pipe threads Replace SaverLok body any time when its thread condition is not better than thread c...

Page 174: ...ly Clamp on pipe when joint is between wrenches Clamp only on the tool joint of the drill pipe as shown This portion of the drill pipe is designed for clamping and is considerably thicker and stronger than the rest of the pipe See Clamp Pipe on page 124 for more information NOTICE If joints get out of alignment during a bore use frame tilt or rear stabilizers to adjust the unit NOTICE Clamping any...

Page 175: ...rd until spindle or pipe contacts threads of pipe in the wrench and begins to collapse spring on the side of the carriage shown Stop thrusting and rotate clockwise until spring is fully relaxed Carefully move thrust forward as you spin the threads together keeping the spring as relaxed as possible Tighten joints fully Once the joint is connected and the shoulder faces are touching tighten to full ...

Page 176: ...d by electric strike On electrical jobsite load and unload pipe only if loader is wearing electrically insulating boots and gloves Crushing weight could cause death or serious injury Stay away 275 326 To help avoid injury Always walk around unit and check for obstructions before moving load Use crane capable of supporting the equipment s size and weight See page 241 or measure and weigh equipment ...

Page 177: ... each support bar 1 into opening and retain with pin through tab 3 Press pipe lower switch to lower pipes onto support bars Remove Pipe Box 1 Install lift block 4 and secure with lift block support bar and pins Adjust to match drill frame angle 2 Remove threaded caps 1 from pins 3 Remove pins 2 4 Move pipe box off of drill frame 1 2 j59om0102w eps j59om101w eps 1 2 1 2 3 ...

Page 178: ...utomated pipeloader is being used the main display will inform you that it is time to select a new row Use row select buttons to select new row See Select next row control on page 32 Backreaming Select next row when active column is full NOTICE Pipe box should only be installed onto pipeloader when pipe box shuttle is in first row position IMPORTANT Lift arms must be fully raised for pipe box to m...

Page 179: ...ongest bore was 320 98 m then only rotate the four columns used Plan to rotate the pipes during the longest bore of the week Procedure 1 Remove rotate pipe retainers 301 8546 from stowed position 2 Raise pipe until the center of the bottom row of pipe is centered in the bottom slots in the pipe box 3 Insert rotate pipe retainers into the bottom slot on front and rear of pipe box on the first row o...

Page 180: ... and unload pipe while drilling or backreaming Unprotected worker can be injured by electric strike On electrical jobsite load and unload pipe only if loader is wearing electrically insulating boots and gloves Read operator s manual Know how to use all controls Your safety is at stake 273 475 To help avoid injury Open or close both auxiliary pipe loaders Moving shuttles with one auxiliary pipe loa...

Page 181: ...liary pipe load restricted operating mode switch on page 73 5 Move shuttles out fully 6 Rotate auxiliary pipe loaders into position as shown Crushing weight could cause death or serious injury Use proper procedures and equipment or stay away To help avoid injury Drill pipe is heavy Have enough people on hand to manually add or remove single pipe to pipe box Do not attempt to move shuttles until ev...

Page 182: ...ll the way out 12 Repeat steps 8 11 to load more pieces of pipe into the last row 13 Move pipe to pipeloader grippers Raise last pipe into last row Move shuttles out Lower pipe into front grippers 14 Before moving pipe to carriage spindle Close both auxiliary pipe loaders Remove pipe guide and store it on shuttle drive cover Pin lifter covers back in upright position Press left side of auxiliary p...

Page 183: ... operating mode switch 3 to override drill operator control of shuttles and lifters and move control to single load switches See Auxiliary pipe load restricted operating mode switch on page 73 5 Move shuttles out fully 6 Rotate auxiliary pipe loaders into position as shown 7 Remove pipe guide stored on shuttle drive cover and attach to front of pipe loader frame as shown 8 Raise pipe in last row 9...

Page 184: ...load restricted operating mode switch to enable drill operator control of shuttles and lifter 15 Finish loading remaining drill pipe into last row using standard procedure See Remove Pipe on page 143 Crushing weight could cause death or serious injury Use proper procedures and equipment or stay away To help avoid injury Drill pipe is heavy Have enough people on hand to manually add or remove singl...

Page 185: ...ion control in neutral until horn sounds Equipment can be operated by remote control Stay away 270 6037 To help avoid injury Keep drilling unit in sight at all times when using wireless remote controller Keep a safe distance away from drilling unit when operating wireless remote controller Ensure bystanders are not near the area the drilling unit will be driven Remove strap from around neck when u...

Page 186: ...ning a safe distance If in an area with interference try changing the channel see below If communication link indicator is red communication has been lost Shut down wireless remote and restart to try to enable communication If that doesn t work contact your Ditch Witch dealer If battery and communication link indicators both display red for several seconds and then the wireless controller shuts of...

Page 187: ...1 Position joystick so that thrust or pullback and rotation are at desired speeds 2 Press set Cruise mode indicator will appear on upper display See Cruise mode indicator on page 51 3 Release joystick 1 Position joystick to desired thrust or pullback setting 2 Press set Cruise mode indicator will appear on upper display See Cruise mode indicator on page 51 3 Release joystick 4 Operator can control...

Page 188: ...joystick out of neutral in direction to be resumed forward or backward 2 Press resume Thrust and rotation resume at the previous settings and cruise mode indicator appears on upper display See Cruise mode indicator on page 51 Setting Instructions Thrust or Pullback To increase thrust or pullback speed set joystick in neutral position and press resume To decrease thrust or pullback speed set joysti...

Page 189: ...ion of wireline is inserted through the new pipe gearbox and water swivel then spliced to the tracking system The operator must be aware of the wireline operation specialist s activity at the front and rear of the machine IMPORTANT This section is intended as an overview for the JT40 drilling unit operator During most bores a wireline operation specialist is responsible for making wireline connect...

Page 190: ...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 Read operator s manual Know how to use all controls Your safety is at stake 273 475 Turning shaft will kill you or crush arm or leg Stay away To help avoid injury Ensure that thrust and rotation are disabled or in restricted mode while wi...

Page 191: ...operation specialist will Remove slack in the wireline Secure the wireline at the spindle Connect the wireline to the offboard computer Turn the wireline ROM switch to the OFF position to enable unrestricted thrust and rotation 7 Install next new section of pipe 8 Continue process for duration of bore ...

Page 192: ...he upper display tell the operator about potential engine problems and certain engine events Depending on the severity of the problem the ECU may reduce engine power or speed or may shut the engine down The ECU also stores all diagnostic codes regardless of severity Reading Engine Diagnostic Codes Engine diagnostic codes are shown in pop up messages on the upper display Amber or yellow messages in...

Page 193: ...alership Pop up Message Displayed Cause With Override Without Override Carriage Encoder Sensor Error If you override the error the carriage will be able to run into the stops and the shuttle This may damage the machine 1 No CAN communications 2 Sensor shows the carriage is beyond the front or rear stop 3 Sensor does not detect movement when the carriage should be moving Two speed thrust disabled P...

Page 194: ...errain Operator s Manual Complete the Job 193 Complete the Job Chapter Contents Antifreeze Drilling Unit 194 Add Antifreeze 194 Reclaim Antifreeze 195 Rinse Equipment 195 Use Washwand 196 Disconnect 197 Stow Tools 197 ...

Page 195: ...ng fluid pump 3 Open valve below antifreeze tank 4 Install optional antifreeze reclaimer adapter in spindle Ensure valve shown is open 5 Turn drilling fluid potentiometer counterclockwise to zero position 6 Start unit and set throttle to slow position 7 Set drilling fluid pump switch to on position 8 Slowly turn drilling fluid potentiometer clockwise until indicator light comes on If light does no...

Page 196: ... from tanks to drilling fluid pump inlet 4 Close valve below antifreeze tank 5 Start unit and run at low throttle 6 Turn drilling fluid pump on low speed 7 Turn drilling fluid pump off when drilling fluid comes out of reclaimer hose 8 Remove antifreeze reclaimer IMPORTANT Antifreeze can be removed from antifreeze tank and disposed of properly or it can be reused until it is too diluted with drilli...

Page 197: ...ce skin and cause severe injury Refer to operator s manual for proper use 270 6035 To help avoid injury Wear protective eyewear and clothing Never use high flow when using washwand Never point or aim the wand at yourself or anyone else Keep nozzle low to the ground Prime the drilling fluid pump before operating washwand Failure to prime the drilling fluid pump will cause flow fluctuations which wi...

Page 198: ...7 Disconnect Disconnect Disconnect and store the following hoses and cables if used electric strike system voltage stake fluid hose Stow Tools Make sure all quick wrenches bits pullback devices and other tools are loaded and properly secured on trailer or truck ...

Page 199: ...Complete the Job 198 JT40 JT40 All Terrain Operator s Manual Stow Tools ...

Page 200: ...0 Washing Precaution 200 Working Under Drilling Unit 201 Recommended Lubricants Service Key 202 Approved Coolant 203 Approved Fuel 204 Diesel Exhaust Fluid DEF 205 Exhaust Cleaning 206 Each Use 207 Startup 10 Hour 208 50 Hour 214 200 Hour 220 250 Hour 220 500 Hour 221 1000 Hour 223 2000 Hour 226 4500 Hour 228 As Needed 228 ...

Page 201: ...amage 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 attachments Connect welder ground close to welding point and make sure no electronic components are in the ground path Disconnect battery at battery disconnect switch before welding to prevent damage to battery See Chec...

Page 202: ...ith curved ends toward stabilizer shoes 2 Lower unit until load is supported by cylinder locks Before working under area of drilling unit supported by frame tilt cylinder make sure drilling unit is parked on hard surface 1 Remove drill frame support stored under rear step 1 and place under drill frame shown 2 Lower drill frame until load is supported by drill frame support Replace cylinder locks o...

Page 203: ... must meet the performance specifications shown above API American Petroleum Institute ACEA European 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 203 MPG Multipurpose grease Use polyurea based NLGI GC LB Grade 1 5 or lithium based NLGI GC LB Grade 2 WRG Multip...

Page 204: ...ace only with coolant meeting this specification such as Fleetguard ES Compleat coolant This coolant is available pre diluted from your Ditch Witch dealer as part number 255 1055 Contact your Cummins service partner for a full list of approved coolants meeting CES 14603 In an emergency non Cummins approved heavy duty diesel engine coolant meeting ASTM D6210 may be used Change to CES 14603 coolant ...

Page 205: ...rmation Biodiesel blends up to 5 B5 are approved for use in this unit The fuel used must meet the specifications for diesel fuel shown above In certain markets higher blends may be used if certain steps are taken Extra attention is needed when using biodiesel especially when operating in cold weather or storing fuel Contact your Ditch Witch dealer or the engine manufacturer for more information Av...

Page 206: ...mited 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 equipment must be compatible with DEF Most materials especially hoses are not compatible and will degrade and contaminate DEF Never use contaminated DEF Containers made of polyethylene or polypropylene...

Page 207: ...leaning activation key on page 57 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 automatic exhaust cleaning mode The exhaust cleaning icon will light when the system is inhibited and an exhaust cleaning cycle is needed The icon will light when an automatic cleaning is...

Page 208: ...ng until new clean grease seeps into the open front port 4 Replace plug 4 5 Inject 1 5 pumps WRG into zerk 6 Remove zerk and reinstall rear plug Location Task Notes DOWNHOLE TOOL AT Rockmaster tool AT only WRG p n 255 1019 IMPORTANT Do not use calcium based grease Use only Ditch Witch recommended grease or equivalent IMPORTANT Discontinue lubing the Rockmaster tool when there is resistance to addi...

Page 209: ...s shown 3 Distance from top edge of bottom of track to straightedge A should be 0 75 19 05 mm Location Task Notes DRILLING UNIT Check track tension and condition Check fuel filter water separator Check engine oil level DEO Check fluid pump piston seals Check engine coolant level DEAC Check pipe auto lubricator spray nozzle Check hydraulic hoses Check hydraulic fluid level THF Check fluid pump oil ...

Page 210: ...Check Engine Oil Level Check engine oil at dipstick 1 before startup and every 10 hours of operation Check with unit on level surface Add DEO at fill 2 as necessary to keep oil level at highest line on dipstick Check Fluid Pump Piston Seals Check piston seals for signs of excessive leakage before startup and every 10 hours of operation Replace if leakage becomes excessive j59om021w eps 1 2 j59om02...

Page 211: ...perly Clean as needed To clean 1 Rotate handle to the upward or cleanout position A 2 Operate pump until obstruction is flushed 3 Rotate handle to the downward or spray position B 4 Clean nozzle guard If necessary pull handle nozzle insert out of housing to clean with fine wire or solvent IMPORTANT See Approved Coolant on page 203 for information on approved coolants NOTICE Ditch Witch tool joint ...

Page 212: ...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 support any raised component with a hoist Cover connection with heavy cloth and loosen connector nut slightly to relieve residual pressure Catch all fluid in a container Before using system check tha...

Page 213: ...eck pipe auto lubricator TJC level before startup and every 10 hours of operation Change pail as needed See Change Auto Lubricator Pail on page 230 for procedure IMPORTANT If hydraulic system must be opened for repair install new filter p n 153 791 for first 50 hours of operation If this filter becomes plugged in fewer than 20 hours replace with new filter After 50 hours of normal operation replac...

Page 214: ...Ensure that strainer is free of debris Inspect Crankcase Breather Tube HRC only Inspect crankcase breather tube shown for debris before startup and every 10 hours of operation Empty Dust Ejector Valve Check dust ejector valve shown before startup and every 10 hours of operation Ensure that valve is not inverted damaged plugged or cracked j59om027w eps j59om094w eps j59om091w eps ...

Page 215: ...ill plug 2 Maintain fluid level at sight glass 1 Location Task Notes DRILLING UNIT Change fluid pump oil Initial service MPL Check radiator Change hydraulic filters Initial service Check ground drive gearbox oil level 2 gearboxes MPL Check rotation gearbox oil level MPL Inspect thrust rollers Drain water from hydraulic tank Check heavy duty anchor gearbox oil level MPL Check SaverLok inner drive c...

Page 216: ...filter every 500 hours thereafter Change filter more often if indicated by filter indicator Check Ground Drive Gearbox Oil Level Check oil level in both ground drive gearboxes every 50 hours Rotate plug shown until level with center of gearbox Open plug If oil does not come out add MPL as needed Never fill more than halfway IMPORTANT Be careful not to damage fins with high pressure air or water IM...

Page 217: ...t Thrust Rollers Inspect thrust rollers at each end of carriage shown every 50 hours Clean or replace if they do not turn freely Drain Water from Hydraulic Tank Drain water out of tank every 50 hours To drain turn plug slightly until water comes out After all water has drained tighten plug IMPORTANT Drill frame must be level for accurate reading j59om031w eps 1 2 j59om033w eps j59om035w eps ...

Page 218: ...n of hex stub 4 every 50 hours Replace if rounded To replace 1 Remove SaverLok connection Do not remove indexing dowels from spindle 2 Slide hex stub 4 and spring 3 off of drive shaft 3 Check condition of hex stub and replace if needed 4 Check o ring on inner water swivel 2 seal kit and replace if needed 5 Install new spring and hex stub 6 Install saver sub See Change Inner Water Swivel Seal Kit o...

Page 219: ...ery 50 hours To check 1 Start unit and position carriage so that collar can be clamped in rear wrenches 2 Clamp wrenches on collar and tighten SaverLok assembly until outer rotation pressure gauge reads 4500 5000 psi 310 345 bar in low speed setting See Outer rotation pressure gauge on page 53 j59om118w eps ...

Page 220: ...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 Rockmaster Tool Rebuild Kit 400 2460 190 2679 bearings and seals 400 2688 bearings seals spindle and hub 400 2630 ...

Page 221: ...cessary Change Rotation Gearbox Oil Change rotation gearbox oil every 250 hours To change 1 Drain oil at gearbox oil drain 3 2 Replace drain plug 3 Add MPL at fill 1 4 Check level at sight tube 2 5 Replace fill plug Location Task Notes DRILLING UNIT Inspect air intake system LRC only Change rotation gearbox oil MPL IMPORTANT Gearbox must be level for accurate reading j59om038w eps j59om045w eps 1 ...

Page 222: ...ge filter more often if indicated by filter indicator Location Task Notes DRILLING UNIT Change engine oil and filter DEO Change hydraulic filters Normal conditions Change hydraulic fluid THF Change fuel filters Inspect radiator cap IMPORTANT See Recommended Lubricants Service Key on page 202 IMPORTANT If hydraulic system must be opened for repair install new filter p n 153 791 for first 50 hours o...

Page 223: ...rs Replace fuel filters every 500 hours Inspect Radiator Cap Inspect radiator cap shown every 500 hours Ensure rubber seal is not damaged IMPORTANT Change oil every 250 hours if jobsite temperature exceeds 100 F 38 C more than 50 of the time Hot parts may cause burns Do not touch until cool or wear gloves 275 355 2 P 273 423 2 P To help avoid injury Wait for machine to cool before inspecting radia...

Page 224: ... is level 2 Drain oil at gearbox oil drain 1 Replace drain plug 3 Fill gearbox with MPL at fill plug 2 Location Task Notes DRILLING UNIT Change heavy duty anchor gearbox oil 2 gearboxes MPL Change standard duty anchor gearbox oil 2 gearboxes MPL Change engine drive belt Replace diesel exhaust fluid DEF tank filter HRC only Change ground drive gearbox oil 2 gearboxes MPL IMPORTANT Gearbox must be l...

Page 225: ...our bolts 1 to remove hydraulic motor 2 4 Remove o ring 3 Replace if needed Contact your Ditch Witch dealer for replacement parts 5 Fill gearbox with MPL at fill shown Change Engine Drive Belt Change engine drive belt every 1000 hours 1 Turn off engine and remove key 2 Use a 1 2 drive rachet at pulley 1 to remove tension 3 Remove belt 2 4 Inspect engine belt tensioner 3 for damage and debris 5 Ins...

Page 226: ...uction tube and press flush against bottom of heater tube fin Ensure filter retention screw aligns with retention screw housing 5 Install new retention screw 6 Install multifunction head unit into DEF tank Take care not to damage unit during installation Change Ground Drive Gearbox Oil Change oil in both ground drive gearboxes every 1000 hours To change 1 Drain oil at plug shown 2 Rotate gearbox 9...

Page 227: ...il full 3 Run engine with thermostat open 195 F 90 C engine temperature for several minutes 4 Stop engine and let it cool 5 Maintain coolant level at halfway point on sight glass 3 6 Install fill cap on expansion tank Location Task Notes DRILLING UNIT Change engine coolant DEAC Change fluid pump oil MPL Replace crankcase breather filter HRC only NOTICE The use of non approved coolant may lead to e...

Page 228: ...fluid level at sight glass 1 Replace Crankcase Breather Filter HRC Only Replace crankcase breather filter every 2000 hours To replace 1 Disconnect crankcase ventilation hose 1 2 Turn breather housing cover 2 counterclockwise 3 Remove filter element 3 4 Install the new filter element either end up in the crankcase ventilation breather housing 5 Install breather housing cover and turn clockwise 6 In...

Page 229: ...filter element 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 dosing unit 3 Install cap 1 and tighten to 177 in lb 20 N m IMPORTANT A disposable service tool is included with the filter to aid in filter removal Use the color of the plastic on the filte...

Page 230: ... mm 5 Drive straight forward one machine length and check tension again Location Task Notes DRILLING UNIT Adjust track tension Change auto lubricator pail TJC Check pipeloader inserts Check pipe guide inserts Check fluid pump ball valve Check track support slide pads Change inner water swivel seal kit Change air filter Clean crankcase breather tube Anytime system is opened Check wrench jaw inserts...

Page 231: ...id assembly from shoulder bolt and lower into pail guiding pump into center hole of follower plate 6 Relatch auto lubricator pail to pump 7 Remove cap from discharge tee on pump Operate pump until discharged TJC is free of air pockets Replace cap Check Pipeloader Inserts Check pipeloader inserts at indicated areas for wear Flip gripper inserts for longer wear or replace as needed NOTICE Use only g...

Page 232: ...uide 3 Remove guide inserts 4 Replace in reverse order To replace rear pipe guide inserts 1 Remove pin 1 to remove pin 2 2 Slide plate 3 up to remove guide inserts 4 3 Replace in reverse order Check Fluid Pump Ball Valve Check ball valve for leaks Tighten stem packing as needed Contact your Ditch Witch dealer for replacement packing NOTICE Failure to replace worn pipe guide inserts may cause damag...

Page 233: ...move seal bodies 2 4 Inspect set screw 1 To replace thread new set screw fully into different hole using Loctite 242 or equivalent 5 Slide new small seal body onto drive shaft 6 Lightly coat seal with SAE 30 engine oil and install large seal body 7 Install hex stub and spring 8 Install SaverLok connection and SaverLok See page 235 IMPORTANT Use care when handling main body to avoid seal contaminat...

Page 234: ... of housing and wash cover and dust ejector valve 4 4 Install new element s 5 Install cover and engage clasps 6 LRC only Reset air intake restriction indicator 3 Clean Crankcase Breather Tube Clean crankcase breather tube with detergent and warm water as needed NOTICE Only open the air filter canister when air restriction is indicated Change the elements do not attempt to clean them Compressed air...

Page 235: ... Wrench Jaw Inserts Check wrench jaw inserts for wear and replace as needed Change Hydraulic Filter Anytime System Opened Change hydraulic filter anytime system is opened for repair Change filter and add THF as needed at hydraulic fluid fill j59om056w eps j59om029w eps ...

Page 236: ...ve collar from system and set aside for later use 5 Remove SaverLok body from SaverLok connection 1 If parts are clean and dry pull SaverLok body free of SaverLok connection by hand If the parts are not clean and dry reposition carriage to clamp SaverLok body in rear wrench and thrust carriage back to pull SaverLok body free from connection 6 Turn off engine NOTICE Clamping front wrench on SaverLo...

Page 237: ...ition SaverLok body by hand for proper engagement of pins and grooves 6 Slide SaverLok collar over SaverLok body and hand tighten the threads typically 3 4 turns 7 Start unit and position carriage so that collar can be clamped in the rear wrenches 8 Clamp wrench on collar and tighten SaverLok assembly to a rotation pressure gauge reading between 4500 5000 psi 310 345 bar This is equivalent to 4500...

Page 238: ... 3 Loosen and remove battery cable clamps carefully negative cable first 4 Clean cable clamps and terminals with wire brush or battery cleaning tool to remove dull glaze 5 Check for signs of internal corrosion in cables 6 Connect battery cable clamps positive cable first 7 Tighten any loose connections 8 Ensure that battery tiedowns are secure 9 Turn battery disconnect switch to the on position Ex...

Page 239: ...low 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 as safety eyewear when charging or cleaning battery Keep sparks flames and any ignition source away from batteries at all times Internal contents are extremely hazardous Leaking fluid is corrosive Batte...

Page 240: ...o 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 charge in the failed battery 8 Stop engine in service vehicle 9 Remove jumper cables from the service vehicle black negative clamp first Do not allow clamps to touch 10 Remove black negative cable clamp f...

Page 241: ...Service 240 JT40 JT40 All Terrain Operator s Manual As Needed ...

Page 242: ...e height driving per SAE J2022 114 in 2 90 m transport per SAE J2022 97 in 2 46 m transport with cab per SAE J2022 97 in 2 46 m Operating mass T4 JT base unit no pipe per SAE J2022 20 500 lb 9300 kg T4 AT base unit no pipe per SAE J2022 21 600 lb 9800 kg LRC T3 JT base unit no pipe per SAE J2022 20 335 lb 9224 kg LRC T3 AT base unit no pipe per SAE J2022 21 435 lb 9723 kg Add cab option heat and a...

Page 243: ...JT40 small box 20 pipe 3797 lb 1720 kg HIWS1 Pipe U S Metric Length per SAE J2022 nominal 180 in 4 57 m Joint diameter per SAE J2022 3 10 in 79 mm Tubing diameter per SAE J2022 2 63 in 67 mm Minimum bend radius per SAE J2022 145 ft 44 m Weight per SAE J2022 165 lb 75 kg Weight of drill pipe and JT40 large box 35 pipe 6915 lb 3140 kg Weight of drill pipe and JT40 small box 15 pipe 3287 lb 1490 kg A...

Page 244: ... 40 000 lb 178 kN Pullback force per SAE J2022 40 000 lb 178 kN Bore diameter 4 50 in 114 mm Bore diameter All Terrain 5 50 in 140 mm Backream diameter soil dependent Ground travel speed forward per SAE J2022 3 0 mph 4 8 km h Ground travel speed reverse per SAE J2022 3 0 mph 4 8 km h Power U S Metric Engine Cummins QSB4 5 Fuel diesel Cooling medium liquid Injection direct Aspiration turbocharged a...

Page 245: ...ng fluid pressure per SAE J2022 1000 psi 69 bar Maximum drilling fluid flow per SAE J2022 70 gpm 265 L min Fluid Capacities U S Metric Hydraulic reservoir 17 gal 64 L Fuel tank 56 gal 212 L Engine oil including filter 14 qt 13 2 L Cooling system 24 qt 22 7 L Antifreeze tank 8 gal 30 L Diesel exhaust fluid DEF tank HRC only 3 6 gal 13 6 L Battery 2 used SAE reserve capacity 195 min 12V negative gro...

Page 246: ...el Ditch Witch XXXX Type machine type Engine Power xxx kW Serial Number CMWXXXXXXXXXXXXXX Conforms to the requirements of 2006 42 EC Machinery Directive 2014 30 EU Electromagnetic Compatibility Directive 2000 14 EC Noise Emission Directive Measured sound power level Annex V xxx dBA Guaranteed sound power level Annex V xxx dBA The Technical Construction File is maintained at the manufacturer s loca...

Page 247: ...Specifications 246 JT40 JT40 All Terrain Operator s Manual Declaration of Conformity Information ...

Page 248: ... 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 dealer Use of another manufacturer s parts may void warranty consideration Resources Publications Contact your Ditch Witch dealer for publications and videos covering safety operation service and repai...

Page 249: ...ERCHANTABILITY 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 AND THERE ARE NO IMPLIED WARRANTIES OF ANY KIND WHICH EXTEND TO A COMMERCIAL BUYER ALL OTHER PROVISIONS OF THIS LIMITED WARRANTY APPLY INCLUDING THE DUTIES IMPOSED Ditch Witch products have been tested to deliver acceptable ...

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Page 252: ...JT40 JT40 All Terrain Operator s Manual Service Record 251 Service Record Service Performed Date Hours ...

Page 253: ...Service Record 252 JT40 JT40 All Terrain Operator s Manual Service Performed Date Hours ...

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