JT25 Tier 3 and Tier 4i Operator’s Manual CMW® Issue 1.
JT25 Operator’s Manual Overview - 1 Overview Chapter Contents Serial Number Location . . . . . . . . . . . . . . . . . . . . . . 2 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Equipment Modification . . . . . . . . . . . . . . . . . . . . . . 3 Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Operator Orientation. . . . . . . . . . . . . . . . . . . . . . . . . 5 About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . .
JT25 Operator’s Manual Overview - 2 Serial Number Location Serial Number Location Record serial numbers and date of purchase in spaces provided. Drilling unit serial number is located as shown.
JT25 Operator’s Manual Overview - 3 Intended Use Intended Use The JT25 is a self-contained horizontal directional drilling unit designed to install buried cable and pipe to distances of 650’ (200 m) depending on soil conditions. The unit is designed for operation in temperatures typically experienced in earth moving and construction work environments. Provisions may be required to operate in extreme temperatures. Contact your Ditch Witch dealer.
JT25 Operator’s Manual Overview - 4 Unit Components Unit Components 1. Operator’s station 6. Tracks 2. Spindle 7. Pipeloader 3. Carriage 8. Vise wrenches 4. Drill frame 9. Anchoring system 5.
JT25 Operator’s Manual Overview - 5 Operator Orientation Operator Orientation 1 IMPORTANT: Top view of unit is shown. 1. Front of unit 2. Right side of unit 3. Rear of unit 4. Left side of unit 4 2 3 j37om003h.eps About This Manual This manual contains information for the proper use of this machine. See the beige Operation Overview pages for basic operating procedures. Cross references such as “See page 50” will direct you to detailed procedures.
Overview - 6 CMW JT25 Operator’s Manual
JT25 Operator’s Manual Foreword - 7 Foreword This manual is an important part of your equipment. It provides safety information and operation instructions to help you use and maintain your Ditch Witch equipment. Read this manual before using your equipment. Keep it with the equipment at all times for future reference. If you sell your equipment, be sure to give this manual to the new owner. If you need a replacement copy, contact your Ditch Witch dealer.
JT25 Operator’s Manual Foreword - 8 JT25 Tier 3 and Tier 4i Operator’s Manual Issue number 1.0/OM-03/13 Part number 053-2593 Copyright 2013 by The Charles Machine Works, Inc. , Ditch Witch, CMW, Jet Trac, Fluid Miser, Power Pipe, and The Underground Authority are registered trademarks of The Charles Machine Works, Inc. This product is covered by one or more of the following patents: U.S.
JT25 Operator’s Manual Contents - 9 Contents Overview 1 machine serial number, information about the type of work this machine is designed to perform, basic machine components, and how to use this manual Foreword 7 part number, revision level, and publication date of this manual, and factory contact information Safety 11 machine safety alerts and emergency procedures Controls 21 machine controls, gauges, and indicators and how to use them Operation Overview 55 an overview for completing a jo
Contents - 10 JT25 Operator’s Manual Specifications 193 machine specifications including weights, measurements, power ratings, and fluid capacities Support 197 the warranty policy for this machine, and procedures for obtaining warranty consideration and training Service Record a record of major service performed on the machine CMW 201
JT25 Operator’s Manual Safety - 11 Safety Chapter Contents Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Safety Alert Classifications . . . . . . . . . . . . . . . . . . 13 Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Emergency Procedures . . . . . . . . . . . . . . . . . . . . . 17 • Electric Strike Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 • If an Electric Line is Damaged . . . . . . . . . . . .
Safety - 12 JT25 Operator’s Manual Guidelines Guidelines Follow these guidelines before operating any jobsite equipment: • Complete proper training and read operator’s manual before using equipment. • Contact your local One-Call (811 in USA) or the One-Call referral number (888-258-0808 in USA and Canada) to have underground utilities located before digging. Also contact any utilities that do not participate in the One-Call service.
JT25 Operator’s Manual Safety - 13 Safety Alert Classifications Safety Alert Classifications These classifications and the icons defined on the following pages work together to alert you to situations which could be harmful to you, jobsite bystanders or your equipment. When you see these words and icons in the book or on the machine, carefully read and follow all instructions. YOUR SAFETY IS AT STAKE. Watch for the three safety alert levels: DANGER, WARNING and CAUTION. Learn what each level means.
JT25 Operator’s Manual Safety - 14 Safety Alerts Safety Alerts Turning shaft will kill you or crush arm or leg. Stay away. Electric shock. Contacting electric lines will cause death or serious injury. Know location of lines and stay away. Moving tools will kill or injure. Shut off drill string power when anyone can be struck by moving or thrown tools. Never use pipe wrenches on drill string. Jobsite hazards could cause death or serious injury. Use correct equipment and work methods.
JT25 Operator’s Manual Safety - 15 Safety Alerts Improper control function could cause death or serious injury. If control does not work as described in instructions, stop machine and have it serviced. Looking into fiber optic cable could result in permanent vision damage. Do not look into ends of fiber optic or unidentified cable. Pressurized fluid or air could pierce skin and cause injury or death. Stay away. Fire or explosion possible. Fumes could ignite and cause burns.
JT25 Operator’s Manual Safety - 16 Safety Alerts Hot pressurized cooling system fluid could cause serious burns. Allow to cool before servicing. Flying objects may cause injury. Wear hard hat and safety glasses. Hot parts may cause burns. Do not touch until cool. Exposure to high noise levels may cause hearing loss. Wear hearing protection. Fall possible. Slips or trips may result in injury. Keep area clean. Battery acid may cause burns. Avoid contact.
JT25 Operator’s Manual Safety - 17 Emergency Procedures Emergency Procedures Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. Before operating any equipment, review emergency procedures and check that all safety precautions have been taken. EMERGENCY SHUTDOWN - Turn ignition switch to stop position or push remote engine stop button (if equipped). Electric Strike Description Electric shock.
Safety - 18 JT25 Operator’s Manual Emergency Procedures If an Electric Line is Damaged If you suspect an electric line has been damaged and you are on drilling unit or bonded equipment, DO NOT MOVE. Remain on drilling machine and take the following actions. The order and degree of action will depend on the situation. • Warn people nearby that an electric strike has occurred. • Have someone contact electric company. • Reverse drilling direction and try to break contact.
JT25 Operator’s Manual Safety - 19 Emergency Procedures If a Gas Line is Damaged Fire or explosion possible. Fumes could ignite and cause burns. No smoking, no flame, no spark. Explosion possible. Serious injury or equipment damage could occur. Follow directions carefully. If you suspect a gas line has been damaged, take the following actions. The order and degree of action will depend on the situation. • Immediately shut off engine(s), if this can be done safely and quickly.
Safety - 20 JT25 Operator’s Manual Emergency Procedures If a Fiber Optic Cable is Damaged Do not look into cut ends of fiber optic or unidentified cable. Vision damage can occur. If Machine Catches on Fire Perform emergency shutdown procedure and then take the following actions. The order and degree of action will depend on the situation. • Immediately move battery disconnect switch (if equipped and accessible) to disconnect position.
JT25 Operator’s Manual Controls - 21 Controls Chapter Contents Set-Up Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Tethered Ground Drive Controller . . . . . . . . . . . . 25 Left Control Console . . . . . . . . . . . . . . . . . . . . . . . 27 • Engine Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 • Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JT25 Operator’s Manual Controls - 22 Set-Up Console Set-Up Console 2 1 3 4 5 6 10 9 8 7 j37om004h.eps 1. Engine shutdown override switch 6. Left track switch 2. Rear hood switch 7. Right stabilizer control 3. Cold start wait indicator 8. Left stabilizer control 4. Ignition switch 9. Back frame tilt control 5. Right track switch 10. Front frame tilt control Item Description Notes 1.
JT25 Operator’s Manual Controls - 23 Set-Up Console Item Description 2. Rear hood switch To open rear hood, press left side of switch. Notes To close rear hood, press right side of switch. 3. Cold start wait indicator Lights when intake air preheater is operating. NOTICE: If indicator is on, wait until it goes out before starting engine. Wait until light goes off before starting engine.
JT25 Operator’s Manual Controls - 24 Set-Up Console Item Description Notes 6. Left track switch To move forward, press top. IMPORTANT: Use track switches only if tethered control is inoperable. To move backward, press bottom. c00ic147h.eps 7. Right stabilizer control To raise, pull up. To lower, push down. IMPORTANT: Lower left and right stabilizers to the ground together, then adjust individually. WARNING: Crushing weight could cause death or serious injury.
JT25 Operator’s Manual Controls - 25 Tethered Ground Drive Controller Tethered Ground Drive Controller 1 5 2 4 3 j10om016h.eps 1. Speed/direction control 4. Operator presence switch 2. Drive mode switch 5. Throttle switch 3. Remote engine stop Item Description Notes 1. Speed/direction control To move forward, push. IMPORTANT: To move backward, pull. • Operator presence switch must be pressed and operator seat must be empty for control to work.
JT25 Operator’s Manual Controls - 26 Tethered Ground Drive Controller Item Description 2. Drive mode switch To select normal driving mode (high), push. Notes To select loading and unloading mode (low), pull. To disable controller, return to center. c00ic146h.eps 3. Remote engine stop To stop engine, press red button. 4. Operator presence switch To operate ground drive with tethered controller, press. To disable controller, release. 5. Throttle switch To increase engine speed, press top.
JT25 Operator’s Manual Controls - 27 Left Control Console Left Control Console Engine Display 1. Fuel gauge 7. Soft key 2. Tachometer 8. Soft key 3. Drilling fluid flow display 9. Main menu key 4. Engine coolant temperature gauge 10. Soft key 5. Hour meter 11. Day/Night mode key 6. Engine oil pressure gauge 12. Voltmeter display Item Description Notes 1. Fuel gauge Displays amount of fuel remaining in tank. See “Approved Fuel” on page 167. 2. Tachometer Displays engine speed. 3.
JT25 Operator’s Manual Controls - 28 Left Control Console Item Description Notes 4. Engine coolant temperature gauge Displays engine coolant temperature. Normal coolant temperature is 160°212° F (71°-100° C). 5. Hour meter Displays number of hours engine has been running. 6. Engine oil pressure gauge Displays engine oil pressure. Full load reading should be 60-80 psi (4.1-5.5 bar). 7. Soft key Press to select a soft key command.
JT25 Operator’s Manual Controls - 29 Left Control Console Controls 4 5 3 2 6 1 12 11 10 j37om007h.eps 9 7 8 1. Wrench control 7. Carve potentiometer 2. Set/Resume switch 8. Carve switch 3. Pipe gripper switch 9. Fluid flow control 4. Pipe shuttle switch 10. Engine throttle switch 5. Pipe lift switch 11. High/Low rotation switch 6. Pipe lubricator switch 12.
JT25 Operator’s Manual Controls - 30 Left Control Console Item Description 1. Wrench control To clamp and rotate rear wrench, push forward. Notes To unclamp rear wrench, pull back. To clamp front wrench, move to right. c00ic612h.eps 2. Set/Resume switch To unclamp rear wrench, move to left. To resume operation or increase operation levels, press top. To set operating conditions or reduce operation levels, press bottom. 3. Pipe gripper switch To close, press top. To open, press bottom. 4.
JT25 Operator’s Manual Controls - 31 Left Control Console Item Description 5. Pipe lift switch To raise, press top. Notes To lower, press bottom. 6. Pipe lubricator switch To apply joint compound, press. c00ic616h.eps 7. Carve window control To increase carve window range, turn clockwise. See “Use AutoCarve” on page 98. To decrease carve window range, turn counterclockwise. c00ic609h.eps 8. AutoCarve switch To enable autocarve, press top. To deactivate autocarve, press bottom. c00ic608h.
JT25 Operator’s Manual Controls - 32 Left Control Console Item Description Notes 10. Engine throttle switch To increase speed, press top. Autothrottle mode slows the engine to low throttle after 15 seconds of inactivity 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. To enable autothrottle mode, leave switch in top position.
JT25 Operator’s Manual Controls - 33 Right Control Console Right Control Console Lights 2 4 3 5 6 7 8 9 10 1 12 11 j37om008h.eps 1. Diagnostic light (red) 7. Control cycle light (green) 2. Rear stop status light 8. Remote display 3. Rear home status light 9. Rotation pressure gauge 4. Front home status light 10. Drilling fluid pump status indicator 5. Shuttle home status light 11. Drilling fluid pressure gauge 6. Operator presence light 12.
JT25 Operator’s Manual Controls - 34 Right Control Console Item Description 1. Diagnostic light (red) If system is OK, light should be off. Notes If system may not be getting power, light should be on. If a non-essential diagnostic code is recorded, light should flash on and off for 10 seconds. If an essential diagnostic code is recorded, light should flash on for three seconds and off for half a second. 2. Rear stop status light If carriage is at rear stop, light should be on.
JT25 Operator’s Manual Controls - 35 Right Control Console Item Description 5. Shuttle home status light If shuttle is retracted, light should be on. Notes If shuttle is extended, light should be off. c00ic620h.eps 6. Operator presence light If seat switch is engaged, light should be on. If seat switch is not engaged, light should be off. c00ic621h.eps 7. Control cycle light (green) If nothing is being controlled, light should be off.
JT25 Operator’s Manual Controls - 36 Right Control Console Item Description 10. Drilling fluid pump status light Lights when pump is on. 11. Drilling fluid pressure gauge Displays drilling fluid pressure. c00ic627h.eps 12. Thrust pressure gauge Displays hydraulic fluid pressure to thrust motor during thrust and pullback. Notes IMPORTANT: Monitor this gauge and drilling fluid flowmeter carefully to see if values are rising or falling at the same time. If they are not, nozzle might be plugged.
JT25 Operator’s Manual Controls - 37 Right Control Console Controls 1. Dual speed carriage control 6. Operator’s station pivot switch 2. Thrust and rotation control 7. Add pipe/manual/remove pipe switch 3. Remote engine start switch 8. Drilling fluid pump switch 4. Remote engine stop switch 9. Drilling fluid quick fill switch 5. Anchor enable switch Item Description Notes 1. Dual speed carriage control To increase carriage travel speed, push and hold.
JT25 Operator’s Manual Controls - 38 Right Control Console Item Description 2. Thrust and rotation control To move carriage forward, push. Notes To move carriage backward, pull. To rotate spindle counterclockwise (breakout), move right. c00ic622h.eps To rotate spindle clockwise (makeup), move left. 3. Remote engine start switch To start engine, press. IMPORTANT: Ignition switch on rear console must be on to start engine remotely. 4. Remote engine stop switch To stop engine, press.
JT25 Operator’s Manual Controls - 39 Right Control Console Item Description Notes 6. Operator’s station pivot control switch To pivot into drilling position, press top. NOTICE: Move carriage only when operator’s station is in drilling position. To pivot into transport position, press bottom. c00ic624h.eps 7. Add pipe/manual/ remove pipe switch To select “add pipe” automated pipeloader function, press top. See “Add Pipe” on page 94. To use manual pipeloader controls, move to center.
JT25 Operator’s Manual Controls - 40 Anchoring System Console Anchoring System Console 1 2 3 4 j37om013h.eps 1. Left rotation control 3. Right rotation control 2. Left thrust control 4. Right thrust control Item Description 1. Left rotation control To drive anchor, pull. To remove anchor, push. c00ic625h.eps 2. Left thrust control To move anchor down, pull. To move anchor up, push. c00ic623h.
JT25 Operator’s Manual Controls - 41 Anchoring System Console Item Description 3. Right rotation control To drive anchor, pull. To remove anchor, push. c00ic625h.eps 4. Right thrust control To move anchor down, pull. To move anchor up, push. c00ic623h.
JT25 Operator’s Manual Controls - 42 Seat Seat 1. Seat recline control 3. Seat lumbar control 2. Seat slide control Item Description 1. Seat recline control To raise seatback, turn toward anchors. To recline seatback, turn toward engine compartment. 2. Seat slide control To slide forward or backward, move left. To lock seat in position, release. 3. Seat lumbar control To have least support, move up. To have medium support, move down. To have maximum support, move toward engine compartment.
JT25 Operator’s Manual Controls - 43 Cab Controls (optional) Cab Controls (optional) Top/Rear 1 2 3 4 5 j29om002t.eps 1. Dome light switch 4. Air conditioner fan speed dial 2. Air conditioner on/off switch 5. Air conditioner filter 3. Air conditioner temperature dial Item Description 1. Dome light switch To turn on dome light, press right. To turn off dome light, press left.
JT25 Operator’s Manual Controls - 44 Cab Controls (optional) Item Description 2. AC on/off switch To turn air conditioner on, press left. Notes To turn air conditioner off, press right. 3. AC temperature dial To adjust air temperature, turn dial. 4. AC fan speed dial To adjust fan speed, turn dial. 5. Air conditioner filter Filters air coming into cab. Clean or replace air filter as needed.
JT25 Operator’s Manual Controls - 45 Cab Controls (optional) Front 1 2 j29om003t.eps 1. Washer switch 3. Worklight switch 2. Wiper switch Item Description 1. Washer switch To spray washer fluid, press top. To stop, press bottom. 2. Wiper switch To start wiper blade, press top. To stop wiper blade, press bottom.
JT25 Operator’s Manual Controls - 46 Cab Controls (optional) Item Description 3. Worklight switch To turn on, press top. To turn off, press bottom. c00ic626h.
JT25 Operator’s Manual Controls - 47 Engine Compartment Controls Engine Compartment Controls 1. Throttle switch 4. Air intake service indicator 2. Tracker Control key 5. Battery disconnect switch 3. J1939 CAN diagnostic port, engine Item Description Notes 1. Throttle switch To increase engine speed, press top. Use this switch only if throttle switch on console does not work. To decrease engine speed, press bottom. c00ic243h.
JT25 Operator’s Manual Controls - 48 Engine Compartment Controls Item Description Notes 2. Tracker Control key To allow tracker operator to stop thrust and rotation, move key to enable position (up). IMPORTANT: Remove key and keep in tracker operator’s possession. To override tracker control mode, move key to disable position (right). 3. J1939 CAN diagnostic port, engine For use only by qualified Ditch Witch technicians. 4. Air intake restriction indicator Shows air intake restriction.
JT25 Operator’s Manual Controls - 49 Miscellaneous Controls Miscellaneous Controls 1 2 3 4 j37om005h.eps 1. EDT diagnostic port, controller 3. Work light switch 2. Auxiliary outlet 4. Audible alarm Item Description 1. EDT diagnostic port, controller For use only by qualified Ditch Witch technicians. 2. Auxiliary outlet Supplies power to 12V devices. 3. Work light switch To turn on, press top. To turn off, press bottom. c00ic151h.
JT25 Operator’s Manual Controls - 50 Miscellaneous Controls Item 4. Description Audible alarm Beeps when key is in run position, but engine is not running. Sounds continuously when hydraulic fluid temperature is too high.
JT25 Operator’s Manual Controls - 51 ESID ESID 2 3 1 4 5 6 7 8 j07om042h.eps 1. Alphanumeric display 5. Current problem indicator 2. Strike indicator 6. OK indicator 3. Alarm interrupt button 7. Electrical power supply indicator 4. Voltage problem indicator 8. Self test button Item Description 1. Alphanumeric display Display amount of current and voltage being detected as a percentage of strike condition.
JT25 Operator’s Manual Controls - 52 ESID Item Description 3. Alarm interrupt button To turn off strike alarm at drilling unit, press. 4. Voltage problem indicator Red light indicates a voltage indicator problem. See “Troubleshoot Strike System” on page 113. 5. Current problem indicator Red light indicates a current indicator problem. See “Troubleshoot Strike System” on page 113. 6. OK indicator Green light means system self test detected no problems. Strike system is ready to operate.
JT25 Operator’s Manual Controls - 53 ESID Item Description 7. Electrical power supply indicator Green light means control box has sufficient electrical power for operation. Notes Strike system is ready to operate if OK indicator is also on. 8. Self test button To start manual self test, press. Checks all systems and circuits except voltage limiter. To reset system after a strike has been detected, press. NOTICE: See “If an Electric Line is Damaged” on page 18.
Controls - 54 JT25 Operator’s Manual ESID
JT25 Operator’s Manual Operation Overview - 55 Operation Overview Chapter Contents Planning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Setting Up at Jobsite . . . . . . . . . . . . . . . . . . . . . . . 56 Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Backreaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Leaving Jobsite. . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Storing Equipment . . . . . . . . . . . . . .
Operation Overview - 56 JT25 Operator’s Manual Planning Planning 1. Gather information about jobsite. See page 61. 2. Inspect jobsite. See page 62. 3. Classify jobsite. See page 64. 4. Plan bore path. See page 66. 5. Check supplies and prepare equipment. See page 72. 6. Load equipment. See page 80. Setting Up at Jobsite 1. Prepare jobsite. See page 71. 2. Mix drilling fluid. See page 117. 3. Unload drilling unit from trailer. See page 82. 4. Assemble drill string. See page 73. 5.
JT25 Operator’s Manual Operation Overview - 57 Drilling Drilling 1. Start system. See page 88. 2. Engage tracker control if desired. See page 121. 3. Drill first pipe. See page 93. 4. Record bore path. See page 100. 5. Enable automated pipeloader system. See page 93. 6. Add pipe. See page 94. 7. Drill remaining pipes in pipe box. • Correct direction. See page 96. • Engage cruise control. See page 140. 8. Add additional drill pipe to empty box (see page 136) to complete bore. 9. Surface drill head.
Operation Overview - 58 JT25 Operator’s Manual Backreaming Backreaming 1. Assemble backream string. See page 102. 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 138) to complete backream. 5. Remove remaining pipe to complete backream. 6. Remove pullback device. See page 105. Backreaming Tips • Plan backreaming job before drilling. Plan bore path as straight as possible.
JT25 Manual Prepare - 59 Prepare Chapter Contents Gather Information . . . . . . . . . . . . . . . . . . . . . . . . . 61 • Review Job Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 • Notify One-Call Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 • Examine Pullback Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 • Arrange for Traffic Control. . . . . . . . . . . . . . . . . . . . . . .
Prepare - 60 Prepare Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 • Mark Bore Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 • Prepare Entry Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Check Supplies and Prepare Equipment . . . . . . . 72 • Check Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 • Prepare Equipment . . . . . . . . . . . . .
JT25 Manual Prepare - 61 Gather Information Gather Information A successful job begins before the bore. The first step in planning is reviewing information already available about the job and jobsite. Review Job Plan Review blueprints or other plans and make sure you have taken bore enlargement during backreaming and pullback into account. Check for information about existing or planned structures, elevations, or proposed work that may be taking place at the same time.
JT25 Manual Prepare - 62 Inspect Site Inspect Site Inspect jobsite before transporting equipment. Check for the following: • overall grade or slope • changes in elevation such as hills or open trenches • obstacles such as buildings, railroad crossings, or streams • signs of utilities (See “Inspect Jobsite” on page 64.) • traffic • access • soil type and condition • water supply • sources of locator and tracker interference (rebar, railroad tracks, etc.
JT25 Manual Prepare - 63 Inspect Site Select Start and End Points Select one end to use as a starting point. Consider the following when selecting a starting point: Slope Fluid system should be parked on a level site. Consider how slope will affect drilling unit setup, bending pipe, and fluid flow out of hole. Traffic Vehicle and pedestrian traffic must be a safe distance from drilling equipment. Allow at least 10’ (3 m) buffer zone around equipment.
JT25 Manual Prepare - 64 Classify Jobsite Classify Jobsite Inspect Jobsite • Follow U.S. Department of Labor regulations on excavating and trenching (Part 1926, Subpart P) and other similar regulations. • Contact your local One-Call (811 in USA) or the One-Call referral number (888-258-0808 in USA and Canada) to have underground utilities located before digging. Also contact any utilities that do not participate in the One-Call service.
JT25 Manual Prepare - 65 Classify Jobsite Apply Precautions Once classified, precautions appropriate for jobsite must be taken. Electric Jobsite Precautions se one or both of these methods. • Expose line by careful hand digging or soft excavation. Use beacon to track bore path. If utility must be crossed, tracker operator must watch the during drilling and backreaming.
Prepare - 66 JT25 Manual Plan Bore Path Plan Bore Path Plan the bore path, from entry to end, before drilling begins. Ditch Witch bore planning software is available for planning your bore path. This special software can be run in the field using a laptop computer. See your Ditch Witch dealer for details. If not using bore planning software, mark the bore path on the ground with spray paint or flags, or record it on paper for operator reference. For complicated bores, consult an engineer.
JT25 Manual Prepare - 67 Plan Bore Path Recommended Bend Limits Ditch Witch drill pipes are designed to bend slightly during operation. Slight bending allows for steering and correcting direction. Bending beyond recommended limits will cause damage that might not be visible. This damage adds up and will later lead to sudden drill pipe failure. IMPORTANT: Consider recommended bend limits during any bend, not just during bore entry.
JT25 Manual Prepare - 68 Plan Bore Path Pipe-By-Pipe Bend Limits Pipe (C) Forward (B) Deflection (A) Pipe (C) Forward (B) Deflection (A) 1 9’ 10” (3.0 m) 0’ 3.7” (0.1 m) 14 120’ 4.2” (36.7 m) 57’ 3.8” (17.5 m) 2 19’ 7.6” (6.0 m) 1’ 3” (0.4 m) 15 126’ 3.7” (38.5 m) 65’ 1.9” (19.9 m) 3 29’ 4.2” (8.9 m) 2’ 9.6” (0.9 m) 16 131’ 9” (40.2 m) 73’ 4.2” (22.4 m) 4 38’ 11.4” (11.9 m) 4’ 11.7” (1.5 m) 17 136’ 8” (41.7 m) 81’ 10.5” (25.0 m) 5 48’ 4.7” (14.7 m) 7’ 9” (2.
JT25 Manual Prepare - 69 Plan Bore Path Entry Pitch Entry pitch is the slope of the drill frame compared with the slope of the ground. Determine entry pitch one of two ways: 1. With Pitch Beacon • Lay pitch beacon on the ground and read pitch. • Lay pitch beacon on drill frame and read pitch. • Subtract ground pitch from drilling unit pitch. 2. With Measurements • Measure from the ground to front end of drill frame (H1). • Measure from the ground to back end of frame (H2).
JT25 Manual Prepare - 70 Plan Bore Path Minimum Depth Because you must bend pipe gradually, entry pitch and bend limits determine how deep the pipe will be when it becomes horizontal. This is called the minimum depth. • To reduce minimum depth (D1), reduce entry pitch. This also decreases setback. • To increase minimum depth (D2), increase entry pitch. This also increases setback. Bore Path Calculator Entry pitch, setback, and minimum depth work together with bend limits to determine the bore path.
JT25 Manual Prepare - 71 Prepare Jobsite Prepare Jobsite Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. To help avoid injury: • Classify jobsite as electric if jobsite classification is in question or if the possibility of unmarked electric utilities exists. • Expose lines by hand before digging. Cutting high voltage cable can cause electrocution. • Remove all vegetation near operator’s station.
JT25 Manual Prepare - 72 Check Supplies and Prepare Equipment Check Supplies and Prepare Equipment Check Supplies • receiver/transmitter or tracker with spare batteries • beacons with new and spare batteries • two-way radios with new and spare batteries • quick wrench (see page 129) • transition sub • anchoring equipment and accessories • bits, screens, nozzles (see page 124) • adapters, pipe, beacon housings • marking flags or paint • water and additional hoses • fuel • drilling f
JT25 Manual Prepare - 73 Check Supplies and Prepare Equipment Prepare Equipment Fluid Levels • fuel • hydraulic fluid • engine coolant • battery charge • engine oil Condition and Function • filters (air, oil, hydraulic) • fluid pump • couplers • tires and tracks • pumps and motors • drilling fluid mixer • hoses and valves • water tanks Assemble Accessories Fire Extinguisher If required, mount a fire extinguisher near the power unit but away from possible points of ignition.
Prepare - 74 CMW JT25 Manual
JT25 Operator’s Manual Drive - 75 Drive Chapter Contents Start Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Steer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Shut Down Unit . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive - 76 JT25 Operator’s Manual Start Unit Start Unit 1. Insert key. 2. Turn key clockwise. See page 23 for more information. 3. Run engine at low throttle for 5 minutes. Steer Unit To steer drilling unit while using tethered ground drive controller, follow instructions for type of steering desired. To steer while moving forward, push forward and move to left or right. Drilling unit will turn to left or right. To steer while moving backward, pull back and move to left or right.
JT25 Operator’s Manual Drive - 77 Shut Down Unit Tips to Reduce Track Wear Rubber tracks are best suited at soil-based job sites with minimal rock and debris. Sharp objects such as gravel, steel shards, and broken concrete will damage rubber tracks and undercarriage components. Excessive operation on concrete or asphalt will shorten track life. When storing your machine, keep tracks away from rain and direct sunlight.
Drive - 78 JT25 Operator’s Manual Shut Down Unit CMW
JT25 Operator’s Manual Transport - 79 Transport Chapter Contents Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 • Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 • Unload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Tow . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JT25 Operator’s Manual Transport - 80 Lift Lift This machine is not configured for lifting. If the machine must be lifted, load machine into a container or onto a platform appropriate for lifting. See “Specifications” for weight of machine. Pipe Box Lifting Procedure Pipe Box lifting points are identified by lifting decals. Lifting at other points is unsafe and can damage machinery. See “Remove/Install Pipe Box” on page 134. Load Crushing weight. If load falls or moves it could kill or crush you.
JT25 Operator’s Manual Transport - 81 Load Tie Down Points Tiedown points are identified by tiedown decals. Securing to trailer at other points can damage machinery. Procedure 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. Loop a transport chain around each tie down point.
JT25 Operator’s Manual Transport - 82 Tow Unload Crushing weight. If load falls or moves it could kill or crush you. Use proper procedures and equipment or stay away. To help avoid injury: • Attach trailer to vehicle before loading or unloading. • Load and unload trailer on level ground. • Ensure trailer wheels are blocked. 1. Lower ramps. 2. Remove tiedowns. 3. Start drilling unit engine. 4. Using tethered ground drive controller, pull power mode switch into low position. See page 25. 5.
JT25 Operator’s Manual Transport - 83 Tow To disengage track planetaries, reverse small cover plate in center of planetary on each track drive. IMPORTANT: When planetaries are disengaged, unit has no brakes. A. Normal operation B.
Transport - 84 JT25 Operator’s Manual Tow CMW
JT25 Operator’s Manual Conduct a Bore - 85 Conduct a Bore Chapter Contents Position Equipment . . . . . . . . . . . . . . . . . . . . . . . . 87 Connect Fluid System . . . . . . . . . . . . . . . . . . . . . . 87 Start System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Prime Drilling Fluid Pump . . . . . . . . . . . . . . . . . . . 88 Operate Carriage Control . . . . . . . . . . . . . . . . . . . 89 Clamp Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conduct a Bore - 86 JT25 Operator’s Manual Use Carve Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Record Bore Path . . . . . . . . . . . . . . . . . . . . . . . . . 100 Surface Drill Head . . . . . . . . . . . . . . . . . . . . . . . . 100 Backream. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Remove Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Remove Pullback Device . . . . . . . . . . . . . . . . . . .
JT25 Operator’s Manual Conduct a Bore - 87 Position Equipment Position Equipment 1. Review bore plan and select drilling unit position and fluid unit position. See “Select Start and End Points” on page 63. 2. Move equipment into selected positions. Connect Fluid System Electric shock. Contacting electric lines will cause death or serious injury. Know location of lines and stay away. To help avoid injury: Do not connect drilling unit to a public or private (business or home) water supply.
JT25 Operator’s Manual Conduct a Bore - 88 Start System Start System 1. Start drilling unit and remote fluid unit. Allow both engines to warm up. IMPORTANT: Ensure that mixture of drilling fluid matches drilling conditions. See “Drilling Fluid” on page 117. 2. Enable tracker control mode if desired. See “Tracker Control” on page 121. 3. Press top of drilling unit throttle switch. Engine will increase to full throttle. If you do not want to use autothrottle mode, return switch to center position.
JT25 Operator’s Manual Conduct a Bore - 89 Operate Carriage Control Operate Carriage Control Drilling During normal drilling operation, the thrust/rotation joystick controls both operations and allows any combination of the two based on the position of the joystick: • Push joystick toward 1A for forward thrust with clockwise rotation. NOTICE: Counterclockwise rotation can unthread pipe in the ground. • Push joystick toward 2A for forward thrust with counterclockwise rotation.
JT25 Operator’s Manual Conduct a Bore - 90 Clamp Pipe Clamp Pipe Turning shaft can kill you or crush arm or 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: Wrenches can open after engine shutdown. Ensure that any downhole tool or pipe in tool joint vises is attached to spindle or removed before transport.
JT25 Operator’s Manual Conduct a Bore - 91 Assemble Drill String Assemble Drill String 1. bit 2. beacon housing 3. adapter 4. collar 5. transition sub 6. JT25 drill pipe Prepare Beacon Housing 1. Select nozzles and bit. IMPORTANT: A variety of nozzles and bits are available to suit your particular job conditions. See page 146 for more information, or contact your Ditch Witch dealer. 2. Insert nozzle into beacon housing. 3. Attach bit to beacon housing. 4.
Conduct a Bore - 92 JT25 Operator’s Manual Assemble Drill String 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. Connect Drill Pipe 1. Start drilling unit engine. 2. Align drill pipe in front wrench. 3. Clamp tool joint in front wrench. See “Clamp Pipe” on page 90. 4.
JT25 Operator’s Manual Conduct a Bore - 93 Drill First Pipe Drill First Pipe Turning shaft can kill you or crush arm or leg. Stay away. To help avoid injury: • Keep everyone at least 10’ (3 m) away from turning drill string. • Push pipe slowly. Forcing can bend string. Do not use bent pipe. Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. 1. Turn on drilling fluid. 2. Visually check for drilling fluid flow. 3.
JT25 Operator’s Manual Conduct a Bore - 94 Add Pipe Add Pipe 1. Press top of drilling unit throttle switch until engine is at full throttle. 2. Enable automated pipeloader system (automated pipeloader control only). See “Enable Automated Pipeloader System” on page 93. 3. Break joint at SaverLok. Manual Pipeloader Controls Automated Pipeloader Control • Clamp pipe joint. See “Clamp Pipe” on page 90. • Clamp pipe joint. See “Clamp Pipe” on page 90. • Locate drill head. • Locate drill head.
JT25 Operator’s Manual Conduct a Bore - 95 Add Pipe 5. Connect pipe to SaverLok. Manual Pipeloader Controls Automated Pipeloader Control IMPORTANT: Always rotate clockwise unless breaking pipe joint. Rotating counterclockwise will separate joints. IMPORTANT: Always rotate clockwise unless breaking pipe joint. Rotating counterclockwise will separate joints. • Move carriage forward until SaverLok meets pipe. • Move carriage forward until SaverLok meets pipe.
Conduct a Bore - 96 JT25 Operator’s Manual Correct Direction Correct Direction Correcting direction is a skill operators gain with experience and knowledge of equipment and soil conditions. These instructions cover only basic procedures. For information about specific equipment or jobsites, contact your Ditch Witch dealer. To track progress and make corrections, one crew member tracks the drill head and sends instructions to the operator.
JT25 Operator’s Manual Conduct a Bore - 97 Correct Direction Procedure 1. Locate drill head. Take readings available with your beacon and tracking equipment such as: • depth • pitch • left/right information • temperature • beacon roll 2. Compare position to bore plan. Determine direction drilling should go. 3. Position drill head. 4. Drill in pipe. Drill Head Position The drill head position is determined by reading beacon roll. Roll is displayed as a clock face position. 1. Read beacon roll.
JT25 Operator’s Manual Conduct a Bore - 98 Use AutoCarve Use AutoCarve AutoCarve helps the operator change direction when thrust stalls in difficult soil conditions. AutoCarve rotates the bit clockwise and counterclockwise to grind away soil, clearing a path to improve steering through tough formations. Movement Description alternating clockwise and counterclockwise rotation Enables the downhole tool to carve tough soil formations. Rotation speed can be adjusted during autocarving.
JT25 Operator’s Manual Conduct a Bore - 99 Use AutoCarve Operation IMPORTANT: • 2-speed thrust is not allowed in AutoCarve mode. • AutoCarve mode is disabled while front wrench is closed. • Adding or removing pipe does not affect AutoCarve position. 1. Position downhole tool for carving. Rotate the toolhead to the desired position. 2. Turn on AutoCarve mode. Press top of AutoCarve switch. 3. Begin carving. Push joystick fully forward then release to neutral to start alternating rotation.
JT25 Operator’s Manual Conduct a Bore - 100 Record Bore Path 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. Ditch Witch bore tracking software is also available for plotting and tracking your bore path.
JT25 Operator’s Manual Conduct a Bore - 101 Backream Backream Sometimes it is necessary to drill a pilot hole first, then enlarge the hole to accommodate larger product. As a general rule, the final hole should be 1.5 times larger than the diameter of the product being installed. The number of passes needed depends on soil conditions. Do not try to increase hole size too much in one pass. Several passes using successively larger reamers will save wear on machine. Moving tools will kill or injure.
Conduct a Bore - 102 JT25 Operator’s Manual Backream Assemble Backream String 1. Select backreaming devices. See “Backreamers” on page 126. 2. Determine fluid rate requirements and install appropriate nozzles to provide sufficient flow. See “Backream Fluid Requirements” on page 127 and “Nozzles” on page 124. 3. Attach backreamer to beacon housing if tracking backream. 4. Install beacon, following beacon instructions for: • battery replacement • beacon positioning 5. Install beacon housing lid.
JT25 Operator’s Manual Conduct a Bore - 103 Remove Pipe Remove Pipe 1. Enable automated pipeloader system (automated pipeloader control only). See “Enable Automated Pipeloader System” on page 93. 2. Stop carriage when alignment pin becomes visible behind rear wrench. 3. Clamp pipes. See “Clamp Pipe” on page 90. 4. Break front joint: • Turn rear wrench counterclockwise to break joint. • Disengage rear wrench and rotate wrench clockwise. 5.
JT25 Operator’s Manual Conduct a Bore - 104 Remove Pipe 7. Break rear joint: Manual Pipeloader Controls Automated Pipeloader Control • Engage rear wrench. • Engage rear wrench. • Slowly rotate spindle counterclockwise and move carriage back until joint is loosened. Do not fully separate joint. • Slowly rotate spindle counterclockwise and move carriage back until joint is loosened. Do not fully separate joint. • Disengage rear wrench. • Disengage rear wrench.
JT25 Operator’s Manual Conduct a Bore - 105 Remove Pullback Device Remove Pullback Device The pullback device can be removed when the last pipe is on the frame. It can also be removed when a target pit along the bore path has been reached. Remaining pipe is then pulled back and removed. Moving tools will kill or injure. Shut off drill string power when anyone can be struck by moving or thrown tools. Never use pipe wrenches on drill string. 1.
Conduct a Bore - 106 JT25 Operator’s Manual Remove Pullback Device CMW
JT25 Operator’s Manual Systems and Equipment - 107 Systems and Equipment Chapter Contents Anchor System . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 • Drive Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 • Remove Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Electric Strike System . . . . . . . . . . . . . . . . . . . . . 111 • FCC Statement . . . . . . . . . . . . . . . . . . . . . . . . . .
Systems and Equipment - 108 JT25 Operator’s Manual Downhole Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 124 • Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 • Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 • Beacon Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 • Backreamers . . . . . . . . . . . . . . . . . . . . . .
JT25 Operator’s Manual Systems and Equipment - 109 Anchor System Anchor System Crushing weight. If load falls or moves, it could kill or crush you. Use proper procedures and equipment or stay away. To help avoid injury: • Drive anchors properly before drilling. • Stand on platform when operating anchor controls. • Wear high-top protective boots with legs of pants completely tucked inside. • Wear protective gloves.
Systems and Equipment - 110 JT25 Operator’s Manual Anchor System Drive Anchors 1. Press top of anchor enable switch. 2. Raise anchor shaft to top of anchor frame. NOTICE: Centering cap MUST be positioned in centering tube to prevent damage to anchor. 3. Use high speed rotation and low thrust speed to start driving anchor into ground. 4. Stop rotation and carefully position cap (1) into centering tube (2). Continue rotation and drive anchor into the ground. 5.
JT25 Operator’s Manual Systems and Equipment - 111 Electric Strike System Electric Strike System Any time you drill in an electric jobsite, electric strike system must be properly set up, tested, and used. You must wear protective boots and gloves meeting the following standards: • Boots must have high tops and meet the electric hazard protection requirements of ASTM F2413 or ASTM F1117 when tested at 14,000 volts. Tuck legs of pants completely inside boots.
Systems and Equipment - 112 JT25 Operator’s Manual Electric Strike System Assemble Voltage Detector 1. Drive voltage stake into ground at least 6’ (2 m) away from any part of system. 2. Clip voltage limiter to voltage stake. Test Strike System If system fails any part of this test, see “Troubleshoot Strike System” on the following page. Do not drill until test is completed successfully. 1. Turn on drilling unit. 2.
JT25 Operator’s Manual Systems and Equipment - 113 Electric Strike System Troubleshoot Strike System When strike system detects a problem, an error code will be displayed. Anytime this happens, press self test button to retest. If error code is still displayed and does not appear in this chart, have control module checked or replaced. Other problem situations and their possible causes and solutions are listed in the chart below.
JT25 Operator’s Manual Systems and Equipment - 114 Electric Strike System Problem Possible cause Possible solution Strobe light on drilling unit does not work during total test Improper connections with control module Check connections and wiring harness Defective strobe light 1. Disconnect strobe and connect to external 12V power source. 2. If strobe does not work, replace it.
JT25 Operator’s Manual Systems and Equipment - 115 Electric Strike System Use Electric Strike Simulator Use the Electric Strike Simulator (p/n 259-506) to test voltage and current sensors on ESID. If readings are less than indicated here, replace 9V battery in simulator and retest. Current Test To test for current at normal levels: 1. Thread one lead wire through current transformer. 2. Clip ends of lead wires together to make one loop. 3. Move simulator switch to "current" and press test button. 4.
Systems and Equipment - 116 JT25 Operator’s Manual Electric Strike System Voltage Test 1. Place voltage limiter on something insulated from ground and drilling unit (such as dry board or tire), but near frame of drilling unit. 2. Clip one lead to frame. 3. Clip other lead to one voltage limiter mount. 4. Move simulator switch to "voltage" and press test button. 5. Watch screen and lights above display on strike system. • All lights should turn on. • Alarm and strobe should turn on.
JT25 Operator’s Manual Systems and Equipment - 117 Drilling Fluid Drilling Fluid Improper handling or use of chemicals may result in illness, injury, or equipment damage. Follow instructions on labels and in material safety data sheets (MSDS). For productive drilling and equipment protection, use these recommended Baroid® products, available from your Ditch Witch dealer.
Systems and Equipment - 118 JT25 Operator’s Manual Drilling Fluid Bentonite Bentonite is a dry powder. When properly mixed with water, it forms a thin cake on bore walls, lubricating the bore, keeping it open, and holding fluid in the bore. Some things to remember when mixing bentonite: • Use clean water free of salt, calcium, or excessive chlorine. • Use water with pH level between 9 and 10. • Use water with hardness of less than 120 ppm. • Do not use bentonite containing sand.
JT25 Operator’s Manual Systems and Equipment - 119 Drilling Fluid Basic Fluid Recipes Soil type Mixture/100 gal (378 L) of water Notes fine sand 35 lb (16 kg) Bore-Gel coarse sand 35 lb (16 kg) Bore-Gel .5 lb (225 g) No-Sag Add .5 lb (225 g) of Quik-Trol for additional filtrate control fine sand below water table 40 lb (18 kg) Bore-Gel .75 lb (340 g) Quik-Trol Add .5 - 1 gal (2-4 L) of Dinomul in high torque situations coarse sand below water table 40 lb (18 kg) Bore-Gel .
Systems and Equipment - 120 JT25 Operator’s Manual Drilling Fluid Drilling Fluid Requirements 1. Determine drilling conditions and choose appropriate drilling fluid mix. 2. Estimate amount of supplies needed and check availability. • Drilling fluid • Water supply. If more water than can be carried with the unit will be needed, arrange to transport additional water. • Bentonite and/or polymer 3. Check water quality. • Use meter or pH test strips to test pH of water. If pH is below 9.
JT25 Operator’s Manual Systems and Equipment - 121 Tracker Control Tracker Control Overview Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly. This mode allows the Ditch Witch Tracker operator to disable hydraulic power to drilling unit thrust and rotation. IMPORTANT: This mode does not disable thrust and rotation immediately. Functions are disabled within 16 seconds. Thrust and rotation are disabled when green light on drilling unit is flashing.
Systems and Equipment - 122 JT25 Operator’s Manual Tracker Control Operation Enable Thrust and Rotation 1. Start drilling unit. 2. Ensure that tracking unit is paired to tracking display and enable tracker control. See tracking system operator’s manual for instructions. 3. Remove tracker control key (shown) from setup console at rear of drilling unit. Keep in tracker operator’s possession. 4. Drill and track bore.
JT25 Operator’s Manual Systems and Equipment - 123 Tracker Control Disable Thrust and Rotation 1. When drill head enters target pit or exits the ground, turn off tracker. After 8-16 seconds, green tracker control light (shown), located on drilling unit anchoring console, will come on. Hydraulic power to thrust and rotation will be disabled.
JT25 Operator’s Manual Systems and Equipment - 124 Downhole Tools Downhole Tools Nozzles Nozzles control fluid flow from the pipe to the bore. Select nozzles that will supply at least the amount of fluid per minute needed for the flow and pressure you will be using. A nozzle that will supply more fluid per minute is recommended. See your Ditch Witch dealer for nozzle recommendations. Bits Selection These charts are meant as a guideline only. No one bit works well in all conditions.
JT25 Operator’s Manual Systems and Equipment - 125 Downhole Tools 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 rocky soil chunk rock, glacial till, cobble, rip rap, gravel soft rock soft limestone, sandstone, shale, coral, caliche hard rock granite, schist, marble, hard limestone Installation Remove all paint from mating surfac
JT25 Operator’s Manual Systems and Equipment - 126 Downhole Tools Backreamers A backreamer enlarges the hole as pipe is pulled back through the bore. No one backreamer works well in all conditions. These charts are meant as a guideline only. See your local Ditch Witch dealer for soil conditions and backreamer recommendations for your area.
JT25 Operator’s Manual Systems and Equipment - 127 Downhole Tools Backream Fluid Requirements Backreaming is only successful when enough fluid reaches the bore. The amount of fluid needed depends on size of bore and soil condition. Follow these steps to find the minimum amount of fluid needed in perfect conditions. IMPORTANT: Use more fluid than recommended or the backream might be dry and unsuccessful. Instructions Example 1. Find amount of fluid needed for your size of backreamer.
JT25 Operator’s Manual Systems and Equipment - 128 Downhole Tools Backream Fluid Requirements Backreamer/product diameter Gal/ft L/m Backreamer/product diameter Gal/ft L/m .5 in 13 mm 0.01 0.13 13.5 in 343 mm 7.44 92.35 1 in 25 mm 0.04 0.51 14 in 356 mm 8.00 99.31 1.5 in 38 mm 0.09 1.14 14.5 in 368 mm 8.58 106.54 2 in 51 mm 0.16 2.03 15 in 381 mm 9.18 114.01 2.5 in 64 mm 0.25 3.17 15.5 in 394 mm 9.80 121.74 3 in 76 mm 0.37 4.56 16 in 406 mm 10.44 129.
JT25 Operator’s Manual Systems and Equipment - 129 Quick Wrench Quick Wrench To attach or remove downhole tools, use quick wrench to join or break the joint. Moving tools will kill or injure. Shut off drill string power when anyone can be struck by moving or thrown tools. Never use pipe wrenches on drill string. NOTICE: Apply TJC to threads and hand-tighten joint before attaching quick wrench components to tighten joint. Attach quick wrench in either the join or break position.
JT25 Operator’s Manual Systems and Equipment - 130 Quick Wrench To Join 1. Scribe straight line across joint on both sides of separating line (A). 2. Scribe second line (B) on moveable side of joint in the opposite direction of tightening action 3/8” (9.5 mm) away from first line. A B 3. Turn handle until second line (B) meets first (A). A B 4. Turn handle opposite direction two turns to relieve pressure. A 5. Remove quick wrench components. A j07om071h.
JT25 Operator’s Manual Systems and Equipment - 131 Drill Pipe Drill Pipe Perform Regular Drill Pipe Care Precondition New Pipe Repeat this procedure three times for each piece of pipe before it is used the first time: 1. Hand-lubricate entire surface of threads and shoulders of both ends of pipe with copper base tool joint compound. See page 200 for recommended lubricant. 2. Join pipe and tighten joint. 3. Break joint. 4. Move pipe back to box.
Systems and Equipment - 132 JT25 Operator’s Manual Drill Pipe Use Drill Pipe Correctly Align the Joints Always carefully align the male and female ends of pipe before threading them together. Poor alignment can damage the threads and destroy the usefulness of the joint. NOTICE: If joints get out of alignment during a bore, use frame tilt or rear stabilizers to adjust the unit. Clamp Pipe Correctly Clamp on pipe when joint is between wrenches. Clamp only on the tool joint of the drill pipe as shown.
JT25 Operator’s Manual Systems and Equipment - 133 Drill Pipe Make Up and Break Out Joints Correctly This consists of two steps: • Make up and break out joints slowly. Do not ram pipes together during makeup or force them apart during breakout. Carefully time rotation with carriage travel speed during makeup, and use floating carriage to lessen stress on threads during breakout. Always connect and disconnect joints slowly and deliberately.
Systems and Equipment - 134 JT25 Operator’s Manual Pipe Boxes Pipe Boxes Remove/Install Pipe Box Crushing weight. If load falls or moves it could kill or crush you. Use proper procedures and equipment or stay away. NOTICE: • Lift only one box of pipe at a time. • Use crane capable of supporting the equipment's size and weight. See page 193 or measure and weigh equipment before lifting. Electric shock. Contacting electric lines will cause death or serious injury. Know location of lines and stay away.
JT25 Operator’s Manual Systems and Equipment - 135 Pipe Boxes Remove Pipe Box 1. Install lift block (1) and adjust to match drill frame angle. 2. Remove pin (3) from top of pipe box. 3. Remove back pin (2) and two front pins (4). 4. Replace pin into top of pipe box. 5. Move pipe box off of drill frame. Install Pipe Box 1. Move pipe box over pipeloader and lower into position. En.sure pipe box is moved all the way to the front. 2. Install back pin (2) and two front pins (4). 3.
Systems and Equipment - 136 JT25 Operator’s Manual Pipe Boxes Add/Remove Single Pipe Load a single drill pipe or up to a whole row of drill pipe into fifth row of pipe box to finish bore without changing pipe boxes. Pipe can be added as soon as fifth row of pipe has been started and other rows are empty. Electric shock. Contacting electric lines will cause death or serious injury. Know location of lines and stay away.
JT25 Operator’s Manual Systems and Equipment - 137 Pipe Boxes Add Single Pipe 1. Move row select to fifth row. 2. Move shuttles out fully. 3. Remove hold pins (1) on each shuttle and rotate auxiliary pipe loaders (2) into position. 4. Remove pipe stop (stored on outside of drill frame) and attach to front of pipe box.
Systems and Equipment - 138 JT25 Operator’s Manual Pipe Boxes Crushing weight. If load falls or moves it could kill or crush you. Use proper procedures and equipment or stay away. NOTICE: Drill pipe is heavy. Have enough people on hand to manually add or remove single pipe to pipe box. 5. Load a pipe in auxiliary pipe loaders and rest it against pipe stop. 6. Move auxiliary pipe loaders under row 5. 7. Raise pipe into row 5. 8. Move shuttles all the way out. 9.
JT25 Operator’s Manual Systems and Equipment - 139 Pipe Boxes 4. Remove pipe stop (stored on outside of drill frame) and attach to front of pipe box. 5. Raise pipe in row 5. 6. Move pipe to auxiliary pipe loaders. • Move shuttles in. • Lower pipe into auxiliary pipe loaders. 7. Move shuttles out. Crushing weight. If load falls or moves it could kill or crush you. Use proper procedures and equipment or stay away. NOTICE: Drill pipe is heavy.
JT25 Operator’s Manual Systems and Equipment - 140 Cruise Control Cruise Control During the bore, you can set the desired thrust/pullback, and rotation speeds to match ground conditions. Cruise control enables the unit to maintain these settings hands-free. You can engage, disengage, override, and resume these settings at any time. IMPORTANT: In order for cruise control to function, front wrench must be open and shuttles must be under pipe delivery chute (fully retracted).
JT25 Operator’s Manual Systems and Equipment - 141 Cruise Control Adjust Settings 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 joystick in neutral position and press set. • To increase rotation speed, move joystick to left and press resume. • To decrease rotation speed, move joystick to left and press set.
Systems and Equipment - 142 JT25 Operator’s Manual Diagnostic Codes Diagnostic Codes The JT25 is equipped with two diagnostic systems: engine and machine. The engine diagnostic system detects critical and non-critical errors within the engine operating system and communicates fault codes on the engine display. The machine diagnostic system detects essential and non-essential errors within the automated machine control system.
JT25 Operator’s Manual Systems and Equipment - 143 Diagnostic Codes SPN FMI Warning Color Circuit Error Description 91 0 red accelerator pedal or lever position sensor 1 data valid, but above normal operational range - most severe level 91 2 red accelerator pedal or lever position sensor 1 data erratic, intermittent or incorrect 91 19 red SAE J1939 multiplexed accelerator pedal or lever sensor system received network data in error 91 9 red SAE J1939 multiplexed accelerator pedal or
Systems and Equipment - 144 JT25 Operator’s Manual Diagnostic Codes SPN FMI Warning Color Circuit Error Description 101 15 amber blinking crankcase pressure data valid but above normal operating range, least severe level 102 3 amber intake manifold 1 pressure sensor voltage above normal or shorted to high source 102 4 amber intake manifold 1 pressure sensor voltage below normal or shorted to low source 102 2 amber intake manifold 1 pressure data erratic, intermittent, or incorrect
JT25 Operator’s Manual Systems and Equipment - 145 Diagnostic Codes SPN FMI Warning Color Circuit Error Description 111 4 amber coolant level sensor 1 voltage below normal or shorted to low source 111 18 amber coolant level data valid but below normal operating range, moderately severe level 111 1 red coolant level data valid but below normal operational range, most severe level 111 17 amber blinking coolant level data valid but below normal operating range, least severe level 157
Systems and Equipment - 146 JT25 Operator’s Manual Diagnostic Codes SPN FMI Warning Color Circuit Error Description 558 2 amber accelerator pedal or lever idle validation switch data erratic, intermittent, or incorrect 558 13 red accelerator pedal or lever idle validation switch out of calibration 558 9 red accelerator pedal or lever idle validation switch abnormal update rate 612 2 red engine magnetic speed/ position lost both of two signals data erratic, intermittent or incorrect
JT25 Operator’s Manual Systems and Equipment - 147 Diagnostic Codes SPN FMI Warning Color Circuit Error Description 723 7 amber engine speed/position camshaft and crankshaft misalignment mechanical system not responding or out of adjustment 723 2 amber engine camshaft speed/ position sensor data erratic, intermittent, or incorrect 723 2 none engine camshaft speed/ position sensor data erratic, intermittent, or incorrect 729 3 amber engine intake air heater 1 voltage above normal or
Systems and Equipment - 148 JT25 Operator’s Manual Diagnostic Codes SPN FMI Warning Color Circuit Error Description 2791 13 amber EGR valve control out of calibration 2791 15 amber EGR valve control over temperature data valid but above normal operating range, least severe level 2791 5 amber EGR valve control current below normal or open circuit 2791 6 amber EGR valve control circuit current above normal or grounded circuit 2791 7 amber EGR valve control circuit mechanical sys
JT25 Operator’s Manual Systems and Equipment - 149 Diagnostic Codes SPN FMI Warning Color Circuit Error Description 5571 7 none [C2ST] High pressure common rail fuel pressure relief valve mechanical system not responding or out of adjustment Reading Machine Diagnostic Codes Use the red diagnostic light to learn the condition of the diagnostic system.
JT25 Operator’s Manual Systems and Equipment - 150 Diagnostic Codes Review Modes IMPORTANT: Do not turn off ignition. Diagnostic codes are cleared each time ignition is turned off. View All Codes View Codes Individually 1. Ensure that engine is running and no one is sitting in operator’s seat. 1. Ensure that engine is running and no one is sitting in operator’s seat. 2. Press and hold RESUME for two seconds. 2. Press and hold SET for two seconds. 3.
JT25 Operator’s Manual Systems and Equipment - 151 Diagnostic Codes Machine Diagnostic Codes The following table lists the attributes of each diagnostic code. Information presented includes: code number, condition causing code to be sent, result, and level of severity.
JT25 Operator’s Manual Systems and Equipment - 152 Diagnostic Codes Code Condition Result Severity 63 no continuity to auxiliary dump valve add pipe or remove pipe aborted and code is stored nonessential 65 no continuity to thrust neutral valve cruise control is blocked essential 66 no 6V internal power add pipe, remove pipe, drive, and cruise control are blocked essential 71 no continuity to drive selector valve drive is blocked essential 73 no continuity to throttle up solenoid cod
JT25 Operator’s Manual Systems and Equipment - 153 Diagnostic Codes Code Condition Result Severity 172 no continuity to pipe shuttle rocker switch code is stored nonessential 173 no continuity to pipe lift rocker switch code is stored nonessential 174 no continuity to pipe box rocker switch code is stored nonessential 175 no continuity to pipe lube rocker switch code is stored nonessential 184 no continuity to throttle rocker switch code is stored nonessential 185 no continuity to
Systems and Equipment - 154 JT25 Operator’s Manual Diagnostic Codes CMW
JT25 Operator’s Manual Complete the Job - 155 Complete the Job Chapter Contents Antifreeze Drilling Unit . . . . . . . . . . . . . . . . . . . . 156 • Add Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 • Reclaim Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Rinse Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 157 Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Complete the Job - 156 JT25 Operator’s Manual Antifreeze Drilling Unit Antifreeze Drilling Unit Your drilling unit can be left overnight in freezing conditions by filling fluid lines with a polyproplyene-based antifreeze (p/n 265-644) with optional antifreeze system before shutdown. Add Antifreeze 1. Fill antifreeze tank with 8 gal (30 L) of approved antifreeze. 2. Install plug on suction side of drilling fluid pump. 3. Open valve below antifreeze tank. 4. Install antifreeze reclaimer adapter in spindle.
JT25 Operator’s Manual Complete the Job - 157 Antifreeze Drilling Unit Reclaim Antifreeze 1. Hold hose on antifreeze reclaimer over top of antifreeze tank. 2. Open valve on reclaimer (shown). 3. Connect drilling fluid transfer hose 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.
JT25 Operator’s Manual Complete the Job - 158 Rinse Equipment Rinse Equipment Using Washwand Pressurized fluid or air could pierce skin and cause injury or death. Stay away. To help avoid injury: • Never use high flow when using washwand. • Prime the drilling fluid pump before operating washwand. Failure to prime the drilling fluid pump will cause flow fluctuations, which will make it difficult to control the washwand. For instructions, see “Connect Fluid System” on page 87.
JT25 Operator’s Manual Complete the Job - 159 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.
Complete the Job - 160 JT25 Operator’s Manual Stow Tools CMW
JT25 Operator’s Manual Service - 161 Service Chapter Contents Service Precautions . . . . . . . . . . . . . . . . . . . . . . . 163 • Welding Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 • Washing Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 • Working Under Drilling Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Recommended Lubricants/Service Key . . . . . .
JT25 Operator’s Manual Service - 162 Service Precautions Service Precautions Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly. To help avoid injury: • Unless otherwise instructed, all service should be performed with engine off. • Refer to engine manufacturer’s manual for engine maintenance instructions. Welding Precaution NOTICE: Welding can damage electronics. • Welding currents can damage electronic components.
JT25 Operator’s Manual Service - 163 Service Precautions Working Under Drilling Unit 1 2 j37om056h.eps Crushing weight could cause death or serious injury. Use proper procedures and equipment or stay away. Before working under area of drilling unit supported by a stabilizer, make sure drilling unit is parked on hard surface. 1. Remove cylinder locks from storage at rear of pipe box (2) and place over extended cylinder rods (shown) with curved ends toward stabilizer shoes. 2.
JT25 Operator’s Manual Service - 164 Service Precautions Opening/Closing Engine Enclosure To open: 1. Unlock enclosure doors at latches (shown), if locked. 2. Open doors outward. 3. Lift up on upper panel for greater access to engine compartment. To close: 1. Disengage the up-latch on the upper panel by holding it up as the hood is pulled up. 2. Pull down on the panel and lower it completely. j37om057h.eps 3. Disengage the latch on each door by holding it up as door is pulled out.
JT25 Operator’s Manual Service - 165 Recommended Lubricants/Service Key Recommended Lubricants/Service Key Item Description Tier 4i DEO Diesel engine oil meeting or exceeding Cummins 20081, API CJ-4, ACEA E9. • Engine must use low SAPS oil (ash will plug aftertreatment device.) • Use viscosity grade SAE 15W40 unless ambient temperatures below 5° F (-15° C) are expected. Lower viscosity oils must meet the performance specifications shown above.
Service - 166 JT25 Operator’s Manual 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 recommended lubricants. Fill to capacities listed in “Fluid Capacities” on page 195. For more information on engine lubrication and maintenance, see your engine manual.
JT25 Operator’s Manual Service - 167 Recommended Lubricants/Service Key Approved Fuel Tier 4i Engine (U.S., Canada, EU, and Japan) Avoid static electricity when fueling. Ultra Low Sulfur Diesel (ULSD) poses a greater static ignition hazard than earlier diesel formulations. Avoid death or serious injury from fire or explosion. Consult with your fuel system supplier to ensure the delivery system is in compliance with fueling standards for proper grounding and bonding practices.
JT25 Operator’s Manual Service - 168 Startup/10 Hour Startup/10 Hour Location Task DRILLING UNIT Check track tension and condition Notes Check fuel filter water separator Check engine air filter service indicator Check engine oil level DEO Check fluid pump piston seals Check engine coolant level DEAC Check hydraulic hoses Check hydraulic fluid level THF Check fluid pump oil level NDO Test control switches Check pipe auto lubricator spray nozzle Check pipe auto lubricator TJC level Clean dril
JT25 Operator’s Manual Service - 169 Startup/10 Hour Drilling Unit Check Track Tension and Condition Check track tension and condition before startup and every 10 hours of operation and adjust or replace as needed. To Adjust: 1. Pump MPG into fitting (shown) until the length of the compressed spring, dimension (A), is 12.75” (323.85 mm). 2. Drive straight forward one machine length and check tension again.
JT25 Operator’s Manual Service - 170 Startup/10 Hour 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. 1 2 j37om020h.eps Check Engine Coolant Level Check coolant level, with engine cool, at sight glass (1) of expansion tank before startup and every 10 hours of operation. Maintain coolant level at halfway point on sight glass.
JT25 Operator’s Manual Service - 171 Startup/10 Hour Check Hydraulic Hoses Fluid or air pressure could pierce skin and cause injury or death. Stay away. To help avoid injury: • Use a piece of cardboard or wood, rather than 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.
JT25 Operator’s Manual Service - 172 Startup/10 Hour Check Hydraulic Fluid Level 1 Check hydraulic fluid level before startup and every 10 hours of operation. Maintain fluid level at halfway point on sight glass (2), when engine is off and fluid is cool. Add THF at hydraulic fluid fill (1). 2 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.
JT25 Operator’s Manual Service - 173 Startup/10 Hour Test Control Switches Check control proximity switches before startup and every 10 hours of operation and clean or replace as needed. 1. front home switch 2. shuttle home switch 3. rear home switch 4. rear stop switch To test: 1. Turn ignition switch to the on position. Do not start engine. 2 1 3 j37om041h.eps 4 2. Place metal object above target on each switch. 3. If yellow LED on switch lights, switch sensor is working.
JT25 Operator’s Manual Service - 174 Startup/10 Hour Check Pipe Auto Lubricator TJC Level Check pipe auto lubricator TJC level before startup and every 10 hours of operation. Change pail as needed. See “Change Auto Lubricator TJC Pail” on page 187 for procedure. NOTICE: Ditch Witch tool joint compound is specially formulated to work with Ditch Witch pipe lubrication system. Use of other tool joint compounds will clog system. See “Recommended Lubricants/Service Key” on page 165 for more information.
JT25 Operator’s Manual Service - 175 50 Hour 50 Hour Location Task Notes DRILLING UNIT Change fluid pump oil Initial service, NDO 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 Lube SaverLok collar Check heavy-duty anchor drive gearbox oil level optional Drilling Unit Change Fluid Pump Oil (Initial Service) 1 2 Change fluid pump oil at
JT25 Operator’s Manual Service - 176 50 Hour Check Radiator Check radiator for dirt, grass, and other debris every 50 hours. Check more often if operating in dusty or grassy conditions. Clean as needed. To clean: • Clean fins with compressed air or spray wash. • Open rear hood and spray through radiator toward engine. • If grease and oil are present on radiator, spray with solvent and allow to soak overnight. IMPORTANT: Be careful not to damage fins with high pressure air or water. j37om030h.
JT25 Operator’s Manual Service - 177 50 Hour Check Rotation Gearbox Oil Level 1 IMPORTANT: Drill frame must be level for accurate reading. Check rotation gearbox oil level every 50 hours. Add MPL through plug (1) to level of sight plug (2) as needed. 2 j37om042h.eps Inspect Thrust Rollers Inspect thrust rollers (at each end of carriage) every 50 hours. Clean or replace if they do not turn freely. j37om045h.
JT25 Operator’s Manual Service - 178 50 Hour Lube SaverLok Collar Lube SaverLok collar with EPS every 50 hours. To lube: • Stop engine and turn battery disconnect switch to the off position. • Clean exposed portion of sliding output shaft with pressure washer to remove grime. • Blow dry with compressed air. • Apply EPS spray lube to all exposed shaft surfaces while manually moving the shaft in and out. • Turn battery disconnect switch to the on position.
JT25 Operator’s Manual Service - 179 250 Hour 250 Hour Location Task DRILLING UNIT Inspect air intake system Notes Tier 3: Change engine oil, initial Only applies to units with Tier 3 engines operating with high sulfur fuel (sulfur content >15 ppm). Drilling Unit Inspect Air Intake System Inspect intake piping for cracked hoses, loose clamps, or punctures. Tighten or replace parts as necessary. j37om055h.
JT25 Operator’s Manual Service - 180 500 Hour 500 Hour Location Task Notes DRILLING UNIT Change engine oil and filter DEO Change hydraulic filters Normal conditions Change fuel filters Check batteries Drilling Unit Change Engine Oil and Filter 1 NOTICE: Incorrect fuel and oil combinations can damage engine. • Tier 4i: Use Tier 4i DEO and ULSD. Change oil every 500 hours. DO NOT use high sulfur fuel (greater than 15 ppm). • Tier 3: If using Tier 3 DEO, change oil every 500 hours.
JT25 Operator’s Manual Service - 181 500 Hour Change Fuel Filters Replace fuel filters every 500 hours. See parts manual or contact your Ditch Witch dealer for correct replacement filter. j37om034h.eps Check Batteries Check batteries every 500 hours. Keep batteries clean and terminals free of corrosion. To clean: 1. Turn battery disconnect switch to the off position. 2. Ensure that no ignition sources are near batteries. 3. Loosen and remove battery cable clamps carefully, negative (-) cable first. 4.
JT25 Operator’s Manual Service - 182 1000 Hour 1000 Hour Location Task Notes DRILLING UNIT Change hydraulic fluid and filters THF Change ground drive gearbox oil 2 gearboxes, MPL Change rotation gearbox oil MPL Lube SaverLok connection EPG Change heavy-duty anchor gearbox oil 2 gearboxes, MPL Drilling Unit Change Hydraulic Fluid and Filters 1 Change hydraulic fluid and filters every 1000 hours. To change: 1. Drain hydraulic fluid at drain (3). 2 2. Change hydraulic filters.
JT25 Operator’s Manual Service - 183 1000 Hour 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 90° and add MPL at fill plug. IMPORTANT: • Drill frame must be parked on level surface for accurate reading. • Use helper to assist in positioning gearbox plugs for checking and adding oil. • Do not overfill. j37om053h.eps 3. Replace fill plug.
JT25 Operator’s Manual Service - 184 1000 Hour Change Heavy-Duty Anchor Gearbox Oil (Optional) 2 Change heavy-duty anchor gearbox oil every 1000 hours. Capacity is 26 oz (0.77 L) MPL per gearbox. To Change: 1 1. Ensure that gearbox is level. 2. Drain oil at gearbox oil drain (1). Replace drain plug. 3. Fill gearbox with MPL at fill plug (2). IMPORTANT: Gearbox must be level for accurate reading. j37om059h.eps Change Rotation Gearbox Oil 1 IMPORTANT: Gearbox must be level for accurate reading.
JT25 Operator’s Manual Service - 185 2000 Hour 2000 Hour Location Task Notes DRILLING UNIT Change engine coolant DEAC Change fluid pump oil NDO Drilling Unit Change Engine Coolant 2 Drain cooling system at drain (1) every two years or 2000 hours. Add approved coolant according to instructions below. Refill capacity is 23 qt (21.8 L). NOTICE: • The use of non-approved coolant may lead to engine damage or premature engine failure and will void engine warranty.
JT25 Operator’s Manual Service - 186 As Needed Change Fluid Pump Oil 1 2 Change fluid pump oil every 2000 hours. To change: 1. Drain at plug (3). Ensure that magnetic drain plug is cleaned of debris before reinstalling. 2. Add NDO at fill plug (2). Maintain fluid level at fill plug (2). Inspect oil level at sight glass (1). 3 j37om024h.
JT25 Operator’s Manual Service - 187 As Needed Drilling Unit Change Auto Lubricator TJC Pail Check pipe auto lubricator TJC level and change pail as needed. To change pail: 1. Remove wingnuts and bolts attaching base ring to pail cover. 2. Rotate base ring slightly to clear hooks on cover and remove pail from cover. 3. Remove follower plate from empty pail and install into new pail. Press firmly on follower plate until TJC comes up in center opening. j37om027h.eps 4.
JT25 Operator’s Manual Service - 188 As Needed Check Pipeloader Inserts Check pipeloader inserts at indicated areas for wear. Flip gripper inserts for longer wear, or replace as needed. See your Ditch Witch dealer for replacement parts. 2 1 3 1. Shuttle gripper pad 2. Wear pad 3. Slide pad IMPORTANT: Ensure bolts are tightened evenly to enable inserts to slide freely and wear evenly. j37om040h.eps Check Pipe Guide Inserts 3 Check pipe guide inserts (2, 4) for wear.
JT25 Operator’s Manual Service - 189 As Needed Check Track Support Slide Pads Check track support slide pads. Replace as needed. See your Ditch Witch dealer for replacement parts. Check Wrench Jaw Inserts Check wrench jaw inserts for wear and replace as needed. j37om048h.eps Change Engine Drive Belt Change engine drive belt as needed. 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. Install new belt. 1 2 j37om037h.
JT25 Operator’s Manual Service - 190 As Needed Change Air Filter Change air filter when air filter service indicator (3) reaches the red zone. NOTICE: Only open the air filter canister when air restriction is indicated. Change the elements, do not attempt to clean them. • Compressed air or water may damage filter elements. • Tapping filter elements to loosen dirt may damage the elements. To change Tier 3 air filter: 2 1. Disengage clasps and remove cover. 2.
JT25 Operator’s Manual Service - 191 As Needed Replace SaverLok Replace SaverLok (2) as needed. See your Ditch Witch dealer for replacement parts. To remove: 1. Position Install SaverLok collar (3) over SaverLok (2). 2. Start unit and position carriage so that collar can be clamped in the rear wrenches but front wrenches will not clamp on the nose of the SaverLok. NOTICE: Clamping front wrench on SaverLok nose will damage the threads and impede disassembly. 3.
Service - 192 JT25 Operator’s Manual As Needed To install: 1. Inspect SaverLok connection (1) for damage. Coat threads with clean TJC. 2. Coat SaverLok (2) shoulder and SaverLok collar (3) threads and shoulder with clean TJC. 3. Apply grease or lubricant to the SaverLok oring and insert SaverLok into SaverLok connection. The connection will not lock fully into place. 4.
JT25 Operator’s Manual Specifications - 193 Specifications H W L j37om039h.eps Dimensions U.S. Metric driving (per SAE J2022) 234.5 in 5.96 m transport (per SAE J2022) 232.5 in 5.90 m base width (per SAE J2022) 87 in 2.21 m width with cab (per SAE J2022) 87 in 2.21 m driving (per SAE J2022) 101 in 2.56 m transport (per SAE J2022) 93 in 2.36 m transport with cab (per SAE J2022) 99.5 in 2.
Specifications - 194 JT25 Operator’s Manual Power Pipe U.S. Metric Length (per SAE J2022), nominal 118 in 3.00 m Joint diameter (per SAE J2022) 3.00 in 76 mm Tubing diameter (per SAE J2022) 2.38 in 60 mm Minimum bend radius 155 ft 47 m Weight (per SAE J2022), lined 90 lb 41 kg Weight of drill pipe and large box (50 pipe) 5200 lb 2358 kg Weight of drill pipe and small box (25 pipe) 2500 lb 1134 kg Operational U.S.
JT25 Operator’s Manual Power Specifications - 195 U.S.
Specifications - 196 JT25 Operator’s Manual Vibration Levels Average vibration transmitted to the operator’s hand and whole body during normal operation does not exceed 2.5 and 0.5 m/sec2 respectively. Operator seat complies with ISO 7096. Specifications are called out according to SAE recommended practices where indicated. Specifications are general and subject to change without notice. If exact measurements are required, equipment should be weighed and measured.
JT25 Operator’s Manual Support - 197 Procedure Support Procedure Notify your dealer immediately of any malfunction or failure of Ditch Witch equipment. Always give model, serial number, and approximate date of your equipment purchase. This information should be recorded and placed on file by the owner at the time of purchase. Return damaged parts to dealer for inspection and warranty consideration if in warranty time frame.
JT25 Operator’s Manual Warranty - 198 Warranty Ditch Witch Equipment and Replacement Parts Limited Warranty Policy Subject to the limitation and exclusions herein, free replacement parts will be provided at any authorized Ditch Witch dealership for any Ditch Witch equipment or parts manufactured by The Charles Machine Works, Inc. (CMW) that fail due to a defect in material or workmanship within one (1) year of first commercial use (Exception: 2 years for all SK5 attachments).
JT25 Operator’s Manual Service Record - 201 Service Record Service Performed Date Hours CMW
Service Record - 202 Service Performed CMW JT25 Operator’s Manual Date Hours
