JT5 Operator’s Manual CMW® Issue 1.
JT5 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 . . . . . . . . . . . . . . . . . . . . . . . . . . 5 • Bulleted Lists.
JT5 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.
JT5 Operator’s Manual Overview - 3 Intended Use Intended Use The JT5 is a self-contained horizontal directional drilling unit designed to install buried cable and pipe at distances to 150’ (45.7 m) depending on soil conditions and is intended for operation in ambient temperatures from 0° to 115°F (-18° to 46°C). Use in any other way is considered contrary to the intended use. The JT5 can be used with Ditch Witch drilling fluid units and Ditch Witch locating equipment.
JT5 Operator’s Manual Overview - 4 Unit Components Unit Components 1. Anchoring system 5. Tracks 2. Operator’s station 6. Spindle 3. Carriage 7. Drill frame 4. Stabilizer 8.
JT5 Operator’s Manual Overview - 5 Operator Orientation Operator Orientation IMPORTANT: Top view of unit is shown. 1. Front of unit 2. Right side of unit 3. Rear of unit 4. Left side of unit About This Manual This manual contains information for the proper use of this machine. See the beige Operation Overview pages for basic operating procedures. Cross references such as “See page 50” will direct you to detailed procedures.
Overview - 6 CMW JT5 Operator’s Manual
JT5 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.
JT5 Operator’s Manual Foreword - 8 JT5 Operator’s Manual Issue number 1.0/OM- 4/11 Part number 053-2380 Copyright 2011 by The Charles Machine Works, Inc. , Ditch Witch, CMW, AutoCrowd, Jet Trac, Roto Witch, Subsite, Fluid Miser, Power Pipe, Super Witch, Pierce Airrow, The Underground, The Underground Authority Worldwide, and Zahn are registered trademarks of The Charles Machine Works, Inc. This product is covered by one or more of the following patents: U.S.
JT520 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 43 an overview for completing a j
Contents - 10 JT520 Operator’s Manual Specifications 151 machine specifications including weights, measurements, power ratings, and fluid capacities Support 155 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 159
JT2720 Mach 1/All Terrain 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 JT2720 Mach 1/All Terrain 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.
JT2720 Mach 1/All Terrain 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.
JT2720 Mach 1/All Terrain 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. Deadly gases. Lack of oxygen or presence of gas will cause sickness or death. Provide ventilation. Moving tools will kill or injure. Shut off drill string power when anyone can be struck by moving or thrown tools.
JT2720 Mach 1/All Terrain Operator’s Manual Safety - 15 Safety Alerts Explosion possible. Serious injury or equipment damage could occur. Follow directions carefully. Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly. 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.
JT2720 Mach 1/All Terrain 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.
JT2720 Mach 1/All Terrain 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 JT2720 Mach 1/All Terrain 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 or mats 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.
JT2720 Mach 1/All Terrain 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 JT2720 Mach 1/All Terrain 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) to disconnect position.
JT5 Operator’s Manual Controls - 21 Controls Chapter Contents Set-Up Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Anchor Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Operator’s Station . . . . . . . . . . . . . . . . . . . . . . . . . 26 • Gauges and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 • Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JT5 Operator’s Manual Controls - 22 Set-up Console Set-up Console 1. Engine stop button 3. Left track control 2. Stabilizer and frame tilt control 4. Right track control Item Description Notes 1. Engine stop button To stop engine, press. IMPORTANT: CMW • If this switch is used to stop drilling unit, turn ignition switch off if machine will be left unattended for long periods of time. Battery discharge can occur.
JT5 Operator’s Manual Controls - 23 Set-up Console Item Description Notes 2. Stabilizer and frame tilt control To raise stabilizer and decrease frame tilt, pull. Note: Stabilizer control lowers the front of the drill frame along with the stabilizer. To lower stabilizer and increase frame tilt, push. 3. Left track control To move forward, push. To move backward, pull. To stop, move to center. c00ic147h.eps 4. Right track control To move forward, push. To move backward, pull.
JT5 Operator’s Manual Controls - 24 Anchor Console Anchor Console 1. Left rotation control 3. Right rotation control 2. Left thrust control 4. Right thrust control Item Description Notes 1. Left rotation control To drive anchor, push down. IMPORTANT: Stand on platform when operating anchor controls. To remove anchor, pull up.
JT5 Operator’s Manual Controls - 25 Anchor Console Item Description Notes 2. Left thrust control To move anchor down, push down. IMPORTANT: Stand on platform when operating anchor controls. To move anchor up, pull up. 3. Right rotation control To drive anchor, push down. IMPORTANT: Stand on platform when operating anchor controls. To remove anchor, pull up. 4. Right thrust control To move anchor down, push down. IMPORTANT: Stand on platform when operating anchor controls.
JT5 Operator’s Manual Controls - 26 Operator’s Station Operator’s Station Gauges and Indicators 1. Hydraulic fluid sight glass 4. Engine oil pressure indicator 2. Hourmeter 5. Engine temperature indicator 3. Cold start wait (glow plug) indicator 6. Drilling fluid pressure gauge Item Description Notes 1. Hydraulic fluid sight glass Displays level of hydraulic fluid. Maintain level in center of glass.
JT5 Operator’s Manual Controls - 27 Operator’s Station Item Description Notes 2. Hourmeter Displays engine operating time. Use engine operating times to schedule service. 3. Cold start wait indicator Lights when intake air preheater (glow plug) is operating. See “Start Unit” on page 64. Wait until light goes off before starting engine. 4. Engine oil pressure indicator 5. Engine temperature indicator Lights when oil pressure is too low. Light will come on briefly when engine is started.
JT5 Operator’s Manual Controls - 28 Operator’s Station Item Description Notes 6. Drilling fluid pressure gauge Displays drilling fluid pressure supplied by drilling fluid pump. If pressure is too high, check if nozzle is plugged.
JT5 Operator’s Manual Controls - 29 Operator’s Station Controls 1. Ignition switch 5. Wrench control 2. Engine throttle control 6. Pipe lubricator control 3. Fluid flow control 7. Auxiliary outlet 4. Carriage control Item Description 1. Ignition switch To start engine, insert key and turn clockwise. Notes To stop engine, turn key counterclockwise.
JT5 Operator’s Manual Controls - 30 Operator’s Station Item Description 2. Engine throttle control To increase engine speed, push up. Notes To decrease engine speed, pull down. 3. Fluid flow control To increase flow, turn counterclockwise. To decrease flow, turn clockwise. To stop flow, turn all the way clockwise. 4. Carriage control To move carriage forward, push. To move carriage backward, pull. To rotate spindle counterclockwise (breakout), move right.
JT5 Operator’s Manual Controls - 31 Operator’s Station Item Description Notes 7. Auxiliary outlet Provides power for other equipment. Power output is 12V, 5A.
JT5 Operator’s Manual Controls - 32 Engine Compartment Engine Compartment 1. Air filter service indicator 3. Battery disconnect switch 2. Tracker control switch Item Description 1. Air filter service indicator Indicates when to change air filter. Press button to reset indicator after changing filter.
JT5 Operator’s Manual Controls - 33 Engine Compartment 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). 1. Battery disconnect switch To connect, turn clockwise. To disconnect, turn counterclockwise.
JT5 Operator’s Manual Controls - 34 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.
JT5 Operator’s Manual Controls - 35 ESID Item Description Notes 2. Strike indicator Red lights come on as values in display increase. NOTICE: The ESID does not indicate proximity to electric lines. System will activate only when voltage and/or amperage detected at the drilling unit are above threshold minimum limits. Light in triangle represents strike warning condition and will trigger alarm(s) and strobe(s). Remember that system can go from one or two lights to an electric strike immediately. 3.
JT5 Operator’s Manual Controls - 36 ESID Item Description 6. OK indicator Green light means system self test detected no problems. Notes Strike system is ready to operate. 7. Electrical power supply indicator Green light means control box has sufficient electrical power for operation. Strike system is ready to operate if OK indicator is also on. 8. Self test button CMW To start manual self test, press. Checks all systems and circuits. To reset system after a strike has been detected, press.
JT5 Operator’s Manual Controls - 37 750/752 Display 750/752 Display Indicators 1. Beacon temperature display 5. Depth estimate 2. Pitch/slope indicator and percentage indicator 6. Display battery status indicator 3. Roll indicator 7. Beacon battery status indicator 4. Target indentifier indicator 8. Beacon temperature indicator IMPORTANT: Some items operate differently depending where data is being saved. Internal refers to pipe data being saved to 750/752 Display memory.
JT5 Operator’s Manual Controls - 38 750/752 Display Item Description Notes 2. Pitch/slope indicator and percentage indicator Indicates pitch beacon percent of grade. Internal: shows pipe label and stored pitch. External: shows desired pitch. 3. Roll indicator Indicates beacon roll angle. 4. Target identifier indicator Indicates approximate beacon location. Only one set of arrows is active at a time. 5. Depth estimate Indicates beacon depth estimate.
JT5 Operator’s Manual Controls - 39 750/752 Display Item Description Notes 6. Display battery status indicator Indicates display power from drilling unit. If all five bars are not showing, check display power connections. 7. Beacon battery status indicator Indicates beacon battery status. See beacon instruction sheet. 8. Beacon temperature indicator Indicates beacon temperature. See beacon instruction sheet.
JT5 Operator’s Manual Controls - 40 750/752 Display Controls 1. Delete button 4. Roll stop button 2. On/Off button 5. Recall button 3. Channel select button 6. Store button IMPORTANT: Some items operate differently depending where data is being saved. Internal refers to pipe data being saved to 750/752 Display memory. External refers to pipe data being sent to a properly connected laptop computer running a version of Trac Management System software. Item Description Notes 1.
JT5 Operator’s Manual Controls - 41 750/752 Display Item Description Notes 3. Channel select button To display current channel, press and release. Unit defaults to last channel used each time unit is turned on. To switch channels, press and hold. IMPORTANT: Make sure display and tracker are set to the same channel. Second function: To start a new job, press with Recall button. “Init” and job number will be displayed. 4. Roll stop button This feature is not yet available. 5.
JT5 Operator’s Manual Controls - 42 750/752 Display Item Description Notes 6. Store button To display serial number, press and hold while pressing on/off button. Pipe number will appear in numeric display when data is stored. To store current pipe data, press. IMPORTANT: Pipe data cannot be stored without a valid depth estimate.
JT5 Operator’s Manual Operation Overview - 43 Operation Overview Chapter Contents Planning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Setting Up at Jobsite . . . . . . . . . . . . . . . . . . . . . . . 44 Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Backreaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Leaving Jobsite. . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Storing Equipment . . . . . . . . . . . . . . .
Operation Overview - 44 JT5 Operator’s Manual Planning Planning 1. Gather information about jobsite. See page 49. 2. Inspect jobsite. See page 50. 3. Classify jobsite. See page 52. 4. Plan bore path. See page 55. 5. Check supplies and prepare equipment. See page 61. 6. Load equipment. Seepage 68. Setting Up at Jobsite 1. Prepare jobsite. See page 60. 2. Unload drilling unit from trailer. See page 70. 3. Assemble drill string. See page 79. 4. Position drilling unit and frame. See page 75. 5.
JT5 Operator’s Manual Operation Overview - 45 Drilling Drilling 1. Start system. See page 75. 2. Prime drilling fluid pump. See page 76. 3. Engage tracker control if desired. See page 107. 4. Drill first pipe. See page 81. 5. Record bore path. See page 84. 6. Add pipe. See page 82. 7. Drill remaining pipes in pipe box and correct direction (page 80) as necessary. 8. Surface drill head. See page 85. Backreaming 1. Assemble backream string. See page 86. 2. Start drilling unit and adjust throttle. 3.
Operation Overview - 46 JT5 Operator’s Manual Leaving Jobsite Leaving Jobsite 1. Remove downhole tools. See page 89. 2. Remove anchors. See page 94. 3. Rinse unit and downhole tools. See page 124. 4. Disassemble strike system and disconnect from fluid system. See page 125. 5. Stow tools. See page 125. 6. Load unit onto trailer. See page 68. Storing Equipment 1. For cold weather storage, antifreeze drilling unit. See page 122. 2. For long-term storage, disconnect battery disconnect switch.
JT5 Operator’s Manual Prepare - 47 Prepare Chapter Contents Gather Information . . . . . . . . . . . . . . . . . . . . . . . . . 49 • Review Job Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 • Notify One-Call Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 • Examine Pullback Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 • Arrange for Traffic Control. . . . . . . . . . . . . . . . . .
Prepare - 48 JT5 Operator’s Manual Prepare Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 • Mark Bore Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 • Prepare Entry Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Check Supplies and Prepare Equipment . . . . . . . 61 • Check Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 • Prepare Equipment . .
JT5 Operator’s Manual Prepare - 49 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.
JT5 Operator’s Manual Prepare - 50 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 52.) • traffic • access • soil type and condition • water supply • sources of locator interference (rebar, railroad tracks, etc.
JT5 Operator’s Manual Prepare - 51 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.
Prepare - 52 JT5 Operator’s Manual 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.
JT5 Operator’s Manual Prepare - 53 Classify Jobsite Apply Precautions Once classified, precautions appropriate for jobsite must be taken. Electric Jobsite Precautions Electric shock. Contacting electric lines will cause death or serious injury. Know location of lines and stay away. In addition to using a directional drilling system with an electric strike system, use one or both of these methods. • Expose line by careful hand digging or soft excavation. Use beacon to track bore path.
JT5 Operator’s Manual Prepare - 54 Classify Jobsite Crystalline Silica (Quartz) Dust Precautions Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. NOTICE: Cutting, drilling, or working materials such as concrete, sand, or rock containing quartz may result in exposure to silica dust. Use water spray or other means to control dust. If workers are exposed to dust they must wear appropriate breathing protection.
JT5 Operator’s Manual Prepare - 55 Plan Bore Path Plan Bore Path Plan the bore path, from entry to end, before drilling begins. The Ditch Witch Trac Management System Plus is available for planning your bore path. This special software can be run in the field using a laptop computer equipped with Windows® 95 or higher operating system. See your Ditch Witch dealer for details.
Prepare - 56 JT5 Operator’s Manual Plan Bore Path Recommended Bend Limits Ditch Witch drill pipes are designed to bend slightly during operation. Slight bending allows for steering and correcting direction. Bending beyond recommended limits will cause damage that might not be visible. This damage adds up and will later lead to sudden drill pipe failure. IMPORTANT: Consider recommended bend limits during any bend, not just during bore entry.
JT5 Operator’s Manual Prepare - 57 Plan Bore Path Pipe-By-Pipe Bend Limits Pipe (C) Forward (B) Deflection (A) Pipe (C) Forward (B) Deflection (A) 1 4’ 11" (1.5 m) 0’ 2" (.05 m) 13 55’ 5" (16.9 m) 27’ 3" (8.3 m) 2 9’ 10" (3.0 m) 0’ 8" (.2 m) 14 58’ 4" (17.8 m) 31’ 3" (9.5 m) 3 14’ 8" (4.5 m) 1’ 7" (.5 m) 15 60’ 11" (18.6 m) 35’ 5" (10.8 m) 4 19’ 5" (5.9 m) 2’ 9" (.8 m) 16 63’ 2" (19.3 m) 39’ 8" (12.1 m) 5 24’ 1" (7.4 m) 4’ 3" (1.3 m) 17 65’ 1" (19.9 m) 44’ 4" (13.
Prepare - 58 JT5 Operator’s Manual Plan Bore Path Entry Pitch Entry pitch is the slope of the drill frame compared with the slope of the ground. Determine entry pitch one of two ways: 1. With Pitch Beacon • Lay pitch beacon on the ground and read pitch. • Lay pitch beacon on drill frame and read pitch. • Subtract ground pitch from drilling unit pitch. 2. With Measurements • Measure from the ground to front end of drill frame (H1). • Measure from the ground to back end of frame (H2).
JT5 Operator’s Manual Prepare - 59 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.
JT5 Operator’s Manual Prepare - 60 Prepare Jobsite Prepare Jobsite Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. NOTICE: • If jobsite classification is in question or if the possibility of unmarked electric utilities exists, classify jobsite as electric. • Cutting high voltage cable can cause electrocution. Expose lines by hand before digging. • All vegetation near operator’s station must be removed.
JT5 Operator’s Manual Prepare - 61 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 115) • transition sub • anchoring equipment and accessories • bits, screens, nozzles (see page 110) • adapters, pipe, beacon housings • marking flags or paint • water and additional hoses • fuel (Use
Prepare - 62 JT5 Operator’s Manual Check Supplies and Prepare Equipment Prepare Equipment Fluid Levels • fuel (Use low sulfur or ultra low sulfur fuel only.
JT5 Operator’s Manual Drive - 63 Drive Chapter Contents Start Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Steer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Shut Down Unit . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive - 64 JT5 Operator’s Manual Start Unit Start Unit 1. Insert key. 2. Turn key clockwise. When the ambient temperature is below 32°F (0°C), use the cold start procedure to activate glow plugs. • Turn key to ON position. Glow plugs will activate. • Wait for cold start wait indicator to turn off. (See page 26.) • Turn key to START position. 3. Run engine at low throttle for 5 minutes. Steer Unit To steer drilling unit, follow instructions for type of steering desired.
JT5 Operator’s Manual Drive - 65 Shut Down Unit Shut Down Unit 1. Stop track movement. 2. Lower drill frame and stabilizer to the ground. IMPORTANT: If frame and stabilizer cannot be lowered, use cylinder locks or other suitable material to block the tracks. Remove cylinder locks or chocks before driving unit. 3. Run engine at low throttle for 3 minutes to cool. 4. Turn key to STOP. 5. Remove key.
Drive - 66 JT5 Operator’s Manual Shut Down Unit CMW
JT5 Operator’s Manual Transport - 67 Transport Chapter Contents Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Haul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 • Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 • Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 • Unload . . . . . . . . . . . . . . . . . . . . . . .
JT5 Operator’s Manual Transport - 68 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” on page 151 for weight of machine. Haul Load Crushing weight. If load falls or moves it could kill or crush you. Use proper procedures and equipment or stay away. NOTICE: • Load and unload trailer on level ground. • Verify that trailer wheels are blocked.
JT5 Operator’s Manual Transport - 69 Haul Tie Down Points Tiedown points are identified by tiedown decals. Securing to trailer at other points is unsafe and can damage machinery. Procedure Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly. Do not use tiedown points for towing or lifting. Loop tiedowns around rear tiedown points. Use D-rings or pin to trailer using hole in anchor plate. Make sure tiedowns are tight before transporting.
JT5 Operator’s Manual Transport - 70 Haul Unload Crushing weight. If load falls or moves it could kill or crush you. Use proper procedures and equipment or stay away. NOTICE: • Load and unload trailer on level ground. • Ensure trailer wheels are blocked. • Attach trailer to vehicle before loading or unloading. 1. Lower ramps. 2. Remove tiedowns. 3. Start drilling unit engine. 4. Raise stabilizer and drill frame. 5. Slow engine to low throttle and slowly back unit down trailer or ramps.
JT5 Operator’s Manual Transport - 71 Tow Tow Under normal conditions, drilling unit should not be towed. If unit breaks down and towing is necessary: • Attach chains to indicated tow points facing towing vehicle. • Disengage track hydraulics. • Tow for short distances at less than 1 mph (1.6 km/h). • Use maximum towing force of 1.5 times unit weight. To disengage track hydraulics: 1. Loosen locknut (2). 2. Turn screw (1) on each counterbalance valve clockwise until it stops.
Transport - 72 JT5 Operator’s Manual Tow Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly. Do not use tiedown points (D-rings) for towing or lifting. Loop chain through tow points on left and right side of unit (shown) and pull straight forward.
JT5 Operator’s Manual Conduct a Bore - 73 Conduct a Bore Chapter Contents Position Equipment . . . . . . . . . . . . . . . . . . . . . . . . 75 Connect Fluid System . . . . . . . . . . . . . . . . . . . . . . 75 Start System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Prime Drilling Fluid Pump . . . . . . . . . . . . . . . . . . . 76 Operate Carriage Control . . . . . . . . . . . . . . . . . . . 77 Assemble Drill String . . . . . . . . . . . . . . . . . . . . . . .
Conduct a Bore - 74 JT5 Operator’s Manual Record Bore Path . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Surface Drill Head . . . . . . . . . . . . . . . . . . . . . . . . . 85 Assemble Backream String . . . . . . . . . . . . . . . . . 86 Remove Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Remove Pullback Device . . . . . . . . . . . . . . . . . . . .
JT5 Operator’s Manual Conduct a Bore - 75 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 47. 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.
JT5 Operator’s Manual Conduct a Bore - 76 Prime Drilling Fluid Pump Prime Drilling Fluid Pump Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly. NOTICE: Failure to prime the drilling fluid pump will cause flow fluctuations, which will make it difficult to control the washwand. Pressurized fluid or air could pierce skin and cause injury or death. Stay away. Prime drilling fluid pump each time tank is changed. To prime the pump: 1.
JT5 Operator’s Manual Conduct a Bore - 77 Operate Carriage Control Operate Carriage Control The thrust/rotation control has eight positions which allow the four basic functions to be combined. The chart below summarizes functions that occur when control is put at a combined position. Operator must be in seat for control to function.
JT5 Operator’s Manual Conduct a Bore - 78 Clamp Pipe Clamp Pipe Turning shaft can kill you or crush arm or leg. Stay away. NOTICE: Clamping anywhere else on the pipe will weaken the pipe. Pipe can later break, even when operating under normal loads. Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly. NOTICE: Wrenches can open after engine shutdown.
JT5 Operator’s Manual Conduct a Bore - 79 Assemble Drill String Assemble Drill String 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. Prepare Beacon Housing 1. Select nozzles and bit. IMPORTANT: A variety of nozzles and bits are available to suit your particular job conditions. See “Downhole Tools” on page 110 for more information, or contact your Ditch Witch dealer. 2.
Conduct a Bore - 80 JT5 Operator’s Manual Assemble Drill String Attach Transition Sub Use either machine torque or quick wrench to attach transition sub. • Attach transition sub (6) directly to beacon housing (1), or • Attach transition sub (5) to EZ-Connect adaptor (4). Machine Torque 1. Apply tool joint compound to shoulders and threads and thread transition sub onto saver sub. 2. Align drill pipe flats of EZ-Connect box or beacon housing with front wrench of drill frame. 3.
JT5 Operator’s Manual Conduct a Bore - 81 Drill First Pipe Drill First Pipe Turning shaft can kill you or crush arm or leg. Stay away. NOTICE: • Keep everyone at least 10’ (3 m) away from turning drill string. • Push rod or pipe slowly. Forcing can bend string. Do not use bent rod or pipe. Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. 1. Turn on drilling fluid. 2. Visually check for drilling fluid flow. 3.
Conduct a Bore - 82 JT5 Operator’s Manual Add Pipe Add Pipe 1. Set engine throttle to full speed. 2. Clamp pipe joint. See “Clamp Pipe” on page 78. 3. Locate drill head. 4. Engage front wrench until pipe is clamped and pressure develops. 5. Slowly rotate spindle counterclockwise. Move carriage back as threads unscrew. 6. After threads are fully unscrewed, stop rotation and move carriage to back of frame, slowing down as carriage approaches rear end. 7. Connect Pipe. See “Connect Drill Pipe” on page 80. 8.
JT5 Operator’s Manual Conduct a Bore - 83 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 locates the drill head and sends instructions to the operator.
Conduct a Bore - 84 JT5 Operator’s Manual Record Bore Path Drill Head Position The drill head position is determined by reading beacon roll. Roll is displayed as a clock face position. 1. Read beacon roll. 2. Slowly rotate pipe until locator displays desired beacon roll. To change direction: 1. Rotate pipe to clock position you intend to travel. 2. Push pipe into ground. To move forward without changing direction: Rotate pipe into ground. Record Bore Path Locate drill head every length of pipe.
JT5 Operator’s Manual Conduct a Bore - 85 Surface Drill Head Surface Drill Head Moving tools will injure or kill. Shut off drill string power when anyone can be struck by moving or thrown tools. Never use pipe wrenches on drill string. Turning shaft will kill you or crush arm or leg. Stay away. NOTICE: • Tracker operator and drill operator should maintain two-way communication. • Keep everyone clear of the exposed drill string.
JT5 Operator’s Manual Conduct a Bore - 86 Assemble Backream String Assemble Backream String Sometimes it is necessary to enlarge the pilot hole to accommodate larger product. As a general rule, the final hole should be 1.5 times larger than the diameter of the product being installed. The number of passes needed depends on soil conditions. Do not try to increase hole size too much in one pass. Several passes using successively larger reamers will save wear on machine. Moving tools will kill or injure.
JT5 Operator’s Manual Conduct a Bore - 87 Assemble Backream String 1. Select backreaming devices. See “Backreamers” on page 112. 2. Determine fluid rate requirements and install appropriate nozzles to provide sufficient flow. See “Backream Fluid Requirements” on page 113 and “Nozzles” on page 110. 3. Attach backreamer to backream beacon housing if tracking backream. 4. Install beacon, following beacon instructions for: • battery replacement • beacon positioning 5. Install beacon housing lid.
Conduct a Bore - 88 JT5 Operator’s Manual Remove Pipe Remove Pipe NOTICE: If engine is shut off during backreaming, drill pipe clamped by wrenches but not connected to saver sub can be pulled downhole as vise wrenches loosen. 1. Stop carriage when pipes are aligned in wrenches. 2. Clamp pipe in front wrench. See page 78. 3. Clamp and rotate rear wrench to break front joint. See “Wrench control” on page 25. 4. Disengage rear wrench. 5. Unscrew front joint.
JT5 Operator’s Manual Conduct a Bore - 89 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 injure or kill. Shut off drill string power when anyone can be struck by moving or thrown tools. Never use pipe wrenches on drill string. 1. Turn off drilling fluid. 2.
Conduct a Bore - 90 JT5 Operator’s Manual Remove Pullback Device CMW
JT5 Operator’s Manual Systems and Equipment - 91 Systems and Equipment Chapter Contents Anchor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 • Drive Anchor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 • Remove Anchor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Electric Strike System . . . . . . . . . . . . . . . . . . . . . . 95 • FCC Statement . . . . . . . . . . . . . . . . . . . . . . . . .
Systems and Equipment - 92 JT5 Operator’s Manual Downhole Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 110 • Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 • Bits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 • Beacon Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 • Backreamers . . . . . . . . . . . . . . . . . . . . . . .
JT5 Operator’s Manual Systems and Equipment - 93 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. NOTICE: • Stand on operator platform. • Drive anchor properly before drilling. • Wear high-top protective boots with legs of pants completely tucked inside. • Wear protective gloves.
Systems and Equipment - 94 JT5 Operator’s Manual Anchor System Drive Anchors IMPORTANT: Carefully time anchor rotation with anchor movement. Properly driven anchors should thread into soil and should not auger up soil. 1. Use anchor rotation and thrust controls to drive anchor into ground. 2. Anchor is set when cap top plate (1) rests firmly on centering tube (2). 3. Repeat process for other anchor. Remove Anchors 1. Use anchor rotation and thrust controls to slowly remove anchor shaft from ground. 2.
JT5 Operator’s Manual Systems and Equipment - 95 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 when tested at 14,000 volts. Tuck legs of pants completely inside boots.
Systems and Equipment - 96 JT5 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 “ESID Diagnostic Codes” on page 97 on the following page. Do not drill until test is completed successfully. 1. Turn on drilling unit. 2.
JT5 Operator’s Manual Systems and Equipment - 97 Electric Strike System ESID Diagnostic Codes 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. Code Display Condition Result 502 2.5V REF 2.
JT5 Operator’s Manual Systems and Equipment - 98 Electric Strike System Troubleshoot Strike System In addition to self-test diagnostic codes, other problem situations and their possible causes and solutions are listed in the chart below. Problem Possible cause Possible solution No lights or readings showing after drilling unit key has been on at least one minute Problems in startup Push self test button.
JT5 Operator’s Manual Systems and Equipment - 99 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.
JT5 Operator’s Manual Systems and Equipment - 100 Electric Strike System Problem Possible cause Possible solution EV2 code displays and voltage problem indicator is on Improper connections with control module Check cable connection on control module Defective voltage limiter Have voltage limiter checked or replaced Defective control module Have control module checked or replaced Use Electric Strike Simulator Use the Electric Strike Simulator (p/n 259-506) to test voltage and current sensors on E
JT5 Operator’s Manual Systems and Equipment - 101 Electric Strike System To test for current at strike levels: 1. Put two or three loops through current transformer. 2. Follow steps above to test. 3. Display should show the following: • All lights should turn on. • Alarm and strobe should turn on. With two loops, • Current "A" should be 80-110%. • Strike indication might go on and off. With three loops, • Current should be 130-160%. • Strike indication should be continuous. Voltage Test 1.
JT5 Operator’s Manual Systems and Equipment - 102 Drilling Fluid Drilling Fluid For productive drilling and equipment protection, use these recommended Baroid® products, available from your Ditch Witch dealer. Use appropriate PPE Material Safety Data Sheet (MSDS) information, available at www.ditchwitch.com/safe.
JT5 Operator’s Manual Systems and Equipment - 103 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.
JT5 Operator’s Manual Systems and Equipment - 104 Drilling Fluid Basic Fluid Recipes Soil type Mixture/100 gal (378 L) of water 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 .75 lb (340 g) Quik-Trol .
JT5 Operator’s Manual Systems and Equipment - 105 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.
Systems and Equipment - 106 JT5 Operator’s Manual Drilling Fluid Funnel Viscosity Viscosity is the measure of internal 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.
JT5 Operator’s Manual Systems and Equipment - 107 Tracker Control Tracker Control Overview Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly. This mode allows the 750/752 Tracker operator to disable hydraulic power to drilling unit thrust and rotation. NOTICE: This mode does not disable thrust and rotation immediately. Functions are disabled within 16 seconds.
Systems and Equipment - 108 JT5 Operator’s Manual Tracker Control 4. Turn on 750/752 Tracker and check four-digit code. If codes on tracker and display match, thrust and rotation hydraulics on the drilling unit are enabled. If codes on tracker and display do not match, adjust tracker code: • Press and hold fore/aft/left/right button while making the following adjustments. • Use ON/OFF to advance first two digits (1). Use DEPTH to lower first two digits. • Use up arrow to advance last two digits (2).
JT5 Operator’s Manual Systems and Equipment - 109 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 carriage, will come on. Hydraulic power to thrust and rotation will be disabled. IMPORTANT: Tracker operator cannot disable thrust and rotation from tracker if tracker control key (shown) is installed in drilling unit and turned to the disable position.
JT5 Operator’s Manual Systems and Equipment - 110 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.
JT5 Operator’s Manual Systems and Equipment - 111 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 surface
JT5 Operator’s Manual Systems and Equipment - 112 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.
JT5 Operator’s Manual Systems and Equipment - 113 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.
JT5 Operator’s Manual Systems and Equipment - 114 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.
JT5 Operator’s Manual Systems and Equipment - 115 Quick Wrench Quick Wrench To attach or remove downhole tools, use quick wrench to join or break the joint. Moving tools will injure or kill. Shut off drill string power when anyone can be struck by moving or thrown tools. Never use pipe wrenches on drill string. IMPORTANT: 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.
JT5 Operator’s Manual Systems and Equipment - 116 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 .25” (6 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. j07om071h.eps To Break 1.
JT5 Operator’s Manual Systems and Equipment - 117 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 120 for correct lubricant. 2. Join pipe and tighten joint. 3. Break joint. 4. Move pipe back to box.
Systems and Equipment - 118 JT5 Operator’s Manual Drill Pipe Use Caps and Plugs Before transporting in dusty conditions or prolonged storage, install caps and plugs to male and female ends of pipe and to saver sub. Replace Worn Saver Sub Because each pipe comes in contact with the saver sub, check saver sub regularly for wear. Replace it when it is worn, or it will damage your drill pipe. See page 149 for replacement procedure. Precondition a new saver sub the same way you do new pipe.
JT5 Operator’s Manual Systems and Equipment - 119 Drill Pipe Use Drill Pipe Correctly Align the Joints Always carefully align the male and female ends of pipe before screwing them together. Poor alignment can damage the threads and destroy the usefulness of the joint. IMPORTANT: The first pipe drilled must be in a straight line with the unit. A misaligned pipe can damage threads on each pipe that is added. Clamp Pipe Correctly Clamp on pipe when joint is centered between wrenches.
Systems and Equipment - 120 JT5 Operator’s Manual Drill Pipe Make Up and Break Out Joints Correctly • 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, and always connect and disconnect joints slowly and deliberately. This will help prevent thread crossing, galling, and shoulder swelling. • Torque joints fully.
JT5 Operator’s Manual Complete the Job - 121 Complete the Job Chapter Contents Antifreeze Drilling Unit . . . . . . . . . . . . . . . . . . . . 122 • Add Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 • Reclaim Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Rinse Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 124 Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Complete the Job - 122 JT5 Operator’s Manual Antifreeze Drilling Unit Antifreeze Drilling Unit Your drilling unit can be left overnight in freezing conditions by circulating a polyproplyene-based antifreeze (p/n 265-644) through optional antifreeze system before shutdown. Add Antifreeze Without optional antifreeze kit: 1. Move carriage to front of drill frame. 2. Position 1-gal (4-L) bucket under spindle. 3. Connect hose to drilling fluid pump inlet (shown). 4.
JT5 Operator’s Manual Complete the Job - 123 Antifreeze Drilling Unit Reclaim Antifreeze 1. Connect remote fluid system. See page 89. 2. Turn on remote fluid system engine and open valves to allow fluid flow. 3. Start drilling unit and run at low throttle. 4. Move carriage to front of drill frame. 5. Position 1-gal (4-L) bucket under spindle. 6. Turn drilling fluid pump on low speed. 7. Turn drilling fluid pump off when drilling fluid comes out of spindle. 8. Pour antifreeze into tank.
JT5 Operator’s Manual Complete the Job - 124 Rinse Equipment Rinse Equipment Using Optional Washwand Connect the washwand at quick connect at rear of unit. Close valve (shown) to shut off flow to spindle. IMPORTANT: • Never use high flow when using wash wand. • Use extreme caution when working with highly pressurized water. Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly.
JT5 Operator’s Manual Complete the Job - 125 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.
Complete the Job - 126 JT5 Operator’s Manual Stow Tools CMW
JT5 Operator’s Manual Service - 127 Service Chapter Contents Service Precautions . . . . . . . . . . . . . . . . . . . . . . . 128 Recommended Lubricants/Service Key . . . . . . 130 Startup/10 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . 132 50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 100 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 150 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 250 Hour . . . . . . . .
JT5 Operator’s Manual Service - 128 Service Precautions Service Precautions Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly. NOTICES: • 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. • Disconnect battery to prevent damage to battery.
JT5 Operator’s Manual Service - 129 Service Precautions Working Under Drilling Unit 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 yellow cylinder lock from storage at rear of pipe box and place over extended cylinder rod (shown) with curved ends toward stabilizer shoe. 2.
JT5 Operator’s Manual Service - 130 Recommended Lubricants/Service Key Recommended Lubricants/Service Key Item Description DEO Diesel engine oil meeting or exceeding CH-4 per the API service classification or E5 per the European Automobile Manufacturer’s Association (ACEA) and SAE viscosity recommended by engine manufacturer (SAE 10W30) EO Engine oil (SAE 10W30) MPG Multipurpose grease. Use polyurea based NLGI GC-LB Grade 1.5 or lithium based NLGI GC-LB Grade 2.
JT5 Operator’s Manual Service - 131 Recommended Lubricants/Service Key Engine Oil Temperature Chart Temperature range anticipated before next oil change Approved Coolant Any coolant is approved for use with this unit. However, it was filled with John Deere Cool-Gard coolant before shipment from factory. Add only Cool-Gard (p/n 255-006) or any fully-formulated, ethylene glycol based, low-silicate, heavy-duty diesel engine coolant meeting ASTM specification D5345 (prediluted) or D4985 (concentrate).
JT5 Operator’s Manual Service - 132 Startup/10 Hour Startup/10 Hour Location Task DRILLING UNIT Check engine air filter service indicator Check engine oil level Notes DEO Check hydraulic hoses Check hydraulic fluid level THF Check pipe auto lubricator spray nozzle optional equipment Check tool joint compound level TJC Check coolant level DEAC Check drilling fluid pump oil level Drilling Unit Check Engine Air Filter Service Indicator Check air filter restriction indicator before startup and
JT5 Operator’s Manual Service - 133 Startup/10 Hour To replace air filter: 1. Open filter canister. 2. Remove and discard primary filter (3) and safety elements (2). 3. Install new safety (2) and primary (3) elements. 4. Close canister. 5. Reset air filter indicator (1). Check Engine Oil Level While engine oil is warm, move carriage to front of drill frame and check oil level at dipstick (1) before startup and every 10 hours of operation.
JT5 Operator’s Manual Service - 134 Startup/10 Hour Check Hydraulic Hoses Pressurized fluid or air could pierce skin and cause injury or death. Stay away. NOTICE: Escaping pressurized fluid can cause injury or pierce skin and poison. • 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.
JT5 Operator’s Manual Service - 135 Startup/10 Hour Check Hydraulic Fluid Level 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) as necessary. Check Pipe Auto Lubricator Spray Nozzle (Optional) Check pipe auto lubricator spray nozzle before startup and every 10 hours of operation. Ensure that nozzle is free of obstructions and operates properly.
Service - 136 JT5 Operator’s Manual Startup/10 Hour Check Coolant Level Check coolant level before startup and every 10 hours of operation. When machine is cold, add coolant as needed to maintain between LOW and FULL indicators shown on overflow bottle. Check Drilling Fluid Pump Oil Level Check drilling fluid pump oil level before startup and every 10 hours of operation. Add EO as needed.
JT5 Operator’s Manual Service - 137 50 Hour 50 Hour Location Task Notes DRILLING UNIT Change engine oil and filter Initial service, DEO Change drilling fluid pump oil (initial) EO Clean drilling fluid pump strainer Check radiator Change hydraulic filter Initial service Check rotation gearbox oil level 2 gearboxes, MPL Inspect thrust rollers Check battery Drilling Unit Change Engine Oil and Filter (Initial) Change engine oil after 50 hours while oil is warm and with unit parked on level groun
Service - 138 JT5 Operator’s Manual 50 Hour Change Drilling Fluid Pump Oil (Initial Service) Change fluid pump oil after first 50 hours and every 750 hours thereafter. Drain at plug (2) and add EO at plug (1). Maintain fluid level at fill plug. Clean Drilling Fluid Pump Strainer Clean drilling fluid pump strainer after the first 50 hours, then clean as needed. Check Radiator Check radiator for dirt, grass, and other foreign matter every 50 hours. Clean out with compressed air or spray wash if required.
JT5 Operator’s Manual Service - 139 50 Hour Change Hydraulic Filter (Initial Service) Change hydraulic filter (shown) after first 50 hours. Check Rotation Gearbox Oil Level Check rotation gearbox oil level every 50 hours. Oil should be visible at plug (2). Add MPL at plug (1) as needed. IMPORTANT: Drill frame must be level for accurate reading. Inspect Thrust Rollers Inspect thrust rollers every 50 hours. Clean or replace if they do not turn freely.
Service - 140 JT5 Operator’s Manual 50 Hour Check Battery Keep batteries clean and free of corrosion. Apply coat of grease to cable clamps after cleaning. In cold weather, battery loses some starting ability. Closely watch voltmeter for signs of battery discharge. If battery will not hold charge, see your Ditch Witch dealer for replacement battery. IMPORTANT: Use battery disconnect switch (shown) when servicing, welding, and during long-term storage.
JT5 Operator’s Manual Service - 141 100 Hour 100 Hour Location Task DRILLING UNIT Change fuel filters Notes Check fan belt tension Drilling Unit Change Fuel Filters Change canister fuel filter (top) and inline fuel filter (bottom) every 100 hours. Note: The canister fuel filter is located behind the engine oil filter. 1. Remove filter. 2. Fill new filter with clean fuel. 3. Apply fuel oil over the gasket and handtighten.
Service - 142 JT5 Operator’s Manual 100 Hour Check Fan Belt Tension Check pump drive belt tension every 100 hours. 1. Turn off engine and remove key. 2. Apply moderate thumb pressure to top of belt. Belt is properly tensioned when deflection (A) is 1/4-3/8” (7-9 mm). To adjust, see page 148.
JT5 Operator’s Manual Service - 143 150 Hour 150 Hour Change Engine Oil and Filter Change engine oil every 150 hours while oil is warm and with unit parked on level ground. 1. Open drain (3). 2. Drain crankcase while oil is warm. 3. Replace filter (4). 4. Close drain. 5. Add DEO at fill (2) until oil level is at highest line on dipstick (1). 250 Hour Change Hydraulic Fluid Filter Change filter (shown) every 250 hours. Change more often if indicated by filter indicator.
Service - 144 JT5 Operator’s Manual 750 Hour 750 Hour Change Drilling Fluid Pump Oil Change fluid pump oil every 750 hours. Drain at plug (2) and add with oil at plug (1). Maintain fluid level at fill plug. Capacity for pump is 1 qt (0.9 L).
JT5 Operator’s Manual Service - 145 1000 Hour 1000 Hour Location Task Notes DRILLING UNIT Change rotation gearbox oil MPL Change hydraulic fluid and filter THF Drilling Unit Change Rotation Gearbox Oil Drain oil at gearbox oil drain (3) every 1000 hours. Replace drain plug. Add MPL at fill plug (1) until oil is visible at plug (2). Replace fill plug. IMPORTANT: Drill frame must be level for accurate reading. Change Hydraulic Fluid and Filter Change hydraulic fluid and filter every 1000 hours.
Service - 146 JT5 Operator’s Manual 2000 Hour 2000 Hour Change Engine Coolant Drain cooling system at drain (2). Add approved coolant at fill (1) every two years or 2000 hours. NOTICE: • The use of non-approved coolant may lead to engine damage or premature engine failure and will void engine warranty. • See “Approved Coolant” on page 131. for list of approved coolants.
JT5 Operator’s Manual Service - 147 As Needed As Needed Location Task Notes DRILLING UNIT Change pipe lubricator TJC tube TJC Check track tension and condition Adjust fan belt Replace saver sub Check fluid pump check valve Replace carriage slide bars Replace fuses Drilling Unit Change Lubricator TJC Tube Check pipe lubricator TJC level and change tube as needed. To change tube 1. Pull lock handle (3) back. 2. Unscrew cartridge (2). 3. Release handle and push tube (1) out. 4. Pull handle lock. 5.
Service - 148 JT5 Operator’s Manual As Needed Check Track Tension and Condition Check track tension and condition and adjust or replace as needed. See your Ditch Witch dealer for replacement parts. To adjust, turn bolt (1) clockwise to tighten and counterclockwise to loosen. Track tension is correct when dimension A is approximately 2.25” (57 mm). Adjust Fan Belt Adjust fan belt as needed. 1. Turn off engine and remove key. 2. Apply moderate thumb pressure to belt between pulleys where shown.
JT5 Operator’s Manual Service - 149 As Needed Replace Saver Sub Check saver sub and replace as needed. See your Ditch Witch dealer for replacement parts. To replace IMPORTANT: Saver sub must mate up to every drill pipe. Check sub for thread wear. If saver sub threads are more worn than pipe threads, saver sub is damaging the drill pipe. 1. Remove six bolts from saver sub flange. 2. Remove and discard saver sub. 3. Replace o-ring, if necessary. 4. Install new saver sub. 5.
Service - 150 JT5 Operator’s Manual As Needed Replace Fuses Change fuses (shown) as needed. Refer to decal inside panels to identify fuses.
JT5 Operator’s Manual Specifications - 151 Specifications Dimensions U.S. Metric L, overall machine length 120 in 3.1 m W, overall machine width 35.9 in 91.2 cm H, overall machine height 70 in 1.78 m Operating weight w/150’/45.7 m of drill pipe, anchoring system and anchor 3690 lb 1674 kg UFE Pipe U.S. Metric Length 59 in 1.5 m Joint diameter 1.88 in 47.8 mm Tubing diameter 1.1 in 28 mm Minimum bend radius 70 ft 21.3 m Weight 16 lb 7.
Specifications - 152 JT5 Operator’s Manual Operational U.S. Metric Maximum spindle speed 195 rpm 195 rpm Maximum spindle torque 550 ft•lb 746 N•m Thrust force 4100 lb 18.2 kN Pullback force 5000 lb 22.2 kN Carriage travel speed 130 fpm 40 m/min Minimum bore diameter 2.5 in 63.5 mm Backream diameter (soil dependent) 4.5 in 114 mm forward 1.53 mph 2.46 km/h reverse 1.53 mph 2.46 km/h Ground bearing pressure 6.0 psi 0.42 kg/cm2 Power U.S.
JT5 Operator’s Manual Specifications - 153 Drilling Fluid System (Onboard) U.S. Metric Maximum drilling fluid flow 0-5 gpm 0-18.9 L/min Maximum drilling fluid pressure 750 psi 51.7 bar Fluid Capacities U.S. Metric Fuel tank 13 gal 49 L Hydraulic reservoir 8 gal 30 L Engine oil, including filter 4.2 qt 4L Battery SAE reserve capacity rating 85 min, 12V, negative ground, SAE cold crank rating @ 0°F (-18°C), 525 amps.
Specifications - 154 CMW JT5 Operator’s Manual
JT5 Operator’s Manual Support - 155 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.
JT5 Operator’s Manual Warranty - 156 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).
JT5 Operator’s Manual Service Record - 159 Service Record Service Performed Date Hours CMW
Service Record - 160 Service Performed CMW JT5 Operator’s Manual Date Hours
