Ditch Witch XP44 Operator’s Manual 053-3081 PDF

XP44

Operator’s Manual

Issue 2.0

053-3081

ORIGINAL INSTRUCTION

XP44 Operator’s Manual

Overview - 1

Overview Chapter Contents Serial Number Location . . . . . . . . . . . . . . . . . . . . . . 2 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 •

Bulleted Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

•

Numbered Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

XP44 Operator’s Manual

Overview - 2

Serial Number Location

Serial Number Location Record serial numbers and date of purchase in spaces provided. Fluid unit serial number is located as shown.

Item date of manufacture date of purchase fluid unit serial number trailer serial number engine serial number

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Intended Use The XP44 is a self-contained drilling fluid unit capable of mixing up to 500 gal (1892 L) or 950 gal (3596 L) of drilling fluid per tank (depending on tank used) and transferring fluid under pressure to the drilling unit. It can also be used as an offboard high-pressure fluid system with capabilities up to 39 gpm (147.6 L/min) and 1000 psi (69 bar). It 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 XP44 can be used with Ditch Witch® drilling units. It should be operated, serviced, and repaired only by persons familiar with its particular characteristics and acquainted with the relevant safety procedures.

XP44 Operator’s Manual

Overview - 3

Unit Components

Unit Components 1

2

3

4

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1. tank

3. power pack/pumps

2. hopper

4. remote operation indicator light

About This Manual This manual contains information for the proper use of this machine. See the beige Operation Overview pages for basic operating procedures. Cross references such as “See page 50” will direct you to detailed procedures.

Bulleted Lists Bulleted lists provide helpful or important information or contain procedures that do not have to be performed in a specific order.

Numbered Lists Numbered lists contain illustration callouts or list steps that must be performed in order.

Overview - 4

XP44 Operator’s Manual About This Manual

XP44 Operator’s Manual

Foreword - 5

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. If you need assistance in locating a dealer, visit our website at www.ditchwitch.com or write to the following address: The Charles Machine Works, Inc. Attn: Marketing Department PO Box 66 Perry, OK 73077-0066 USA The descriptions and specifications in this manual are subject to change without notice. The Charles Machine Works, Inc. reserves the right to improve equipment. Some product improvements may have taken place after this manual was published. For the latest information on Ditch Witch equipment, see your Ditch Witch dealer.

Thank you for buying and using Ditch Witch equipment.

XP44 Operator’s Manual

Foreword - 6

XP44 Operator’s Manual Issue number 2.0/OM-02/18 Part number 053-3081 Copyright 2017, 2018

by The Charles Machine Works, Inc.

and Ditch Witch are registered trademarks of The Charles Machine Works, Inc. This product and its use may be covered by one or more patents at http://patents.charlesmachine.works.

XP44 Operator’s Manual

Contents - 7

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

5

part number, revision level, and publication date of this manual, and factory contact information

Safety

9

machine safety alerts and emergency procedures

Controls

21

machine controls, gauges, and indicators and how to use them

Operation Overview

37

an overview for completing a job with this machine: planning, setting up, handling drilling fluid, and leaving the jobsite; with cross references to detailed procedures

Prepare

41

procedures for inspecting the jobsite and preparing the jobsite for work

Transport

45

procedures for lifting and hauling

Systems and Equipment

49

procedures for selecting fluid additives, determining fluid requirements, and measuring viscosity; procedure for remote pairing

Complete the Job

55

procedures for rinsing and storing equipment

Service

59

service intervals and instructions for this machine including lubrication, replacement of wear items, and basic maintenance

Specifications

83

machine specifications including weights, measurements, power ratings, and fluid capacities

Support

87

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

91

Contents - 8

XP44 Operator’s Manual

Appendix the warranty policy for this machine, and procedures for obtaining warranty consideration and training

93

XP44 Operator’s Manual

Safety - 9

Safety Chapter Contents Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 California Proposition 65 Warning . . . . . . . . . . . . 10 Emergency Procedures . . . . . . . . . . . . . . . . . . . . . 11 •

Electric Strike Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

•

If an Electric Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

•

If a Gas Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

•

If a Fiber Optic Cable is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

•

If Machine Catches on Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Safety Alert Classification . . . . . . . . . . . . . . . . . . . 15 Machine Safety Alerts. . . . . . . . . . . . . . . . . . . . . . . 16

Safety - 10

XP44 Operator’s Manual Guidelines

Guidelines When you see this safety alert sign, carefully read and follow all instructions.

YOUR SAFETY IS AT STAKE. Read this entire section before using your equipment.

Follow these guidelines before operating any jobsite equipment: •

Complete proper training and read operator’s manual before using equipment.

•

Mark proposed path with white paint and have underground utilities located before working. In the US or Canada, call 811 (US) or 888-258-0808 (US and Canada). Also contact any local utilities that do not participate in the One-Call service. In countries that do not have a One-Call service, contact all local utility companies to have underground utilities located.

•

Classify jobsite based on its hazards and use correct tools and machinery, safety equipment, and work methods for jobsite.

•

Mark jobsite clearly and keep spectators away.

•

Wear personal protective equipment.

•

Review jobsite hazards, safety and emergency procedures, and individual responsibilities with all personnel before work begins. Safety videos are available from your Ditch Witch® dealer or at www.ditchwitch.com/safe. Safety Data Sheets (SDS) are available at www.ditchwitch.com/support.

•

Fully inspect equipment before operating. Repair or replace any worn or damaged parts. Replace missing or damaged safety shields and safety signs. Contact your Ditch Witch dealer for assistance.

•

Use equipment carefully. Stop operation and investigate anything that does not look or feel right.

•

Do not operate machine where flammable gas may be present.

•

Only operate equipment in well-ventilated areas.

•

Contact your Ditch Witch dealer if you have any question about operation, maintenance, or equipment use.

•

Complete the equipment checklist located at www.ditchwitch.com/safe.

California Proposition 65 Warning This product may contain chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

•

battery posts, terminals and related accessories

•

engine exhaust

•

ethylene glycol

XP44 Operator’s Manual

Safety - 11

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 will cause death or serious injury. Stay away.

274-049

When working near electric cables, remember the following: •

Electricity follows all paths to ground, not just path of least resistance.

•

Pipes, hoses, and cables will conduct electricity back to all equipment.

•

Low voltage current can injure or kill. Many work-related electrocutions result from contact with less than 440 volts.

Most electric strikes are not noticeable, but indications of a strike include: •

power outage

•

smoke

•

explosion

•

popping noises

•

arcing electricity

If any of these occur, assume an electric strike has occurred.

Safety - 12

XP44 Operator’s Manual Emergency Procedures

If an Electric Line is Damaged If you suspect an electric line has been damaged and you are on truck or trailer, DO NOT MOVE. Remain on truck or trailer 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. Instruct them to leave the area and contact utility.

•

Do not allow anyone into area until given permission by utility company.

•

Do not allow anyone to touch equipment.

If you suspect an electric line has been damaged and you are off truck or trailer, DO NOT TOUCH EQUIPMENT. Take the following actions. The order and degree of action will depend on the situation.

•

LEAVE AREA. The ground surface may be electrified so take small shuffle steps with feet close together to reduce the hazard of being shocked from one foot to the other.

•

Contact utility company to shut off power.

•

Do not return to area or allow anyone into area until given permission by utility company.

XP44 Operator’s Manual

Safety - 13

Emergency Procedures

If a Gas Line is Damaged Fire or explosion possible. Fumes could ignite and cause burns. No smoking, no flame, no spark. 275-419 (2P)

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 orders and degree of action will depend on the situation.

•

Immediately shut off engine(s), if this can be done safely and quickly.

•

Remove any ignition source(s), if this can be done safely and quickly.

•

Warn others that a gas line has been cut and that they should leave the area.

•

Leave jobsite as quickly as possible.

•

Immediately call your local emergency phone number and utility company.

•

If jobsite is along street, stop traffic from driving near jobsite.

•

Do not return to jobsite until given permission by emergency personnel and utility company.

Safety - 14

XP44 Operator’s Manual Emergency Procedures

If a Fiber Optic Cable is Damaged Do not look into cut ends of fiber optic or unidentified cable. Vision damage can occur. Contact utility company.

If Machine Catches on Fire Perform emergency shutdown procedure and then take the following actions. The order and degree of action will depend on the situation.

•

Immediately move battery disconnect switch (if equipped and accessible) to disconnect position.

•

If fire is small and fire extinguisher is available, attempt to extinguish fire.

•

If fire cannot be extinguished, leave area as quickly as possible and contact emergency personnel.

XP44 Operator’s Manual

Safety - 15

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. indicates a hazardous situation that, if not avoided, will result in death or serious injury.

This signal word is to be limited to the most extreme situations. indicates a hazardous situation that, if not avoided, could result in death or serious injury. indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

Watch for two other words: NOTICE and IMPORTANT. NOTICE indicates information considered important, but not hazard-related (e.g., messages relating to property damage).

IMPORTANT can help you do a better job or make your job easier in some way.

XP44 Operator’s Manual

Safety - 16

Machine Safety Alerts

Machine Safety Alerts XP44

Moving parts. Contact can cause serious injury.

1

2

3

Stay away.

Hot parts. Contact can cause burns. Do not touch unit cool. Wear gloves.

Silica dust. Exposure can cause lung disease. Use breathing protection.

XP44 Operator’s Manual

Safety - 17

Machine Safety Alerts

4

5

Buried electric lines. Contact will cause death or serious injury. Know locations of lines. Stay away.

Misuse of machine can cause death or serious injury. Read and understand operator’s manual and all other safety instructions before use.

Tiedown point. See Transport chapter for more information.

6

7

Pre-heater. Fire or explosion can cause death or serious injury. Do not use starter fluid.

Lift point. See Transport chapter for more information.

8

9

High noise levels. Exposure can cause hearing loss. Wear hearing protection.

Safety - 18

XP44 Operator’s Manual Machine Safety Alerts

Tanks

Lift point. See Transport chapter for more information.

1

Tiedown location. See Transport chapter for more information.

2

3

Buried electric lines. Contact will cause death or serious injury. Know locations of lines. Stay away.

XP44 Operator’s Manual

Safety - 19

Machine Safety Alerts

Hose Reel

1

Pressurized fluid or air could pierce skin and cause severe injury. Refer to operator’s manual for proper use. 270-6035

Safety - 20

XP44 Operator’s Manual Machine Safety Alerts

XP44 Operator’s Manual

Controls - 21

Controls Chapter Contents Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 •

Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

•

Graphic Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

•

Engine Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Mixing Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

XP44 Operator’s Manual

Controls - 22

Power Unit

Power Unit Controls and Indicators 1

2

3

6

4

5

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1. Autothrottle switch

4. Mixing pump control

2. Air filter restriction indicator

5. Fluid flow control

3. Ignition switch

6. Graphic display

Item

Description

Notes

1. Autothrottle switch

To turn autothrottle on, press top of switch.

IMPORTANT: Engine will not throttle up in autothrottle mode unless fluid flow is commanded.

To turn autothrottle off, press bottom.

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XP44 Operator’s Manual

Controls - 23

Power Unit Item

Description

2. Air filter restriction indicator

Replace primary and secondary air filters when indicator reaches 22” of H2O (red area).

Notes

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3. Ignition switch

To start engine, insert key and turn clockwise.

IMPORTANT: •

If engine does not start or stalls, turn key to STOP and then restart.

•

Do not allow starter motor to run continuously for more than 20 seconds.

•

Unit will buzz when key is in on position without engine running.

To stop engine, turn key counterclockwise.

4. Mixing pump control

To increase speed, turn clockwise.

Use speeds under 50% to circulate fluid in tank.

To decrease speed, turn counterclockwise.

Use speeds above 50% to supply fluid to high-pressure pump.

To stop pump, turn all the way counterclockwise.

NOTICE: Do not run pump without fluid.

To increase flow, turn clockwise.

NOTICE: Do not run pump without fluid.

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5. Fluid flow control

To decrease flow, turn counterclockwise.

To stop flow, turn all the way counterclockwise.

XP44 Operator’s Manual

Controls - 24

Power Unit Item

Description

6. Graphic display

See “Graphic Display” on page 25.

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Notes

XP44 Operator’s Manual

Controls - 25

Power Unit

Graphic Display 1

125

230 100

190

STOP

Engine 75 13

150

32 F

Load

0% 50

110

25

15

0

70

20

10

30

25

STARTUP

5

30

RPMx100

12

0.0V

2

0

0

0 HRS

35

3 4

11

10

9

8

7

6

5

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1. Alert display area

8. Throttle system state indicator

2. Engine coolant temperature indicator

9. Remote operation enable button

3. Hourmeter

10. Engine RPM setpoint indicator

4. Engine speed setpoint increase button

11. Drill fluid control screen button

5. Engine speed setpoint decrease button

12. Electrical system voltage

6. Menu button

13. Engine percent load gauge

7. Engine speed (RPM)

Item

Description

1. Alert display area

Engine and exhaust cleaning alerts are displayed in this area.

High exhaust temperature indicator

Lights when exhaust temperatures are high

Notes

IMPORTANT: Will light when exhaust cleaning (DPF regeneration) is occurring.

XP44 Operator’s Manual

Controls - 26

Power Unit Item

Description

Notes

Air filter restriction indicator

Indicator will begin flashing once the air filter is 25% unrestricted. Percentage will decrease as air filter becomes more restricted.

To view the air filter percentage before 25% unrestricted, press the diagnostics menu button at any time.

Hydraulic fluid temperature indicator

Lights and alarm sounds when hydraulic fluid is overheating.

For best results, replace filter between 25% and 0%. Reset after replacing air filter.

Check hydraulic fluid level.

Reduce load.

Ensure oil cooler is clean.

Engine over-temperature indicator

Flashes when temperature rises above 230°F (110°C).

IMPORTANT: If temperature goes above 230°F (110°C): 1. Stop operation, set throttle to low idle, and allow engine to cool.

2. Stop engine.

3. Check coolant level.

4. Ensure radiator is clean.

Diagnostic message indicator

Appears when there is a diagnostic trouble code.

!

Go to Diagnostics menu to see the active and stored error messages.

Indicates a warning code.

Indicates a stop code.

Glow plug indicator

Lights when ignition switch is on and engine ECU determines glow plugs are required to start machine.

Exhaust cleaning (DPF regen) indicator

Flashes when a system cleaning is needed. Lights solid when cleaning is occurring.

Lights when operator has disabled exhaust cleaning.

IMPORTANT: System will remain in disabled mode until unit is returned to automatic mode. Manual exhaust cleaning (DPF REGEN) must be initiated through Tier 4 menu when this indicator is on. See “Exhaust Cleaning - Tier 4 Only” on page 64.

XP44 Operator’s Manual

Controls - 27

Power Unit Item

Description

Notes

2. Engine coolant temperature indicator

Displays coolant temperature.

IMPORTANT: If temperature goes above 230°F (110°C): 1. Stop operation, set throttle to low idle, and allow engine to cool.

2. Stop engine.

3. Check coolant level.

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3. Hourmeter

4. Ensure radiator is clean.

Displays engine operating time.

Use these times to schedule service.

To increase engine speed, push once.

IMPORTANT: Each button press increases engine by 360 rpm.

HRS c00ic106w.eps

4. Engine speed increase button

To increase to full speed, push twice.

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5. Engine speed decrease button

To decrease engine speed, push once.

To decrease to lowest speed, push twice.

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IMPORTANT: Each button press decreases engine by 360 rpm.

XP44 Operator’s Manual

Controls - 28

Power Unit Item

Description

Notes

6. Menu button

Press to go to the menu screen.

Use the main menu to access settings such as: •

diagnostics menu

•

exhaust cleaning menu

•

service menu

•

wireless pairing menu

•

Startup indicates the system is controlling its own throttle during startup conditions.

•

Auto indicates that the autothrottle system is active and controlling engine throttle based on the user’s selected rpm setpoint. To enable auto-throttle, go to the settings menu.

•

No indication means that the rpm setting is under manual control.

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7. Engine speed (RPM)

Displays engine RPM.

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8. Throttle system state indicator

Displays one of the three states of the throttle system.

STARTUP AUTO c00ic111w.eps

9. Remote operation enable button

Press to control fluid pump from drill operator’s station.

Press again to control fluid pump from fluid unit.

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XP44 Operator’s Manual

Controls - 29

Power Unit Item

Description

Notes

10. Engine RPM setpoint indicator

Indicates the current throttle setpoint.

IMPORTANT: •

When in manual throttle mode, this is the RPM the engine will try to maintain.

•

When in auto-throttle mode, this indicates the full throttle setpoint.

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11. Drill fluid control screen button

Press to go to the drill fluid control screen.

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12. Electrical system voltage

Displays system voltage.

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13. Engine percent load gauge

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Displays the load on the engine.

Should show 12-14V with engine running.

XP44 Operator’s Manual

Controls - 30

Power Unit Drill Fluid Control Screen

!

100%

100% 7

50%

50%

0%

0%

6

1

0.0%

0 gpm

0.0% 5

2

3

4

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1. Drilling fluid flow requested display

5. Measured drilling fluid flow rate

2. Return to main gauge display

6. Mixing pump flow requested display

3. Remote/Local operation mode indicator

7. Alert display area

4. Drilling fluid flow button Item

Description

1. Drilling fluid flow requested display

Displays percentage of drilling fluid being requested.

2. Return to main gauge display

Returns to the main gauge display.

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Notes

XP44 Operator’s Manual

Controls - 31

Power Unit Item

Description

Notes

3. Remote/Local operation mode indicator

Indicates the operation mode.

In remote mode, fluid pump flow is controlled from the drilling unit.

In local mode (shown), fluid pump flow is controlled at the fluid unit control station.

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4. Drilling fluid flow button

Press button to allow drilling fluid flow.

Press button again to stop fluid flow.

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5. Measured drilling fluid flow rate

Displays measured amount of drilling fluid flow.

6. Mixing pump flow requested display

Displays percentage of mixing pump flow being requested.

7. Alert display area

Displays alerts from main screen.

XP44 Operator’s Manual

Controls - 32

Power Unit Service Interval Screen

ENGINE

1

INTERVAL

0 HRS

2

REMAINING

0 HRS

3

ENG HRS

4

HOUR RESET

10

5

9

8

7

6

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1. Selected service reminder

6. Return to main gauge display

2. Service reminder interval

7. Interval decrease

3. Time remaining

8. Interval increase

4. Time base calculator

9. Up selection

5. Reset option

10. Down selection

Item

Description

Notes

1. Selected service reminder

Displays current service reminder.

Service reminders are programmed to follow initial service reminders. See the Service chapter on page 67 for intervals.

2. Service reminder interval

Displays current interval of the service reminder.

3. Time remaining

Displays time remaining until the next service reminder.

4. Time base calculator

Displays the time base for the service reminder.

5. Reset option

Resets service reminder.

XP44 Operator’s Manual

Controls - 33

Power Unit Item

Description

6. Return to main gauge display

Returns to the main gauge display.

Notes

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7. Interval decrease

Selects the previous reminder or parameter, or decreases service intervals by 10 hours.

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8. Interval increase

Selects the next reminder or parameter, or increases service interval by 10 hours.

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9. Up selection

Will move the selection on the screen up.

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10. Down selection

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Will move the selection on the screen down.

IMPORTANT: Use the Service chapter beginning on page 67 to set service reminder intervals.

XP44 Operator’s Manual

Controls - 34

Power Unit

Engine Compartment

1

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Item

Description

1. Battery disconnect switch

To connect, turn clockwise.

To disconnect, turn counterclockwise.

OFF

ON

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Notes

XP44 Operator’s Manual

Controls - 35

Mixing Station

Mixing Station 5

6

1

2

3 t58om029w.eps

4

1. Antifreeze valve

4. Dry chemical hopper valve

2. Tank jet valve

5. Pump priming valve

3. Liquid additive pickup valve

6. Mixing pump pressure gauge

Item

Description

1. Antifreeze valve

To allow antifreeze to flow to fluid pump, open valve.

Notes

To stop flow, close valve.

2. Tank jet valve

To allow flow from mixing pump to tank jets, open valve.

To stop flow, close valve.

3. Liquid additive pickup valve

To allow liquid additives to flow into mixture, open valve.

To stop flow of liquid additives, close valve.

IMPORTANT: Do not open valve unless pump is running and mixing venturi valve is open. Fluid could flow out of pickup tube.

XP44 Operator’s Manual

Controls - 36

Mixing Station Item

Description

Notes

4. Dry chemical hopper valve

To allow flow from hopper to mixing venturi, open valve.

IMPORTANT: •

Open valve only when pouring additives into hopper for mixing.

Close valve when finished.

•

Do not open valve unless pump is running and mixing venturi valve is open. Fluid could flow back into hopper.

To stop flow from hopper to mixing venturi, close valve.

5. Pump priming valve

To prime pump, open valve.

When pump is airlocked (run without fluid), prime pump with water.

To return pump to normal operation, close valve.

6. Mixing pump pressure gauge

Displays the pressure at the mixing pump.

Normal system pressure is above 20 psi (1.4 bar).

XP44 Operator’s Manual

Operation Overview - 37

Operation Overview Chapter Contents Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Setting Up at Jobsite . . . . . . . . . . . . . . . . . . . . . . . 38 Mixing Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Transferring Fluid . . . . . . . . . . . . . . . . . . . . . . . . . 40 Operating in Cold Weather . . . . . . . . . . . . . . . . . . 40 Leaving Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

XP44 Operator’s Manual

Operation Overview - 38

Planning

Planning 1. Gather information about jobsite (page 42).

2. Inspect jobsite (page 43).

3. Check supplies and prepare equipment (page 44).

Setting Up at Jobsite 1. Prepare jobsite (page 43).

2. Position fluid unit and connect fluid hose to drilling unit. See drilling unit operator’s manual.

IMPORTANT: Leave unit hitched to towing vehicle or properly stabilized.

3. Ensure fluid unit and drilling unit are communicating (remote light on XP44 is on). See “Thoroughly rinse measuring cup and Marsh funnel.” on page 54 for more information.

4. Block trailer wheels.

Mixing Fluid Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment.

To help avoid injury: •

Wear personal protective equipment including hard hat, safety eye wear, and hearing protection.

•

Do not wear jewelry or loose clothing.

Improper handling or use of chemicals may result in illness, injury, or equipment damage. Follow instructions on labels and in safety data sheets (SDS).

1. Ensure valve in suction line and at least one valve on the pressure side of the pump is open.

2. Turn ignition switch to start position and release when engine starts.

XP44 Operator’s Manual

Operation Overview - 39

Mixing Fluid 3. Move throttle to half open.

IMPORTANT: •

If chemicals are added in the wrong order, they will not mix properly and will form clumps.

See “Mixtures” in Preparation.

•

If tank contains bentonite/polymer mix and more drilling fluid is needed, completely empty tank and start with fresh water before mixing another batch.

4. Open tank jet valve (3) and mixing venturi valve (6).

5. Adjust speed of mixing pump.

6. Partially open dry chemical hopper valve (4). Listen for a noticeable “suction” sound.

IMPORTANT: Add polymers at a very slow rate.

7. For dry chemicals, open sack using bag ripper located inside dry chemical hopper and pour chemicals into hopper.

IMPORTANT: Metering plate can be seated in bottom of dry chemical hopper to allow dry chemicals to be added at a slower rate.

•

Approximate feed rate with metering plate, 50 lb : 1.5 minutes.

•

Approximate feed rate without metering plate, 50 lb : 0.7 minutes.

8. Open dry chemical valve (4) slowly.

9. For liquid polymer and other liquid chemicals, pour needed amount of additive into liquid hopper.

10. Open liquid chemical valve (3) slowly.

11. Open fillwell on top of tank and check fluid in tank to ensure that chemicals are mixed correctly.

12. If clumps of chemical or polymer can be seen in fluid tank, reduce the rate at which materials are added.

Operation Overview - 40

XP44 Operator’s Manual Transferring Fluid

Transferring Fluid Electric shock. Contacting electric lines will cause death or serious injury.

Know location of lines and stay away.

To help avoid injury: Remember that if electrical strike occurs while fluid hose is connected to drilling unit, fluid system will also become electrified. See “Emergency Procedures” on page 11.

•

With remote operation enabled, drilling fluid flow is controlled at the drill operator’s station.

•

With remote operation disabled, drilling fluid flow is controlled at the fluid unit.

Operating in Cold Weather For successful operation in cold weather, follow these procedures.

•

Use pump to keep drilling fluid circulating at all times, even during transport to and from the jobsite.

•

If possible, use all drilling fluid in tank before transporting unit.

•

For cold weather storage, “Antifreeze Fluid System” on page 56.

Leaving Jobsite 1. Rinse unit and tools (page 57).

2. Disconnect hose (page 57).

XP44 Operator’s Manual

Prepare - 41

Prepare Chapter Contents Gather Information . . . . . . . . . . . . . . . . . . . . . . . . . 42 •

Arrange for Traffic Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

•

Prepare for Working Near Existing Utilities . . . . . . . . . . . . . . . . . . . . . .42

•

Plan for Emergency Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Inspect Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Prepare Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Check Supplies and Prepare Equipment . . . . . . . 44 •

Assemble Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

•

Check Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

•

Prepare Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Prepare - 42

XP44 Operator’s Manual Gather Information

Gather Information A successful job begins before the excavation. The first step in planning is reviewing information already available about the job and jobsite.

Arrange for Traffic Control If working near a road or other traffic area, contact local authorities about safety procedures and regulations.

Prepare for Working Near Existing Utilities If jobsite may contain electrical lines, 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 18,000 volts. Tuck legs of pants completely inside boots.

•

Gloves must have 17,000 AC maximum use voltage, according to ASTM specification D120.

If working around higher voltage, use gloves and boots with appropriately higher ratings.

Plan for Emergency Services Have the telephone numbers for local emergency and medical facilities on hand. Check that you will have access to a telephone.

XP44 Operator’s Manual

Prepare - 43

Inspect Jobsite

Inspect Jobsite •

Follow U.S. Department of Labor regulations on excavating and trenching (Part 1926, Subpart P) and other similar regulations.

•

Mark proposed path with white paint and have underground utilities located before working.

– In the US or Canada, call 811 (US) or 888-258-0808 (US and Canada). Also contact any local utilities that do not participate in the One-Call service.

– In countries that do not have a One-Call service, contact all local utility companies to have underground utilities located.

•

Inspect jobsite and perimeter for evidence of underground hazards, such as: – “Buried utility” notices – Utility facilities without overhead lines – Gas or water meters – Junction boxes – Drop boxes – Light poles – Manhole covers – Sunken ground

•

Mark location of all buried utilities and obstructions.

Prepare Jobsite Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. 274-050; 274-724 (2P)

To help avoid injury: •

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. Contact with trees, shrubs, or weeds during electrical strike could result in electrocution.

XP44 Operator’s Manual

Prepare - 44

Check Supplies and Prepare Equipment

Check Supplies and Prepare Equipment Assemble Accessories Fire Extinguisher If required, mount a fire extinguisher near the power unit but away from possible points of ignition. The fire extinguisher should always be classified for both oil and electric fires. It should meet legal and regulatory requirements.

Check Supplies •

water and additional hoses

•

fuel

•

drilling fluid additives, such as bentonite and polymer

Prepare Equipment Fluid Levels •

fuel

•

engine oil

Condition and Function •

all controls

Improper control function could cause death or serious injury. If control does not work as described in instructions, stop machine and have it serviced.

•

filters (air, oil)

•

tires

•

hoses and valves

•

couplers and fittings

•

water tank

XP44 Operator’s Manual

Transport - 45

Transport Chapter Contents Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 •

Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

•

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Haul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

XP44 Operator’s Manual

Transport - 46

Lift

Lift Crushing weight. If load falls or moves it could kill or crush you. Use proper procedures and equipment or stay away.

Points Lifting points are identified by lifting decals. Lifting at other points is unsafe and can damage machinery.

Procedure Tank Use crane capable of supporting the equipment's size and weight. See “Specifications” on page 83 or measure and weigh equipment before lifting.

IMPORTANT: Empty tank before lifting.

XP44 Operator’s Manual

Transport - 47

Haul Power Pack Use crane capable of supporting the equipment's size and weight. See “Specifications” on page 83 or measure and weigh equipment before lifting.

1. Lift power pack by attaching chain to lift point on top of power pack.

2. Bolt base to truck or trailer bed using provided holes.

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Haul IMPORTANT: For trailer information, see the trailer manufacturer’s manual.

Transport - 48

XP44 Operator’s Manual Haul

XP44 Operator’s Manual

Systems and Equipment - 49

Systems and Equipment Chapter Contents Drilling Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 •

Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

•

Polymer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

•

Bentonite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

•

Mixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

•

Basic Fluid Recipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

•

Drilling Fluid Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

•

Funnel Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Systems and Equipment - 50

XP44 Operator’s Manual Drilling Fluid

Drilling Fluid Recommended Products Improper handling or use of chemicals may result in illness, injury, or equipment damage. Follow instructions on labels and in safety data sheets (SDS).

Breathing crystalline silica dust may cause lung disease.

Cutting, drilling, or working materials such as concrete, sand, or rock containing quartz may result in exposure to silica dust.

To help avoid injury: •

Use water spray or other means to control dust.

•

Use appropriate breathing protection when exposed to silica dust.

•

Refer to U.S. Department of Labor Occupational Safety and Health Administration guidelines to learn more about appropriate breathing protection and permissible exposure limits.

For productive drilling and equipment protection, use these recommended Baroid® products, available from your Ditch Witch® dealer.

•

Soda ash

•

Quik-Gel™ dry powder bentonite (p/n 259-804)

•

E-Z Mud™ liquid polymer (p/n 259-805)

•

Liqui-Trol™ liquid polymer suspension (p/n 259-808)

•

Quik-Trol™ dry powder polymer (p/n 259-809)

•

Bore-Gel™ drilling fluid (p/n 259-807)

•

Con-Det™ water-soluble cleaning solution (p/n 259-810)

XP44 Operator’s Manual

Systems and Equipment - 51

Drilling Fluid

Guidelines Match drilling fluid to soil type. This chart is meant as a guideline only. See your local Ditch Witch® dealer for soil conditions and drilling fluid recommendations for your area.

Soil type

Drilling fluid recommendation

smooth, flowing sand

bentonite or Bore-Gel + medium chain polymer

coarse sand or light soil

bentonite or Bore-Gel

heavy clay

long chain polymer + Con-Det

swelling clay

long chain polymer + Con-Det

rock

Bore-Gel

Polymer This drilling fluid additive provides excellent lubrication and increases viscosity in average soils and heavy clay. In swelling clay, polymer can reduce swelling that traps pipe in the bore.

There are two types of polymer: •

long chain such as Baroid EZ-Mud

•

medium chain such as Baroid Quik-Trol

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.

•

Mix bentonite thoroughly or it will settle in tank.

•

Do not mix bentonite to a funnel viscosity of over 50.

For information on measuring funnel viscosity, see “Funnel Viscosity” on page 54.

XP44 Operator’s Manual

Systems and Equipment - 52

Drilling Fluid

Mixtures NOTICE: Bentonite does not mix well in water containing polymer. To use both, mix bentonite first, then add polymer.

•

If chemicals are added in the wrong order, they will not mix properly and will form clumps.

•

If tank contains bentonite/polymer mix and more drilling fluid is needed, completely empty tank and start with fresh water before mixing another batch.

General mixing order 1. Soda ash 2. Bentonite 3. Polymer 4. Con-Det Bore-Gel contains premixed bentonite, polymer, and soda ash. Follow guidelines below to ensure proper drilling fluid viscosity for expected drilling conditions.

Conditions

Amount to Use

normal drilling

15 lb/100 gal

7 kg/380 L

sand or gravel

up to 45 lb/100 gal

up to 21 kg/380 L

rock

up to 50 lb/100 gal

up to 23 kg/380

XP44 Operator’s Manual

Systems and Equipment - 53

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 .75 lb (340 g) Quik-Trol .75 lb (340 g) No-Sag

Add .5 - 1 gal (2-4 L) of Dinomul in high torque situations

gravel

50 lb (23 kg) Bore-Gel .75 lb (340 g) Quik-Trol .75 lb (340 g) No-Sag

Add .5 lb (225 g) of Barolift to reduce loss of returns

cobble

50 lb (23 kg) Bore-Gel .75 lb (340 g) Quik-Trol .75 lb (340 g) No-Sag

Add .5 lb (225 g) of Barolift to reduce loss of returns

sand, gravel, clay or shale

35 - 40 lb (16-18 kg) Bore-Gel .5 pt (235 mL) EZ-Mud .5 gal (2 L) Con-Det

Vary mixture according to percentage of sand and clay

clay

.5 lb (225 g) Poly Bore .5 gal (2 L) Con-Det

Flow rate should be 3-5 parts fluid to 1 part soil. May use .25 - .5 gal (1-2 L) of Penetrol instead of Con-Det

swelling/sticky clay

.75 - 1 lb (340-450 g) Poly Bore .5 - 1 gal (2-4 L) Con-Det

Flow rate should be 3-5 parts fluid to 1 part soil. May use .25 - .5 gal (1-2 L) of Penetrol instead of Con-Det

solid rock (shale)

40 lb (18 kg) Bore-Gel

Use .5 pt (235 mL) of No Sag for large diameter or longer bores

solid rock (other than shale)

40 - 50 lb (18-23 kg) Bore-Gel

Use .5 pt (235 mL) of EZ-Mud in reactive shales

rock/clay mixture

40 - 50 lb (18-23 kg) Bore-Gel .5 pt (235 mL) EZ-Mud

rock/sand mixture

40 - 50 lb (18-23 kg) Bore-Gel

Use .5 pt (235 mL) of No Sag for large diameter or longer bores

fractured rock

50 lb (23 kg) Bore-Gel .5 - 1lb (225-450 g) No-Sag

Use .5 lb (225 g) of Barolift to reduce fluid loss to formation

Systems and Equipment - 54

XP44 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 9.0, add 1 lb (454 g) soda ash per tank. Test and repeat until pH is between 9 and 10.

•

Check water hardness using hardness test strips. Treat with soda ash if hardness exceeds 125 ppm.

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.

IMPORTANT: Make sure Marsh funnel is clean and free of obstruction and that you have a stopwatch available for timing the viscosity.

1. Using wash hose and a clean container, take a fresh sample of drilling fluid. The sample must be at least 1.5 qt (1.4 L).

2. With finger over bottom of funnel, fill with fluid from the container through the screen until fluid reaches the bottom of the screen.

3. Move funnel over 1 qt (.95 L) container.

4. Remove finger from bottom of funnel and use the stopwatch to count the number of seconds it takes for 1 qt (.95 L) of fluid to pass through the funnel. The number of seconds is the viscosity.

5. Thoroughly rinse measuring cup and Marsh funnel.

XP44 Operator’s Manual

Complete the Job - 55

Complete the Job Chapter Contents Antifreeze Fluid System . . . . . . . . . . . . . . . . . . . . 56 Rinse Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

XP44 Operator’s Manual

Complete the Job - 56

Antifreeze Fluid System

Antifreeze Fluid System Follow these steps for overnight or long-term storage of unit during cold weather.

1. Fill antifreeze tank.

2. Drain water tank.

3. Disconnect suction hose (3) from water tank.

1

4. Remove hose connected to tank jet valve (2).

5. Open tank jet valve to drain manifold.

6. Once manifold is drained, close tank jet valve.

7. Start engine.

8. With engine at low throttle, turn mixing pump on above 50%.

2

NOTICE: Do not run mixing pump without fluid for more than one hour.

9. Open antifreeze valve (1).

10. Open high pressure bleed valve (4).

3

11. Turn fluid pump on and use fluid flow control to slowly fill the hose reel with antifreeze.

When antifreeze reaches high pressure bleed valve, close valve.

4

NOTICE: •

Ensure entire hose reel is filled with antifreeze.

•

Reclaim antifreeze into antifreeze tank if needed.

12. Turn both mixing pump and fluid pump off.

13. Turn engine off.

14. Open all valves to 45°.

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XP44 Operator’s Manual Rinse Equipment

Rinse Equipment Spray water onto equipment to remove dirt and mud.

Disconnect Disconnect and store hoses.

Complete the Job - 57

Complete the Job - 58

XP44 Operator’s Manual Disconnect

XP44 Operator’s Manual

Service - 59

Service Chapter Contents Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . 60 •

Welding Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

•

Washing Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Recommended Lubricants/Service Key . . . . . . . . 61 •

Engine Oil Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

•

Approved Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

•

Approved Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

•

Exhaust Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

Each Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 250 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 500 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 750 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 1000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 As Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

XP44 Operator’s Manual

Service - 60

Service Precautions

Service Precautions Misuse of machine can cause death or serious injury.

Read and understand operator’s manual and all other safety instructions before use.

To help avoid injury: •

Unless otherwise instructed, all service should be performed with engine off and engine cool.

•

Refer to engine manufacturer’s manual for engine maintenance instructions.

•

Wear personal protective equipment.

Welding Precaution NOTICE: Welding can damage electronics.

•

Welding currents can damage electronic components. Connect welder ground close to welding point and make sure no electronic components are in the ground path. .

•

Disconnect battery at battery disconnect switch before welding to prevent damage to battery.

•

Do not turn off battery disconnect switch with engine running, or alternator and other electronic devices may be damaged.

Washing Precaution NOTICE: Water can damage electronics. When cleaning equipment, do not spray electrical components with water.

XP44 Operator’s Manual

Service - 61

Recommended Lubricants/Service Key

Recommended Lubricants/Service Key Item

Description DEO

Diesel engine oil meeting or exceeding API service classification CJ-4, ACEA E6, or JASO DH-2. No synthetics. Engine must use low sulfated ash, phosphorous, and sulfur (low SAPs) oil. See “Engine Oil Temperature Chart” on page 62.

DEAC

Diesel engine antifreeze/coolant meeting CES 14603.

THF

Tractor hydraulic fluid, similar to Phillips 66® PowerTran Fluid, Mobilfluid® 423, Chevron® Tractor Hydraulic Fluid, Texaco® TDH Oil, or equivalent

MPG

Multipurpose grease meeting NLGI GC-LB Grade 2

NDO

SAE 30 Non-detergent oil

GT22

barrier fluid 255-1060 (Royal Purple GT22) Check level of fluid or lubricant Filter

Check condition

Adjust, service or test

Change or replace

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. .

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

NOTICE: •

Use only genuine Ditch Witch parts, filters, approved lubricants, TJC, and approved coolants to maintain warranty.

•

Use the “Service Record” on page 91 to record all required service to your machine.

XP44 Operator’s Manual

Service - 62

Recommended Lubricants/Service Key

Engine Oil Temperature Chart

SAE 10W-30 SAE 5W-30 SAE 15W-40 SAE 20 SAE 30

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Temperature range anticipated before next oil change For more information on engine lubrication and maintenance, see your engine manual.

Approved Coolant This unit was filled with coolant meeting Cummins CES 14603 before shipment from factory. Add or replace only with coolant meeting this specification, such as Fleetguard ES Compleat coolant. This coolant is available, pre-diluted, from your Ditch Witch dealer as part number 255-1055. Contact your Cummins service partner for a full list of approved coolants meeting CES 14603.

NOTICE: •

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

•

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

XP44 Operator’s Manual

Service - 63

Recommended Lubricants/Service Key

Approved Fuel Tier 4 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.

This engine is designed to run on diesel fuel. Use only high quality fuel meeting ASTM D975 No. 2D, EN590, or equivalent. At temperatures below 32°F (0°C) winter fuel blends are acceptable. See the engine operation manual for more information.

NOTICE: Use only Ultra Low Sulfur Diesel (less than 15 ppm (15 mg/kg) sulfur content) in this unit.

Operating with higher sulfur content will damage the engine and aftertreatment device.

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

Only add fuel with engine off.

Service - 64

XP44 Operator’s Manual Recommended Lubricants/Service Key

Exhaust Cleaning - Tier 4 Only This engine has a Diesel Particulate Filter (DPF) that purifies NOx emissions in the exhaust into nitrogen and water. The DPF system uses a small amount of engine lubricating oil during the high-temperature combustion. The system cleans itself automatically, unless it is manually disabled by the operator.

Automatic exhaust cleaning (REGEN) happens during normal machine operation when sensors in the engine determine the need. During an engine exhaust cleaning cycle, engine exhaust can reach high temperatures. When this happens, the high exhaust temperature icon will light.

If the jobsite is in an area where high exhaust temperature might cause a problem, disable exhaust cleaning through the Tier 4 menu for the duration of the job and return to automatic cleaning when the job is finished. The exhaust cleaning disabled icon will light and remain on until the system is returned to automatic exhaust cleaning mode.

The exhaust cleaning icon will light when the system is disabled and an exhaust cleaning cycle is needed.

•

The icon will flash when exhaust cleaning is needed. If the area will allow it, return the unit to automatic cleaning mode in the Tier 4 menu and let it run automatically.

•

A manual exhaust cleaning cycle (DPF REGEN) is required after automatic exhaust cleaning has been disabled multiple times. Take system out of disabled mode through the Tier 4 menu, set the engine to low throttle with no load and initiate the DPF REGEN exhaust cleaning cycle. The light will remain on steady until the manual exhaust cleaning cycle is finished (approximately 30 minutes). If manual cleaning is not done when indicated, the engine will derate.

•

Ash buildup in soot filter part of DPF will have adverse effects on engine performance. The soot filter must be serviced every 3000 hours of operation or more often if high-ash oil and/or fuel is used. See your Yanmar engine distributor for this service.

XP44 Operator’s Manual

Service - 65

Each Use

Each Use Location

Task

Notes

Check engine oil level

DEO

Check engine air filter service indicator and clean dust ejector valve Check hydraulic fluid level

THF

Check engine coolant level

DEAC

Check water separator filter Check hydraulic hoses Check fluid pump oil level Check mixing pump seal air level

Check Engine Oil Level

2 Check engine oil level at dipstick opening (1) at startup and every 10 hours. Oil level should be at top of marking. If low, add DEO at fill (2). Check with unit on level surface and at least 15 minutes after stopping engine.

1

IMPORTANT: Use oil specified in “Engine Oil Temperature Chart” on page 62.

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Check Engine Air Filter Service Indicator and Clean Dust Ejector Valve Check air filter service indicator (on dash) at startup and every 10 hours. Clean dust ejector valve (shown) at startup and every 10 hours and change filter as needed. Ensure that valve is not inverted, damaged, plugged, or cracked.

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XP44 Operator’s Manual

Service - 66

Each Use Check Hydraulic Fluid Level Check hydraulic fluid level at startup and every 10 hours. Maintain fluid level at halfway point on sight glass (2), when engine is off and fluid is cool. If low, add THF at fill (1).

2

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Check Coolant Level Check coolant level at overflow coolant bottle, with engine cool, at startup and every 10 hours.

Maintain coolant level at 1/3 point on bottle. If low, add approved coolant.

IMPORTANT: See page 62 for information on approved coolants.

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Check Water Separator Filter Check water separator filter at startup and every 10 hours. When red float ring is raised, drain water. See “Drain Water Separator Filter” on page 79.

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XP44 Operator’s Manual

Service - 67

Each Use Check Hydraulic Hoses

Pressurized fluid or air could pierce skin and cause severe injury. Refer to operator’s manual for proper use. 270-6035

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.

•

Cover connection with heavy cloth and loosen connector nut slightly to relieve residual pressure.

Catch all fluid in a container.

•

Before using system, check that all connections are tight and all lines are undamaged.

•

If you are injured, seek immediate medical attention from a doctor familiar with this type of injury.

Check hydraulic hoses for leaks at startup and every 10 hours.

XP44 Operator’s Manual

Service - 68

Each Use Check Fluid Pump Oil Level

1

Check fluid pump oil level at fill plug (1) before startup and every 10 hours of operation. Maintain fluid level at fill plug. Add NDO at fill plug (1) as needed.

2 Check Mixing Pump Air Seal Level

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Check mixing pump seal air level at gauge (shown) before startup and every 10 hours of operation. If gauge is not in green area, add compressed air as needed.

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XP44 Operator’s Manual

Service - 69

50 Hour

50 Hour Location

Task

Notes

Change engine oil and filter

initial service

Check fan belt tension and damage

1/4-1/3” (7-9 mm), initial

Change hydraulic fluid filter

initial

Check fuel hose and clamp band Check radiator/hydraulic fluid cooler for dirt and debris Check mixing pump lubricant level

MPG

Change fluid pump oil

initial service

Change Engine Oil and Filter (Initial)

3 Change engine oil and filter after 50 hours. Drain oil (1), change filter (2) and add 5 qt (4.7 L) of DEO at fill (3).

IMPORTANT: Use oil specified in “Engine Oil Temperature Chart” on page 62.

2 1

t58om011w.eps

Change Hydraulic Filter (initial) Change hydraulic filter after 50 hours.

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XP44 Operator’s Manual

Service - 70

50 Hour Check Fan Belt for Tension and Damage Check belt tension after 50 hours. Belt is properly tensioned when it moves about 1/4-3/8” (7-9 mm) when pushed at the long span. Replace the belt when it is worn and sinks into the pulley groove.

1 2

Adjust Tension 1. Loosen two alternator bolts (1, 2).

2. Adjust position as needed.

3. Tighten bolts.

4. Check tension.

t58om013w.eps

Check Fuel Hose and Clamp Bands Check fuel hose and clamp bands every 50 hours.

If the clamp is loose, apply oil to the threads and retighten it. If the hose is worn, replace it.

Bleed the fuel system if the hose and/or clamp is changed.

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Check Radiator/Fluid Cooler Check radiator/hydraulic fluid cooler for dirt, grass, and other foreign matter every 50 hours.

Clean out with compressed air or spray wash if required. Be careful not to damage fins with highpressure air or water. Check more often if operating in dusty or grassy conditions.

Check radiator hoses for wear. Check hose clamps for proper tightness.

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XP44 Operator’s Manual

Service - 71

50 Hour Check Mixing Pump Lubricant Level Check mixing pump lubrication every 50 hours.

Add GT22 barrier fluid at reservoir (shown) as needed to maintain lubricant level at half full.

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Change Fluid Pump Oil (Initial Service)

1

Change fluid pump oil after first 50 hours and every 1000 hours thereafter. Drain at plug (2) and fill with NDO engine oil at plug (1). Maintain fluid level at fill plug.

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XP44 Operator’s Manual

Service - 72

250 Hour

250 Hour Location

Task

Notes

Change engine oil and filter

DEO

Check intake air line Check fan belt for tension and damage

1/4-1/3” (7-9 mm)

Change hydraulic filter

Change Engine Oil and Filter

3 Change engine oil and filter every 250 hours.

Drain oil (1), change filter (2) and add 5 qt (4.7 L) of DEO at fill (3).

IMPORTANT: Use oil specified in “Engine Oil Temperature Chart” on page 62.

2 1

t58om011w.eps

Check Intake Air Line Check the intake air line every 250 hours.

NOTICE: Keep dust out of the intake air line to prevent damage to the engine.

If the clamp is loose, apply oil to the threads and retighten it.

If the hose appears cracked or worn, replace it.

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XP44 Operator’s Manual

Service - 73

250 Hour Check Fan Belt for Tension and Damage Check belt tension every 250 hours. Belt is properly tensioned when it moves about 1/4-3/8” (7-9 mm) when pushed at the long span. Replace the belt when it is worn and sinks into the pulley groove.

1 2

Adjust Tension 1. Loosen two alternator bolts (1, 2).

2. Adjust position as needed.

3. Tighten bolts.

t58om013w.eps

4. Check tension.

Change Hydraulic Filter Change hydraulic filter every 250 hours.

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XP44 Operator’s Manual

Service - 74

500 Hour

500 Hour Location

Task

Notes

Change fuel filter Change hydraulic fluid and filter Change water separator filter Change fan belt

Change Fuel Filter Change filter every 500 hours. If you refuel from cans, replace filter more often.

The canister filter is located in the engine compartment.

See parts manual or contact your Ditch Witch® dealer for correct replacement filter.

t58om019w.eps

Change Hydraulic Fluid and Filter Change hydraulic fluid and filter every 500 hours.

Change every 250 hours if jobsite temperature exceeds 100°F (38°C) more than 50% of the time.

1

2

1. Remove drain plug (3).

2. Drain fluid and replace plug.

3. Change filter. See page 73.

4. Add THF at fill (1) until fluid level is at halfway point on sight glass (2). Capacity is 9.2 gal (35 L).

3 t58om020w.eps

XP44 Operator’s Manual

Service - 75

500 Hour Change Water Separator Filter

1

Change water separator filter every 500 hours.

1. Turn off at valve (1).

2. Purge fuel out of filter by unscrewing bottom drain plug (2).

3. Unscrew bottom of filter (3).

4. Replace filter (4).

5. Screw bottom of filter back on.

6. Turn on at valve.

2 t58om021w.eps

Change Fan Belt Change fan belt every 500 hours. Belt is properly tensioned when it moves about 1/4-3/8” (7-9 mm) when pushed at the long span (shown).

1

To change:

2

1. Loosen two alternator bolts (1,2).

2. Replace fan belt. Adjust position as needed.

3. Tighten bolts.

4. Check tension. t58om022w.eps

XP44 Operator’s Manual

Service - 76

750 Hour

750 Hour Change Fluid Pump Oil

1

Change fluid pump oil after first 50 hours and every 750 hours thereafter. Drain at plug (2) and fill with NDO engine oil at plug (1). Maintain fluid level at fill plug. Capacity for pump is 1 qt (0.9 L).

2 t58om017w.eps

XP44 Operator’s Manual

Service - 77

1000 Hour

1000 Hour Location

Task

Notes

Change engine coolant Adjust valve clearance

Yanmar® certified technician

Change Engine Coolant Drain cooling system at drain (2). Add approved coolant at fill (1) every 1000 hours.

1 NOTICE: •

The use of non-approved coolant may lead to engine damage or premature engine failure and will void engine warranty.

•

See page 62 for list of approved coolants.

2

t58om023w.eps

Adjust Valve Clearance Adjust valve clearance every 1000 hours.

To adjust, see a certified Yanmar® engine technician.

NOTICE: If valve clearance is adjusted by anyone other than a certified Yanmar® engine technician, engine warranties could be voided. Please see engine manual for more information.

XP44 Operator’s Manual

Service - 78

As Needed

As Needed Location

Task

Notes

Change air filter Drain water separator filter Check fluid pump ball valve Check engine compartment for debris Check battery Charge battery

Change Air Filter

1

Change air filter when indicator (on dash) is in the red area. Replace secondary element (2) every third change of primary element (3) or any time primary element has become damaged.

2

1. Open air filter housing at latches.

2. Remove primary element (3).

3. Wipe inside of housing and end cup (1, 4) and clean dust ejector valve.

3

4. Insert new secondary element (2) if necessary and ensure it is seated correctly.

5. Insert new primary element.

4 t58om024w.eps

6. Latch air filter housing with dust ejector facing downward.

7. Reset air filter service indicator.

NOTICE: Only open the air filter housing when indicator (on dash) is red. Change the elements. Do not attempt to clean them.

•

Improperly installed primary element can lead to premature engine failure.

•

Compressed air or water may damage filter elements.

•

Tapping filter elements to loosen dirt may damage the elements.

XP44 Operator’s Manual

Service - 79

As Needed Drain Water Separator Filter Drain water separator filter when red float ring is raised, indicating water in the filter.

1

1. Turn off at valve (1).

2. Unscrew drain plug (2) at bottom and drain water out.

3. Tighten drain plug.

4. Turn on at valve.

2 t58om025w.eps

Check Fluid Pump Ball Valve Check ball valve for leaks. Tighten stem packing as needed. See your Ditch Witch® dealer for replacement packing.

t58om026w.eps

Check Engine Compartment Check engine compartment for debris as needed.

Do not use water or compressed air to remove debris from engine compartment. Check more often if operating in large brush, grassy conditions or being stored.

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XP44 Operator’s Manual

Service - 80

As Needed Check Battery

Explosion possible. Serious injury or equipment damage could occur.

Follow directions carefully.

To help avoid injury: Do not create sparks and do not short across battery terminals for any reason.

Check battery as needed. Keep battery 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. Clean cable clamps and terminals to remove dull glaze.

5. Check for signs of internal corrosion in cables.

t58om028w.eps

6. Connect battery cable clamps, positive (+) cable first.

7. Tighten any loose connections.

8. Ensure that battery tiedowns are secure.

9. Turn battery disconnect switch to the on position.

XP44 Operator’s Manual

Service - 81

As Needed Charge Battery

Explosion possible. Serious injury or equipment damage could occur.

Follow directions carefully.

To help avoid injury: •

Use a single 12V maximum source for charging. Do not connect to rapid chargers or dual batteries.

•

Use caution and wear personal protective equipment such as safety eyewear, when charging or cleaning battery.

•

Keep sparks, flames, and any ignition source away from batteries at all times. Internal contents are extremely hazardous. Leaking fluid is corrosive. Battery may be explosive at higher temperatures.

•

NEVER lean over battery when making connections.

•

Do not allow vehicles to touch when charging.

•

Do not attempt to charge a battery that is leaking, bulging, heavily corroded, frozen, or otherwise damaged.

•

NEVER short-circuit battery terminals for any reason or strike battery posts or cable terminals.

•

Refer to MSDS for additional information regarding this battery.

Before You Start Electronic components can be easily damaged by electrical surges. Jump starting can damage electronics and electrical systems, and is not recommended. Try to charge the battery instead. Use quality large diameter jumper cables capable of carrying high currents (400 amps or more). Cheap cables may not allow enough current flow to charge a dead/discharged battery.

Read all steps thoroughly and review illustration before performing procedure.

Service - 82

XP44 Operator’s Manual As Needed

Charging Procedure (Engine Off) 1. Park service vehicle close to disabled equipment but do not allow vehicles to touch. Engage parking brake in both vehicles.

2. Turn the ignition switch to the OFF position in both vehicles, and turn off all electrical loads. Disconnect the machine controller.

3. Inspect battery in disabled vehicle (B) for signs of cracking, bulging, leaking, or other damage.

Connect red positive (+) jumper cable clamp to positive (+) post (2) of battery in disabled vehicle first.

IMPORTANT: Some equipment may have a positive jumper cable terminal (1) located externally.

If so equipped, connect red positive (+) jumper cable clamp to terminal.

4. Connect the other red positive (+) jumper cable clamp to positive (+) post of battery (A) in the service vehicle.

5. Connect black negative (-) cable clamp to negative (-) post of battery (A) in service vehicle.

6. Connect the other black negative (-) cable clamp to the engine or frame ground on the disabled vehicle, at least 12” (305 mm) from the failed battery, as shown.

7. Operate service vehicle engine at 1500-2000 rpm for a few minutes to build an electrical charge in the failed battery.

8. Stop engine in service vehicle.

9. Remove jumper cables from the service vehicle, black negative (-) clamp first. Do not allow clamps to touch.

10. Remove black negative (-) cable clamp from the disabled engine or frame ground first.

11. Remove red positive (+) cable clamp from the disabled vehicle positive (+) battery post last.

12. Reconnect machine controller and try to start disabled vehicle.

If the disabled vehicle did not start, check for loose or corroded battery cable connections. Poor connections will prevent current from charging the failed battery. Clean terminals and posts if necessary and repeat steps above.

XP44 Operator’s Manual

Specifications - 83

Specifications W3

W1

W2

H3 H1

H2

L1

Dimensions

L2

L3

U.S.

Metric

Power pack/pumps L1

Length

76.8 in

1.95 m

W1

Width

24 in

609.6 mm

H1

Height

43.2 in

1.1 m

Mixing station L2

Length

28.4 in

721.4 mm

W2

Width

17.4 in

442 mm

H2

Height

33.5 in

851 mm

500-gal (1892-L) tank L3

Length

93.7 in

2.38 m

W3

Width

31 in

787 mm

H3

Height

75 in

1.9 m

124.5 in

3.16 m

950-gal (3596 L) tank (shown) L3

Length

Specifications - 84

XP44 Operator’s Manual

Dimensions

U.S.

Metric

W3

Width

42 in

1.07 m

H3

Height

80 in

2.03 m

Power pack/pumps (dry)

1615 lb

733

Power pack/pumps (everything full)

1805 lb

819

Mixing station

450 lb

205 kg

500-gal (1892-L) tank with hoses, empty

550 lb

250 kg

System weight with 500-gal (1892-L) of fluid in tank

5160 lb

2341 kg

950-gal (3596-L) tank with hoses, empty

1000 lb

454 kg

System weight with 950-gal (3596-L) of fluid in tank

8,933 lb

4052 kg

Performance

U.S.

Metric

Centrifugal pump suction port diameter

3 in

76 mm

Centrifugal pump discharge port diameter

2 in

51 mm

Maximum fluid pressure

50 psi

3.4 bar

Maximum mixing pump discharge rate (water)

250 gpm

946 L/min

Maximum flow rate to drilling unit

0-39 gpm

0-147 L/min

Maximum pressure to drilling unit

1000 psi

69 bar

Drilling fluid tank capacity (nominal)

950 gal

3596L

Dry mixing hopper capacity

1 ft3

28 L

Typical tank mixing time

7-10 min

Weights

XP44 Operator’s Manual

Power

Specifications - 85

U.S.

Metric

Engine: Yanmar® 3TNV86CT, diesel, EPA Tier 4 Final, EU Stage IIIA Number of cylinders

3

Displacement

95.8 in3

1.57 L3

Bore

3.39 in

86 mm

Stroke

3.54 in

90 mm

Manufacturer’s gross power rating (per SAE J1955)

43.5 hp

32.4 kW

Rated engine speed

3000 rpm

3000 rpm

Maximum tilt angle, fore and aft *

30°

30°

Maximum tilt angle, side to side *

30°

30°

* Exceeding these operating angles will cause engine damage. This DOES NOT imply that the machine is stable to maximum angle of safe engine operation.

Hydraulic System

U.S.

Metric

Flow rate

17.5 gpm

66.2 L/min

Pressure

2465 psi

170 bar

Flow rate

14 gpm

53 L/min

Pressure

2320 psi

160 bar

Drilling fluid pump

Mixing pump

Noise levels This machine can generate sound levels exceeding 80 dBA. Always wear appropriate hearing protection when operating machine. Find sound power and pressure information at www.ditchwitch.com, or contact customersupport@ditchwitch.com.

Specifications are called out according to SAE recommended practices. Specifications are general and subject to change without notice. If exact measurements are required, equipment should be weighed and measured. Due to selected options, delivered equipment may not match that shown.

Specifications - 86

XP44 Operator’s Manual

XP44 Operator’s Manual

Support - 87

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.

Order genuine Ditch Witch replacement or repair parts from your authorized Ditch Witch dealer. Use of another manufacturer's parts may void warranty consideration.

Resources Publications Contact your Ditch Witch dealer for publications and videos covering safety, operation, service, and repair of your equipment.

Ditch Witch® Training For information about on-site, individualized training, contact your Ditch Witch dealer.

XP44 Operator’s Manual

Warranty - 88

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 Ditch Witch factory that fail due to a defect in material or workmanship within one (1) year of first commercial use. Free labor will be provided at any authorized Ditch Witch dealership for installation of parts under this warranty during the first year following “initial commercial” use of the serial-numbered Ditch Witch equipment on which it is installed. The customer is responsible for transporting their equipment to an authorized Ditch Witch dealership for all warranty work.

Exclusions from Product Warranty •

All incidental or consequential damages.

•

All defects, damages, or injuries caused by misuse, abuse, improper installation, alteration, neglect, or uses other than those for which products were intended.

•

All defects, damages, or injuries caused by improper training, operation, or servicing of products in a manner inconsistent with manufacturer’s recommendations.

•

All engines and engine accessories (these are covered by original manufacturer’s warranty).

•

Tires, belts, and other parts which may be subject to another manufacturer’s warranty (such warranty will be available to purchaser).

•

ALL IMPLIED WARRANTIES NOT EXPRESSLY STATED HEREIN, INCLUDING ANY WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY.

IF THE PRODUCTS ARE PURCHASED FOR COMMERCIAL PURPOSES, AS DEFINED BY THE UNIFORM COMMERCIAL CODE, THEN THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE FACE HEREOF AND THERE ARE NO IMPLIED WARRANTIES OF ANY KIND WHICH EXTEND TO A COMMERCIAL BUYER. ALL OTHER PROVISIONS OF THIS LIMITED WARRANTY APPLY INCLUDING THE DUTIES IMPOSED. Ditch Witch products have been tested to deliver acceptable performance in most conditions. This does not imply they will deliver acceptable performance in all conditions. Therefore, to assure suitability, products should be operated under anticipated working conditions prior to purchase.

Defects will be determined by an inspection within thirty (30) days of the date of failure of the product or part by Ditch Witch Product Support (DWPS) or its authorized dealer. DWPS will provide the location of its inspection facilities or its nearest authorized dealer upon inquiry. DWPS reserves the right to supply remanufactured replacements parts under this warranty as it deems appropriate.

Extended warranties are available upon request from your local Ditch Witch dealer or the Ditch Witch factory.

Some states do not allow exclusion or limitation of incidental or consequential damages, so above limitation of exclusion may not apply. Further, some states do not allow exclusion of or limitation of how long an implied warranty lasts, so the above limitation may not apply. This limited warranty gives product owner specific legal rights and the product owner may also have other rights which vary from state to state.

For information regarding this limited warranty, contact the DWPS department, P.O. Box 66, Perry, OK 73077-0066, or contact your local dealer.

First version: 1/91; Latest version: 8/16

XP44 Operator’s Manual

Service Record - 91

Service Record Service Performed

Date

Hours

Service Record - 92

Service Performed

XP44 Operator’s Manual Date

Hours

XP44 Operator’s Manual

Appendix - 93

Appendix Chapter Contents Engine Diagnostic Codes

Engine Diagnostic Trouble Codes Yanmar 3TNV88C engine

P code P0336 P0337

SPN 522400

P0341 P0342

P0123 P0122 P0223 P0222

523249 91 28 522624

P1647

522623

P0228

P1125 P02E9 P02E8

29

28 51

3 4 3 4 7 7 4 0 1 3 4 4

Crank speed, cam speed sensor Accelerator sensor 1 Accelerator sensor 2 Accelerator sensor 1 + 2 Accelerator sensor 3 Pulse sensor Accelerator sensor 3 Intake throttle opening sensor

4

No crank signal No cam signal No signal on both crank and cam speed sensor Accelerator sensor 1 (excessive sensor output) Accelerator sensor 1 (insufficient sensor output) Accelerator sensor 2 (excessive sensor output) Accelerator sensor 2 (insufficient sensor output) Dual accelerator sensor (closed position) failure Dual accelerator sensor (open position) failure Accelerator sensor 3 (excessive sensor output) Accelerator sensor 3 (insufficient sensor output) Pulse sensor failure (pulse communication) Accelerator sensor 3 failure (foot pedal in open position) Accelerator sensor 3 failure (foot pedal in closed position) Intake throttle opening sensor fault (high voltage) Intake throttle opening sensor fault (low voltage) EGR low pressure side sensor fault (high voltage)

EGR low pressure side sensor

EGR low pressure side sensor fault (low voltage) EGR low pressure side sensor fault (abnormal learning value)

3 1209

Crank signal malfunction

Angle offset failure

13

P0473

State

Cam signal malfunction Cam speed sensor

3 102

P0236 P0472

5

8

P0238 P0237

5

3

P1227 P1126

Crank speed sensor

7

P1646

P0227

2 5 2

522401

P1341 P0008

FMI Part

EGR high pressure side sensor fault (high voltage) EGR high pressure side sensor

EGR high pressure side sensor fault (low voltage)

P0471

13

EGR high pressure side sensor fault (abnormal learning value)

P0118

3

Cooling water temperature sensor fault (high voltage)

P0117

110

4

Cooling water temperature sensor

Cooling water temperature sensor fault (low voltage)

P0217

0

Cooling water temperature abnormal high (overheat)

P0113

3

New air temperature sensor fault (high voltage)

P0112

172

P0183 P0182

4 3

174

4

P0168

0

P0193

3

P0192

New air temperature sensor

157

4

New air temperature sensor fault (low voltage) Fuel temperature sensor fault (HIGH voltage)

Fuel temperature sensor

Fuel temperature sensor fault (low voltage) Fuel temperature sensor temperature abnormal high

Rail pressure sensor

Rail pressure sensor fault (high voltage) Rail pressure sensor fault (low voltage)

P2455

3

DPF differential pressure sensor fault (high voltage)

P2454

4

DPF differential pressure sensor fault (low voltage)

P2452

3251

0

DPF differential pressure sensor

DPF differential pressure sensor abnormal high

P2453

13

DPF differential pressure sensor (abnormal learning value)

P1455

3

DPF high pressure side sensor fault (high voltage)

P1454

3609

P1428 P1427 P1436

4

DPF high pressure side sensor

3 3242

4 0

DPF high pressure side sensor fault (low voltage) DPF inlet temperature sensor fault (high voltage)

DPF inlet temperature sensor

DPF inlet temperature sensor fault (low voltage) DPF inlet temperature sensor abnormal high

P1434

3

P1435

4

DPF intermediate temperature sensor fault (high voltage)

P1426

0

P2229

3

DPF intermediate temperature sensor fault (low voltage) DPF intermediate temperature sensor DPF intermediate temperature sensor temperature abnormal low DPF intermediate temperature sensor temperature abnormal high (postinjection failure) Atmospheric pressure sensor fault (high voltage)

4

Atmospheric pressure sensor

P0420

P2228

3250

108

1

Atmospheric pressure sensor fault (low voltage)

P1231

10

Atmospheric pressure sensor characteristic fault

P041D

3

EGR gas temperature sensor fault (high voltage)

P041C P040D P040C P0546 P0545 P068B P068A P0543

412 105 173 1485 522243

P0541 P0204 (4TNV), P0203 (3TNV) P0271 (4TNV), P0268 (3TNV) P1271 (4TNV), P1262 (3TNV) P0202

651 (4TNV), 652 (3TNV)

P0265

653

3 4 3 4 7 2 5 6

Intake manifold temperature sensor Exhaust manifold temperature sensor Main relay Startup assist relay

6

5 6 3 5 654

P1262

6 3

P0203

5 652

6

P0611

4257

12

P1146

2797

6

P1149

2798

6

P1268

3

P1648

523462

13

P1649

523463

13

P1650

523464

13

P1651

523465

13

EGR gas temperature sensor fault (low voltage) Intake manifold temperature sensor fault (high voltage) Intake manifold temperature sensor fault (low voltage) Exhaust manifold temperature sensor fault (high voltage) Exhaust manifold temperature sensor fault (low voltage) Main relay contact stuck Main relay early opening Startup assist relay interrupted Startup assist relay GND interrupted Injector 1 open circuit (inherent location of the injector)

Injector 1 4TNV: Cyl No. 4, 3TNV: Cyl No. 3; Corresponding port 4TNV: 1-2, Injector 1 coil short circuit 3TNV: 1-3

3

P0201

P0268

EGR gas temperature sensor

5

P1265 P0262

4

Injector 1 short circuit Injector 2 4TNV: Cyl No. 2, 3TNV: Cyl Injector 2 open circuit (inherent location of the injector) No. 2; Corresponding port 4TNV: 2-1, Injector 2 coil short circuit 3TNV: 1-2 Injector 2 short circuit Injector 3 4TNV: Cyl No. 1, 3TNV: Cyl Injector 3 open circuit (inherent location of the injector) No. 1; Corresponding port 4TNV: 2-2, Injector 3 coil short circuit 3TNV: 1-1 Injector 3 short circuit Injector 4 4TNV: Cyl No. 3; Corresponding port 4TNV: 1-1

Injector (common)

Injector (correction value)

Injector 4 open circuit (inherent location of the injector) Injector 4 coil short circuit Injector 4 short circuit Injector drive IC error Injector drive circit (Bank1) short circuit (4TN: Common circuit for No. 1, No. 4 and all 3TN cylinders) Injector drive circit (Bank2) short circuit (4TN: Circuit for No. 2 and No. 3 cylinders) IQA corrected injection amount for injector 1 error IQA corrected injection amount for injector 2 error IQA corrected injection amount for injector 3 error IQA corrected injection amount for injector 4 error

P1641 P1643

522571

P0629 P1642

633

P0627 P062A P1645

522572

P0088 P0094 P0093

157

P000F

3

High-pressure pump drive circuit (low side VB short-circuit)

6

High-pressure pump drive circuit (low side GND short-circuit)

3

High-pressure pump drive circuit (high side VB short-circuit)

6

SCV (MPROP)

High-pressure pump drive circuit (high side GND short-circuit)

5

High-pressure pump drive circuit (open circuit)

6

High-pressure pump drive circuit (drive current (high level))

11

High-pressure pump drive circuit (pump overload error)

0

Actual rail pressure rise error

18

Abnormal rail pressure

Rail pressure deviation error during the actual rail pressure drop

15

Rail pressure deviation error during the actual rail pressure rise

16

PLV open valve Rail pressure fault (the times of PLV valve opening error)

P1666

523469

0

P1667

523470

0

P1668

523489

0

P1665

523468

9

P1669

523491

0

P1670

523460

7

P0219

190

16

PLV (Common rail pressure limit valve)

Rail pressure fault (the time of PLV valve opening error) Rail pressure fault (the actual rail pressure is too high during PRV limp home) Rail pressure fault (controlled rail pressure error after PLV valve opening)

Rail pressure control

Rail pressure fault (injector B/F temperature error during PLV4 limp home) Rail pressure fault (operation time error during RPS limp home)

Overspeed

Overspeed

P0660

5

No-load of throttle valve drive H bridge circuit

P1658

3

Power short circuit of throttle valve drive H bridge output 1

P1659

2950

P1660 P1661 P1662

4 6

2951

Intake throttle drive circuit

3

GND short circuit of throttle valve drive H bridge output 1 Overload on the drive H bridge circuit of throttle valve VB Power short circuit of throttle valve drive H bridge output 2

4

GND short circuit of throttle valve drive H bridge output 2

U0292

522596

9

TSC1 (CAN message) reception time out (SA1)

U1301

522597

9

TSC1 (CAN message) reception time out (SA2)

U1292

522599

9

Y_ECR1 (CAN message) reception time out

U1293

522600

9

Y_EC (CAN message) reception time out

U1294

522601

9

Y_RSS (CAN message) reception time out

U1296

522603

9

VH (CAN message) reception time out

U1298

522605

9

U0168 U3002 U1300

237 522609

CAN2

Y_ECM3 (CAN message) reception time out

31

VI (CAN message) reception time out

13

VI (CAN message) reception data fault

9

Y_ETCP1 (CAN message) reception time out

U1302

522618

9

EBC1 (CAN message) reception time out

U1303

522619

9

Y_DPFIF (CAN message) reception time out

U010B

522610

9

U1107

522611

9

CAN1

CAN1 (for EGR): reception time out Exhaust throttle (CAN message from the exhaust throttle time out)

P0404

0

EGR over-voltage fault

P1404

1

EGR under-voltage fault

7

EGR feedback malfunction

P1409

2791

U0401

9

EGR ECM data fault

P0403

12

Open circuit between the EGR motor coils

P1405

522579

12

P0488

522580

12

P148A

522581

7

EGR valve

Short circuit between the EGR motor coils EGR position sensor malfunction EGR stuck open valve malfunction

P049D

522582

7

EGR initialization malfunction

P1410

522183

1

EGR high temperature thermistor malfunction

P1411

522184

1

EGR low temperature thermistor malfunction

U1401

522617

12

EGR target value out of range

P1438

522746

12

Exhaust throttle (voltage fault)

P1439

522747

12

Exhaust throttle (motor fault)

P1440

522748

12

P1441

522749

12

P1442

522750

12

Exhaust throttle (PCB fault)

P1443

522751

19

Exhaust throttle (CAN fault)

P0601

630

12

EEPROM memory deletion error

P160E

522576

12

P160F

522578

12

Exhaust throttle

EEPROM

Exhaust throttle (sensor system fault) Exhaust throttle (MPU fault)

EEPROM memory read error EEPROM memory writing error