User guide

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FX25

Operator’s

Manual

Issue 2.1

CMW

053-2379

Summary of content (119 pages)

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FX25 Operator’s Manual CMW® Issue 2.
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FX25 Operator’s Manual Overview - 1 Overview Chapter Contents Serial Number Location . . . . . . . . . . . . . . . . . . . . . . 2 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Equipment Modification . . . . . . . . . . . . . . . . . . . . . 3 Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Operator Orientation. . . . . . . . . . . . . . . . . . . . . . . . . 4 About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 4 • Bulleted Lists.
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FX25 Operator’s Manual Overview - 2 Serial Number Location Serial Number Location Record serial numbers and date of purchase in spaces provided. FX25 serial number is located as shown. j32om001h.
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FX25 Operator’s Manual Overview - 3 Equipment Modification Equipment Modification This equipment was designed and built in accordance with applicable standards and regulations. Modification of equipment could mean that it will no longer meet regulations and may not function properly or in accordance with the operating instructions.
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FX25 Operator’s Manual Overview - 4 Operator Orientation Operator Orientation 1. Front of unit 3. Rear of unit 2. Right of unit 4. Left of unit Right and left sides of machine are determined by facing towing vehicle. 1 4 2 3 j33om003h.eps About This Manual This manual contains information for the proper use of this machine. See Operation Overview for basic operating procedures. Cross references such as “See page 50” will direct you to detailed procedures.
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FX25 Operator’s Manual Foreword - 5 Reporting Safety Defects 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.
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FX25 Operator’s Manual Foreword - 6 FX25 Operator’s Manual Issue number 2.1/OM-4/13 Part number 053-2379 Copyright 2011, 2012, 2013 by The Charles Machine Works, Inc. , Ditch Witch, and CMW are registered trademarks of The Charles Machine Works, Inc. U.S. patents pending.
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FX25 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 19 machine controls, gauges, and indicators and how to use them Operation Overview 29 an overview for completing a job
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Contents - 8 Service Record FX25 Operator’s Manual 109 a record of major service performed on the machine Appendix additional information about Ditch Witch equipment CMW 111
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FX25 Operator’s Manual Safety - 9 Safety Chapter Contents Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Safety Alert Classifications . . . . . . . . . . . . . . . . . . 11 Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Emergency Procedures . . . . . . . . . . . . . . . . . . . . . 15 • Electric Strike Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 • If an Electric Line is Damaged . . . . . . . . . . . .
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Safety - 10 FX25 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.
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FX25 Operator’s Manual Safety - 11 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.
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FX25 Operator’s Manual Safety - 12 Safety Alerts Safety Alerts Electric shock. Contacting electric lines will cause death or serious injury. Know location of lines and stay away. Confined space will cause suffocation. Use proper procedures for entering or stay away. Vacuum will suffocate. Maintain distance between face and vacuum inlets. Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment.
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FX25 Operator’s Manual Safety - 13 Safety Alerts Improper control function could cause death or serious injury. If control does not work as described in instructions, stop machine and have it serviced. Fire or explosion possible. Fumes could ignite and cause burns. No smoking, no flame, no spark. 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.
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FX25 Operator’s Manual Safety - 14 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.
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FX25 Operator’s Manual Safety - 15 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.
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Safety - 16 FX25 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.
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FX25 Operator’s Manual Safety - 17 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.
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Safety - 18 FX25 Operator’s Manual Emergency Procedures If a Fiber Optic Cable is Damaged Do not look into cut ends of fiber optic or unidentified cable. Vision damage can occur. If Machine Catches on Fire Perform emergency shutdown procedure and then take the following actions. The order and degree of action will depend on the situation. • Immediately move battery disconnect switch (if equipped and accessible) to disconnect position.
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FX25 Operator’s Manual Controls - 19 Controls Chapter Contents Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Operator’s Station . . . . . . . . . . . . . . . . . . . . . . . . . 21 Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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FX25 Operator’s Manual Controls - 20 Engine Engine 1 2 3 4 j32om005t.eps 1. Fuel level sight glasses 3. Choke 2. Throttle 4. Ignition switch Item Description 1. Fuel level sight glasses Monitor sight glasses to determine fuel level. 2. Throttle To increase engine speed, move to right. Notes IMPORTANT: Run engine at full throttle during operation. To decrease engine speed, move to left. 3. Choke To help start cold engine, pull knob. When engine has warmed, push in completely. 4.
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FX25 Operator’s Manual Controls - 21 Operator Station Operator Station 1 5 4 3 2 6 7 9 8 j32om004h.eps 1. Flow direction control (optional) 6. Hydraulic function switch 2. Water pressure gauge 7. Water pressure switch 3. Auxiliary outlet 8. Water pressure control 4. Hourmeter 9. Tethered tank control outlet 5. Battery disconnect switch Item Description Notes 1. Flow direction control To operate in reverse flow mode, turn counterclockwise.
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FX25 Operator’s Manual Controls - 22 Operator Station Item Description Notes 2. Water pressure gauge Displays water pressure when water pressure switch is on and spray wand is in use. 3. Auxiliary outlet To operate work lights or other 12V devices, plug into outlet. Outlet has power only when ignition switch is on. 4. Hourmeter Displays engine operating time. Hourmeter runs when engine is running. Use these times to schedule service. c00ic112t.eps 5.
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FX25 Operator’s Manual Controls - 23 Operator Station Item Description 6. Hydraulic function switch To operate the vacuum boom option, press top. Notes To operate hydraulic door lift, move to center position. To operate hydraulic tank tilt, press bottom. 7. Water pressure control To increase water pressure, turn clockwise. To decrease water pressure, turn counterclockwise. c00ic113t.eps 8. Water pressure switch To turn on water pump, press top. To turn off water pump, move to center position.
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FX25 Operator’s Manual Controls - 24 Operator Station Item Description Tethered tank control To lift and lower tank, set hydraulic function switch to the tank position, then UP c00ic064t.eps DOWN c00ic065t.eps CMW • To lift tank, press UP. • To lower tank, press DOWN. To open and close tank door, set hydraulic function switch to the door position, then • To open door, press UP. • To close door, press DOWN.
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FX25 Operator’s Manual Controls - 25 Machine Machine 1 2 3 7 6 5 4 j32om005h.eps 1. Inlet valve 5. Reverse flow gauge (optional) 2. Water tank supply valve 6. Antifreeze tank supply valve 3. Water tank drain 7. Vacuum gauge 4. Drain/Outlet valve Item Description Notes 1. Inlet valve To close valve (stop suction), rotate up. NOTICE: Do not idle engine with inlet valve closed. To open valve (start suction), rotate down.
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FX25 Operator’s Manual Controls - 26 Machine Item Description Notes 2. Water tank supply valve To open valve (send water from the water tank through the pump and water lance), rotate counterclockwise. IMPORTANT: Water tank supply valve or antifreeze supply valve must be open when pump is running or pump will be damaged. To close valve (stop water flow), rotate clockwise. c00ic603h.eps 3. Water tank drain To drain tank, open valve. Close valve when tank is empty. c00ic604h.eps 4.
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FX25 Operator’s Manual Controls - 27 Machine Item Description Notes 6. Antifreeze tank supply valve To open valve (send antifreeze through pump and water lance), rotate counterclockwise. IMPORTANT: Water tank supply valve or antifreeze supply valve must be open when pump is running or pump will be damaged. To close valve (stop antifreeze flow), rotate clockwise. c00ic602h.eps 7. Vacuum gauge Displays blower vacuum reading in inches of mercury.
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Controls - 28 FX25 Operator’s Manual Machine CMW
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FX25 Operator’s Manual Operation Overview - 29 Operation Overview Chapter Contents Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Setting Up at Jobsite . . . . . . . . . . . . . . . . . . . . . . . 30 Vacuuming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Potholing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Leaving Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Storing Equipment . . . . . . . . . . . . . . . . . .
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Operation Overview - 30 FX25 Operator’s Manual Planning Planning 1. Gather information about jobsite (page 34). 2. Inspect jobsite (page 35). 3. Check supplies and prepare equipment (page 37). Setting Up at Jobsite 1. Prepare jobsite (page 36). 2. Position vacuum excavation unit (page 30). 3. Leave unit hitched to towing vehicle or properly stabilized if trailer-mounted unit. 4. Block trailer wheels if trailer-mounted unit. Vacuuming 1. Connect hoses (page 44). 2. Start unit (page 47). 3.
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FX25 Operator’s Manual Operation Overview - 31 Potholing Potholing 1. Connect hoses (page 44). 2. Start unit (page 47). 3. Pothole (page 49). 4. Disconnect hoses. 5. Drain tank (page 51). Leaving Jobsite 1. Rinse unit and tools (page 59). 2. Stow tools (page 59). Storing Equipment 1. For cold weather storage, antifreeze vacuum excavation unit (page 58). 2. For long-term storage, disconnect battery disconnect switch (page 22).
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Operation Overview - 32 FX25 Operator’s Manual Storing Equipment CMW
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FX25 Operator’s Manual Prepare - 33 Prepare Chapter Contents Gather Information . . . . . . . . . . . . . . . . . . . . . . . . . 34 • Arrange for Traffic Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 • Prepare for Working Near Existing Utilities . . . . . . . . . . . . . . . . . . . . . 34 • Plan for Emergency Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Inspect Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Prepare - 34 FX25 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.
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FX25 Operator’s Manual Prepare - 35 Inspect 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 working. Also contact any utilities that do not participate in the One-Call service.
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FX25 Operator’s Manual Prepare - 36 Prepare Jobsite Prepare Jobsite Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. To help avoid injury: • 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 using unit.
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FX25 Operator’s Manual Prepare - 37 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. Lighting Kit If you will need additional light, plug lighting kit into provided outlet.
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Prepare - 38 FX25 Operator’s Manual Check Supplies and Prepare Equipment Prepare Equipment Fluid Levels • fuel • battery • engine oil • blower oil Condition and Function • filters (air, oil) • belts • blower • tires • hoses and valves • couplers and fittings • water tanks • trailer parking brake (trailer-mounted unit) CMW
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FX25 Operator’s Manual Transport - 39 Transport Chapter Contents Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 • Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 • Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Haul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 • Inspect Trailer . . . . . . . . . . . . . . . . . .
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FX25 Operator’s Manual Transport - 40 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 Power Pack Use a crane capable of supporting 1500 lb (680 kg). Attach lifting device to corners and lift as shown. Tank j32om006h.eps Use crane capable of supporting the 2000 lb (907 kg).
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FX25 Operator’s Manual Transport - 41 Haul Haul Crushing weight. If load falls or moves it could kill or crush you. Use proper procedures and equipment or stay away. To help avoid injury: • Do not haul or move trailer unless tank is fully lowered and horizontal. Damage to machine or injury to personnel could occur. • Do not travel on roads with reducer or any other fitting installed on tank outlet valve. Fitting will extend beyond the rear impact guard and will not be legal for operation on roadways.
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FX25 Operator’s Manual Transport - 42 Haul Hitch Trailer 1. Back tow vehicle to trailer. 2. Put manual transmission into first or reverse gear or automatic transmission into park. Turn off ignition. Set parking brake. 3. Connect trailer drawbar, lunette or coupler to tow vehicle hitch and lock in place with lock pin. If needed, adjust drawbar, lunette or coupler height (shown) to level load. 4. Connect safety chains to tow vehicle chain keepers (cross-shaped slots on bumper of tow vehicle).
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FX25 Operator’s Manual Vacuum and Pothole - 43 Vacuum and Pothole Chapter Contents Connect Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Determine Tank Fill Level . . . . . . . . . . . . . . . . . . . 45 • 500-gal Vacuum Tank on T9S Trailer . . . . . . . . . . . . . . . . . . . . . . . . . 45 • 500-gal Vacuum Tank on T12S Trailer . . . . . . . . . . . . . . . . . . . . . . . . 46 Start Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 • Standard Procedure .
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FX25 Operator’s Manual Vacuum and Pothole - 44 Connect Hoses Connect Hoses 1. Remove vacuum hoses from storage. 2. If potholing, remove 2-in-1 potholing tool or basic potholing tool from storage. 3. Connect hoses. Secure all locking clamps. 4. Ensure drain/outlet valve is closed. 5. If potholing, connect water pressure hose.
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FX25 Operator’s Manual Vacuum and Pothole - 45 Determine Tank Fill Level Determine Tank Fill Level Use these reference charts to help determine how full of various materials the vacuum tank can be without overloading trailer. Exceeding the maximum fill level will overload the trailer. Never exceed the trailer capacity. You can exceed the vacuum tank lifting capacity if you drain the tank down to the lifting capacity before lifting tank.
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FX25 Operator’s Manual Vacuum and Pothole - 46 Determine Tank Fill Level 500-gal Vacuum Tank on T12S Trailer Material Maximum Vacuum Tank Fill Level Water tank fill level CMW full (200 gal) empty (0 gal) wood chips (dry) 100% 100% snow (dry) 100% 100% water 100% 100% light weight mud (8-10 lb/gal) 100% 100% earth (dry, loose) 100% 100% caliche 94% 100% earth, loam 94% 100% medium weight mud (10-12 lb/gal) 89% 100% limestone (crushed) 77% 100% asphalt 73% 95% sand (dry)
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FX25 Operator’s Manual Vacuum and Pothole - 47 Start Unit Start Unit EMERGENCY SHUTDOWN: Turn ignition switch to STOP. Standard Procedure IMPORTANT: If power pack is not connected to external tank control valves, connect a -04 hose with a minimum working pressure rating of 3000 psi (207 bar) from pressure (1) to power beyond (2) connections on power pack. 1 1 2 2 j32om007h.eps 1. Open tank inlet valve. NOTICE: Avoid idling engine with inlet valve closed. 2.
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FX25 Operator’s Manual Vacuum and Pothole - 48 Remove Debris Remove Debris EMERGENCY SHUTDOWN: Turn ignition switch to STOP. Procedure 1. Position vacuum hose in area to be excavated. 2. Start engine. Vacuum will suffocate. Maintain distance between face and vacuum inlets. Fire or explosion possible. Do not vacuum flammable or combustible substances. Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly.
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FX25 Operator’s Manual Vacuum and Pothole - 49 Pothole Pothole EMERGENCY SHUTDOWN: Turn ignition switch to STOP. 1. Start engine. Vacuum will suffocate. Maintain distance between face and vacuum inlets. Fire or explosion possible. Do not vacuum flammable or combustible substances. 2. Open inlet valve. NOTICE: Avoid idling engine with inlet valve closed. 3. Open water tank valve. 4. Move water pump switch to on. 5. Position tool over area to be excavated and begin pothole. Electric shock.
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Vacuum and Pothole - 50 FX25 Operator’s Manual Pothole 6. Adjust water pressure as needed to match soil conditions and/or material of utility being exposed. Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. To help avoid injury: Test water pressure on a sample of the utility line material to be exposed. Adjust pressure until no damage occurs to the material. High pressure water can cut utility lines. 7.
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FX25 Operator’s Manual Vacuum and Pothole - 51 Drain Tank Drain Tank EMERGENCY SHUTDOWN: Turn ignition switch to STOP. 1. Ensure that unit is hitched to vehicle. See “Hitch Trailer” on page 42. 2. Haul unit to approved dumping area. Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly. To help avoid injury: • Do not unhitch unit from tow vehicle before or during dumping. A freestanding unit can become unstable when tilting tank.
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Vacuum and Pothole - 52 FX25 Operator’s Manual Drain Tank 9. If further draining is necessary, open tank door. See “Open/Close Tank Door” on page 55. Crushing weight could cause death or serious injury. Use proper procedures and equipment or stay away. To help avoid injury: Use tools (provided with unit) if unit must be serviced with tank door up. 10. Tilt tank up fully. Allow tank to drain completely. 11. Connect water pressure hose to water lance. 12. Turn water pump switch on. Adjust water pressure.
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FX25 Operator’s Manual Vacuum and Pothole - 53 Unload to Another Tank Unload to Another Tank Optional reverse flow mode can be used to transfer vacuumed material to another tank or disposal site. Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly. To help avoid injury: • Keep unit in “vacuum” mode unless pressure is needed. • Restrain hose prior to pressurization. Unrestrained hose may cause property damage, injury or death.
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Vacuum and Pothole - 54 FX25 Operator’s Manual Unload to Another Tank 5. Move valve handle counterclockwise to engage “reverse flow” mode and start engine. Material will flow into offboard tank. 6. Increase throttle as desired to transfer material. 7. When transfer is complete, throttle down completely and turn off engine. Close FX tank drain/outlet valve. 8. Close offboard tank inlet valve and disconnect hose from offboard tank inlet valve. 9. Move handle clockwise to “vacuum” mode and turn on engine.
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FX25 Operator’s Manual Vacuum and Pothole - 55 Open/Close Tank Door Open/Close Tank Door Open Crushing weight could cause death or serious injury. Use proper procedures and equipment or stay away. To help avoid injury: Use tools (provided with unit) if unit must be serviced with tank door up. To help avoid injury: Do not raise tank with door held closed only by vacuum. Door may suddenly open and possibly injure someone. NOTICE: Do not drive with tank or door raised.
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Vacuum and Pothole - 56 FX25 Operator’s Manual Open/Close Tank Door CMW
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FX25 Operator’s Manual Complete the Job - 57 Complete the Job Chapter Contents Antifreeze Fluid Excavation Unit . . . . . . . . . . . . . 58 • Add Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 • Reclaim Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Rinse Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Complete the Job - 58 FX25 Operator’s Manual Antifreeze Fluid Excavation Unit Antifreeze Fluid Excavation Unit Add Antifreeze Follow these steps for overnight or long-term storage of unit during cold weather. 1. Fill antifreeze tank with a propylene-glycol based antifreeze. 2. Ensure that water tank valve is closed. 3. Open antifreeze tank valve. 4. Connect water pressure hose to water lance. 5. Start engine. 6. Move water pump switch to on. If freshwater tank is empty, move to bypass. 7.
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FX25 Operator’s Manual Complete the Job - 59 Rinse Equipment Rinse Equipment Spray water onto equipment to remove dirt and mud. Use water lance. Thoroughly rinse inside of tank and around door seal. Confined space will cause suffocation. Use proper procedures for entering or stay away. To help avoid injury: Enter tank only if necessary. Follow U.S. Department of Labor guidelines for entering confined spaces. NOTICE: Do not spray water onto operator’s console. Electrical components could be damaged.
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Complete the Job - 60 FX25 Operator’s Manual Stow Tools CMW
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FX25 Operator’s Manual Service - 61 Service Chapter Contents Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . 62 Recommended Lubricants/Service Key . . . . . . . 64 Each Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 10 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 100 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 1000 Hour .
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FX25 Operator’s Manual Service - 62 Service Precautions Service Precautions Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly. To help avoid injury: • Unless otherwise instructed, all service should be performed with engine off. • Refer to engine manufacturer’s manual for engine maintenance instructions. Working Under Raised Debris Tank Crushing weight could cause death or serious injury. Use proper procedures and equipment or stay away.
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FX25 Operator’s Manual Service - 63 Service Precautions Working Under Raised Tank Door Crushing weight could cause death or serious injury. Use proper procedures and equipment or stay away. To help avoid injury: Use tools (provided with unit) if unit must be serviced with tank door up. 1. Locate door lock tools in tool storage area and bring to rear of tank. 2. Raise tank door completely. 3. Pin door lock tools into place as shown. 4. Lower tank lid until load is supported by door lock tools.
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FX25 Operator’s Manual Service - 64 Recommended Lubricants/Service Key Recommended Lubricants/Service Key Item Description GEO Gasoline engine oil meeting API service classification CF-4 or E1-96 and SAE viscosity recommended by engine manufacturer (SAE 15W40) SGL Synthetic gear oil (ISO 100), cmw p/n 256-044 MPG Multipurpose grease meeting ASTM D217 and NLGI 5 HTG High temperature, NLGI #2 premium grade, petroleum-based grease with high temperature resistance and good mechanical stability NDO
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FX25 Operator’s Manual Service - 65 Recommended Lubricants/Service Key Engine Oil Temperature Chart SAE 30 SAE 10W-30 SAE 5W-30 Synthetic SAE 5W-30 F -20 C -30 -20 0 10 20 0 40 10 60 20 80 30 100 40 j32om079t.eps Temperature range anticipated before next oil change IMPORTANT: If temperature is below 40°F (4°C), using SAE 30 will result in hard starting. If temperature is above 80°F (27°C), using 10W-30 can cause increased oil consumption. Check oil level more frequently.
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FX25 Operator’s Manual Service - 66 Each Use Each Use Location Task Notes Trailer Check torque of hitch bolts 200 ft•lb (271 N•m) Check hydraulic brake actuator bolts If equipped Check hydraulic brake fluid level If equipped; DOT 3 or 4 Check trailer battery Check tire pressure and lug nut torque Check lights and reflectors Trailer Check Hitch Bolts Check that trailer hitch bolts are properly tightened. Torque varies by trailer model. Refer to “Specifications” beginning on page 99. j32om009h.
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FX25 Operator’s Manual Service - 67 Each Use Check Hydraulic Brake Fluid Level Check hydraulic brake fluid level at master cylinder each use. Fluid should be visible at top of master cylinder. Add DOT 3 or DOT 4 brake fluid and bleed brakes as needed. See page 92. j32om011h.eps Check Trailer Battery Check battery connections for wear or corrosion. Keep connections clean and tight. Batteries supplied by factory are maintenance-free. Service replacement batteries according to manufacturer’s instructions.
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FX25 Operator’s Manual Service - 68 Each Use Check Trailer Lights and Reflectors Check lights and reflectors for correct operation and cleanliness. j33om013h.
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FX25 Operator’s Manual Service - 69 10 Hour 10 Hour Location Task VACUUM SYSTEM Check engine air filter service indicator Check engine oil level Notes GEO Check hydraulic hoses Check hydraulic fluid level THF Check blower oil level SGL Check blower belt tension Check water pump oil level NDO Clean water pump filter Check tension of water pump belts Clean vacuum air filter Check spray nozzle Drain cyclonic separator canister DEBRIS TANK Check strobe light Check vacuum tank door seals/fittings
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FX25 Operator’s Manual Service - 70 10 Hour Vacuum System Check Engine Air Filter Check air filter every 10 hours. Press dust ejector valve to release dust. Change air filter elements when air filter restriction indicator (1) reaches the red zone. NOTICE: Only open the air filter canister when air restriction is indicated. Change the elements, do not attempt to clean them. • Compressed air or water may damage filter element. • Tapping filter elements to loosen dirt may damage the element. j32om033h.
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FX25 Operator’s Manual Service - 71 10 Hour Check Hydraulic Hoses Fluid or air pressure could pierce skin and cause injury or death. Stay away. To help avoid injury: 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.
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FX25 Operator’s Manual Service - 72 10 Hour Check Hydraulic Fluid Level DC Units Check hydraulic fluid level every 10 hours. Maintain fluid level at 3/4 tank when engine is off and fluid is cool. Add THF at hydraulic fluid fill (shown) as necessary. j32om035h.eps Gear Pump Units Check hydraulic fluid level at cap (shown) every 10 hours. Maintain fluid level at 2” (51 mm) from top of tank when engine is off and fluid is cool. Add THF at hydraulic fluid fill (shown) as necessary. j32om056h.
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FX25 Operator’s Manual Service - 73 10 Hour Check Blower Belt Tension Check belt every 10 hours for correct tension, damage or wear. Idler pulley tensioner should be set to 70 lb of force. Verify that the indication marks on tensioner are in the same position as initially set, or apply 10 lb of force to the belt and check that deflection is .25-.375” (6-10 mm). j32om037h.eps Check Water Pump Oil Level With frame level, check water pump oil at sight glass (2) every 10 hours.
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FX25 Operator’s Manual Service - 74 10 Hour Check Water Pump Belt Tension Check belt every 10 hours for correct tension, damage or wear. Contact your Ditch Witch dealer for adjustment or belt replacement. To check 1. Turn ignition to STOP and remove key. 2 2. Apply moderate thumb pressure to belt between pulleys. 3. Belt is properly tensioned when deflection is .125-.25” (3-6 mm). 4 j32om040h.eps Clean Vacuum Air Filter Breathing crystalline silica dust may cause lung disease.
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FX25 Operator’s Manual Service - 75 10 Hour Check Spray Nozzle Check spray nozzle every 10 hours. Ensure that water sprays from nozzle in a fan pattern. Clean or replace nozzle as necessary. j32om016h.eps Drain Cyclonic Separator Canister IMPORTANT: Depressurize tank before emptying cyclonic canister, cleaning filter, clearing hoses or opening any doors. 1 Drain canister at drain (2) every 10 hours or when water is visible in sight glass 2 j32om017h.
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FX25 Operator’s Manual Service - 76 10 Hour Debris Tank Check Strobe Light Check strobe light for proper function every 10 hours. When ignition is on, strobe light should be flashing. Repair if necessary. j32om018h.eps Check Vacuum Tank Door Seals and Fittings Check door seal every 10 hours for wear or damage. Repair if necessary. Check for leaks and loose fittings every 10 hours. Repair or replace if necessary. j32om019h.
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FX25 Operator’s Manual Service - 77 50 Hour 50 Hour Location Task Notes VACUUM SYSTEM Change engine oil and filter Initial service, GEO Change fuel filters Initial service Check battery Check water pressure hoses Check vacuum relief valve Lube blower bearings Change water pump oil DEBRIS TANK Initial service, NDO Lube tank pivot pins CMW
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FX25 Operator’s Manual Service - 78 50 Hour Vacuum System Change Engine Oil and Filter (Initial Service) Change engine oil and filter after 50 hours, and every 100 hours thereafter. Drain oil (4), change filter (3), and add 2.5 qt (2.3 L) of GEO at fill (2). IMPORTANT: Use oil specified in temperature chart found in “Recommended Lubricants/ Service Key” on page 64. 2 4 j32om040h.eps 3 j32om041h.
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FX25 Operator’s Manual Service - 79 50 Hour Check Battery Keep battery 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 when servicing, welding, and during long-term storage. j32om043h.
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FX25 Operator’s Manual Service - 80 50 Hour Lube Blower Bearings Wipe two zerks clean and lube every 50 hours with HTG. Inject grease into zerk until clean grease comes out of relief fittings. NOTICE: Do not inject grease too quickly. Drive shaft seal damage could occur. j32om045h.eps Change Water Pump Oil Change oil after the first 50 hours of operation and every 100 hours thereafter. Change oil more frequently if working in dusty conditions. • Drain at drain plug (3) while oil is warm.
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FX25 Operator’s Manual Service - 81 50 Hour Debris Tank Lube Tank Pivot Pins Lube two pins every 50 hours with MPG. j32om021h.
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FX25 Operator’s Manual Service - 82 100 Hour 100 Hour Location Task Notes VACUUM SYSTEM Change engine oil and filter GEO DEBRIS TANK Change fuel filters Change blower oil initial service, SGL Change hydraulic fluid DC unit initial service, THF Change water pump oil NDO Check tank deflector Check tank mounting bolts Vacuum System Change Engine Oil and Filter (Regular Service) Change engine oil and filter every 100 hours. Drain oil (4), change filter (3), and add 2.5 qt (2.
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FX25 Operator’s Manual Service - 83 100 Hour Change Fuel Filter Replace filter every 100 hours. 1. Remove filter. 2. Install new filter. Apply fuel oil thinly over the gasket and hand-tighten. j32om042h.eps Change Blower Oil 2 Change oil after the first 100 hours of operation, and every 1000 hours thereafter. Change oil more frequently if working in dusty conditions. • Drain at drain plug (4) while oil is warm. • Add SGL at fill (2) until oil is at halfway point on sight glass (3). 4 3 j32om047h.
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FX25 Operator’s Manual Service - 84 100 Hour Change Water Pump Oil Change oil after the first 25 hours of operation and every 100 hours thereafter. Change oil more frequently if working in dusty conditions. • Drain at drain plug (3) while oil is warm. • Add NDO at fill (1) until oil is at halfway mark on sight glass (2). 1 3 j32om046h.eps Debris Tank Check Tank Mounting Bolts Check vacuum tank mounting bolts (shown, both sides) every 100 hours for looseness and damage. Tighten or replace as needed.
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FX25 Operator’s Manual Service - 85 250-Hour 250-Hour Location Task Notes VACUUM SYSTEM Change hydraulic fluid gear pump unit initial service, THF Vacuum System Change Hydraulic Fluid (Gear Pump Units) 1 Change hydraulic fluid after the first 250 hours, and every 1000 hours thereafter. Drain hydraulic fluid (2), remove and clean strainer, add THF at hydraulic fluid fill (1) and check level. 2 j32om058h.
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FX25 Operator’s Manual Service - 86 1000 Hour 1000 Hour Location Task Notes VACUUM SYSTEM Change blower oil SGL Change hydraulic fluid THF Vacuum System Change Blower Oil 2 Change oil every 1000 hours. Change oil more frequently if working in dusty conditions. • Drain at drain plug (4) while oil is warm. • Add SGL at fill (2) until oil is at halfway point on sight glass (3). 4 3 j32om047h.
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FX25 Operator’s Manual Service - 87 1000 Hour Change Hydraulic Fluid DC Units Change hydraulic fluid every 1000 hours. Drain hydraulic fluid (2), add THF at hydraulic fluid fill (1) and check level. 1 2 j32om048h.eps 1 G ear Pump Units Change hydraulic fluid every 1000 hours. Drain hydraulic fluid (2), remove and clean strainer, add THF at hydraulic fluid fill (1) and check level. 2 j32om058h.
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FX25 Operator’s Manual Service - 88 2000 Hour 2000 Hour Location Task VACUUM SYSTEM Replace water pump belts Notes Replace blower belt Vacuum System Replace Water Pump Belts Replace belt every 2000 hours. j32om049h.eps Replace Blower Belt Replace belt every 2000 hours. j32om050h.
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FX25 Operator’s Manual Service - 89 As Needed As Needed Location Task VACUUM SYSTEM Change water pump filter Notes Lube blower for longterm storage Change blower relief air filter Empty cyclonic filter canister DEBRIS TANK Clean primary shutoff valve TRAILER Add surge brake fluid DOT 3 or 4 Vacuum System Change Water Pump Filter 1. Open filter housing. 2. Remove element and rinse housing thoroughly with clean water. 3. Install new element and close filter housing. j32om051h.
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FX25 Operator’s Manual Service - 90 As Needed Change Blower Relief Air Filter Check air filter whenever vacuum gauge goes over 16” (406 mm) of mercury. Change as needed. NOTICE: Operating system above 16” (406 mm) of mercury may result in blower damage. 1. Remove clamp. 2. Remove filter and discard. 3. Install new filter. 4. Replace clamp. j32om053h.
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FX25 Operator’s Manual Service - 91 As Needed Debris Tank Clean Primary Shut-off Valve Clean primary shut-off valve as needed. Replace primary shut-off valve as needed. 2 To clean: 1 3 1. Open tank door. See “Drain Tank” on page 51. 2. Spray valve housing inside vacuum tank with high-pressure water. 3. Store water pressure hose. 4. Close tank door. See “Drain Tank” on page 51. j32om026h.eps To remove: 1. Loosen three wingnuts (1) and pull out valve housing (2). 2. Remove ball (3). 3.
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FX25 Operator’s Manual Service - 92 As Needed Trailer Add Surge Brake Fluid Add surge brake fluid at cap (1) as needed and bleed brakes. 1 2 1. Remove lever guide and flat emergency lever spring by removing two 5/16” hex head bolts and lock washers. 2. Using short strokes, pull forward on emergency lever (2) until brake fluid in master cylinder stops bubbling. 3.
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FX25 Operator’s Manual Service - 93 200 Mile 200 Mile Location Task Notes Trailer Adjust electric brakes Initial Adjust hydraulic brakes Initial Trailer Adjust Electric Brakes (Initial) Adjust brakes after 200 miles (320 km). 1. Place adequate jack stands under frame rails and remove wheels. 2. Remove cover from adjusting slot on bottom of backing plate. 3. Rotate adjuster starwheel with screwdriver or brake spoon to expand brake shoes. Adjust until drum is very difficult to turn by hand. 4.
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FX25 Operator’s Manual Service - 94 200 Mile Adjust Hydraulic Brakes (Initial) Adjust hydraulic brakes after 200 miles (320 km). Crushing weight could cause death or serious injury. Use proper procedures and equipment or stay away. 1. Use a jack and suitable jack stands to raise wheels so that wheels can be rotated by hand. 1 2. Rotate wheel forward by hand to reposition free backing primary brake shoe. 3. Remove adjusting plug from backing plate at wheel. 2 4.
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FX25 Operator’s Manual Service - 95 3000 Mile 3000 Mile Location Task Trailer Adjust electric brakes Notes Adjust hydraulic brakes Trailer Adjust Electric Brakes Adjust brakes every 3000 miles (5000 km). 1. Place adequate jack stands under frame rails and remove wheels. 2. Remove cover from adjusting slot on bottom of backing plate. 3. Rotate adjuster starwheel with screwdriver or brake spoon to expand brake shoes. Adjust until drum is very difficult to turn by hand. 4.
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FX25 Operator’s Manual Service - 96 3000 Mile Adjust Hydraulic Brakes Adjust hydraulic brakes every 3000 miles (5000 km). Crushing weight could cause death or serious injury. Use proper procedures and equipment or stay away. 1. Use a jack and suitable jack stands to raise wheels so that wheels can be rotated by hand. 1 2. Rotate wheel forward by hand to reposition free backing primary brake shoe. 3. Remove adjusting plug from backing plate at wheel. 2 4.
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FX25 Operator’s Manual Service - 97 12,000 Mile 12,000 Mile Location Task Trailer Inspect brake shoes and linings Notes Adjust and lubricate bearings Trailer Inspect Brake Shoes and Linings Inspect shoes and linings every 12 months or 12,000 miles (20 000 km) for wear. When lining is worn to 1/16” (2 mm) or less, replace linings. Replace shoe and lining if contaminated by oil. j32om030h.
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FX25 Operator’s Manual Service - 98 12,000 Mile Adjust and Lubricate Bearings 1. Place adequate jack stands under frame rails and remove wheels. 2 2. Unscrew grease cap (11) while holding the hub stationary. 3. Bend locking tang (14) down from outer spindle nut (13) and remove spindle nut (3). 4. Remove tang washer, unscrew inner spindle nut and remove spindle washer (16). 8 9 5. Remove hub from spindle. Do not drop outer bearing cone. 6. Pry seal (2) from hub and remove inner bearing cone (3).
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FX25 Operator’s Manual Specifications - 99 500 Specifications 500 L W H j32om032h.eps Dimensions U.S. Metric L Length, T9S or T9SH trailer 200 in 5.1 m H Height 86 in 2.3 m W Width 96 in 2.
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Specifications - 100 FX25 Operator’s Manual 500 Engine U.S. Metric Briggs & Stratton Vanguard, gasoline Cooling medium air Aspiration natural Number of cylinders 2 Displacement 54.68 in3 896 cc Bore 3.37 in 86 mm Stroke 3.07 in 78.5 mm Engine manufacturer’s gross power rating (per SAE J1940) 31 hp 23.1 kW Rated engine speed 3600 rpm 3600 rpm Hydraulic system U.S. Metric Pressure 2500 psi 172 bar Drive type gear pump Flow rate 3.0 gpm 11.
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FX25 Operator’s Manual Specifications - 101 500 Vacuum system U.S. Metric Tank capacity 500 gal 1893 L Drive type belt Displacement 543 cfm 15.3 m3/min Maximum vacuum 15 in Hg 381 mm Hg Vacuum tank door diameter 52 in 1.3 m Drain valve size 6 in 152 mm Inlet valve size 4 in 102 mm Primary shutoff valve size (ball type) 12 in 305 mm Filter type washable polyester Filter area 100 ft2 9.3 m2 Suction hose size 3 in 76 mm Suction hose length (total) 30 ft 9.
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Specifications - 102 FX25 Operator’s Manual 500 T9S Trailer U.S. Metric Clearance (at jack foot pad) 12 in 305 mm Adj. coupler height 18-24 in 457-610 mm Width between fenders 76 in 1.9 m Width outside fenders 96 in 2.4 m Number of axles 2 Coupler (square mount drawbar) 3 in or 2.5 in Type of brakes electric or hydraulic surge Lug nut torque 90-120 ft•lb 122-163 N•m Hitch bolt torque 160 ft•lb 217 N•m Electrical system 12V DC ST235/85R16 load range E 80 psi 5.
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FX25 Operator’s Manual Specifications - 103 500 T12SE Trailer U.S. Metric Clearance (at jack foot pad) 12 in 305 mm Adj. coupler height 18-24 in 457-610 mm Width between fenders 76 in 1.9 m Width outside fenders 96 in 2.4 m Number of axles 2 Coupler (square mount drawbar) 3 in or 2.5 in Type of brakes electric or hydraulic surge Lug nut torque 90-120 ft•lb 122-163 N•m Hitch bolt torque 160 ft•lb 217 N•m Electrical system 12V DC LT215/85R16 load range E 80 psi 5.
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Specifications - 104 FX25 Operator’s Manual 500 CMW
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FX25 Operator’sManual Support - 105 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.
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FX25 Operator’sManual Warranty - 106 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).
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FX25 Operator’s Manual Service Record - 109 Service Record Service Performed Date Hours CMW
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Service Record - 110 Service Performed CMW FX25 Operator’s Manual Date Hours
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FX25 Operator’s Manual Appendix - 111 Appendix Chapter Contents Tire Safety Information CMW
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TIRE SAFETY INFORMATION 1.1. STEPS FOR DETERMINING CORRECT LOAD LIMIT – TRAILER Determining the load limits of a trailer includes more than understanding the load limits of the tires alone. On all trailers there is a Federal certification/VIN label that is located on the forward half of the left (road) side of the unit. This certification/VIN label will indicate the trailer’s Gross Vehicle Weight Rating (GVWR). This is the most the fully loaded trailer can weigh.
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The Tire Information Placard is attached adjacent to or near the trailer’s VIN (Certification) label at the left front of the trailer. 1.1.2. TRAILERS OVER 10,000 POUNDS GVWR (NOTE: These trailers are not required to have a tire information placard on the trailer.) 1. Determine the empty weight of your trailer by weighing the trailer using a public scale or other means. This step does not have to be repeated. 2.
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Innerliner separation - the parting of the innerliner from cord material in the carcass. Light truck (LT) tire - a tire designated by its manufacturer as primarily intended for use on lightweight trucks or multipurpose passenger vehicles. Load rating - the maximum load that a tire is rated to carry for a given inflation pressure. Maximum load rating - the load rating for a tire at the maximum permissible inflation pressure for that tire.
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1.4. TIRE SAFETY - EVERYTHING RIDES ON IT The National Traffic Safety Administration (NHTSA) has published a brochure (DOT HS 809 361) that discusses all aspects of Tire Safety, as required by CFR 575.6. This brochure is reproduced in part below. It can be obtained and downloaded from NHTSA, free of charge, from the following web site: http://www.nhtsa.dot.gov/cars/rules/TireSafety/ridesonit/tires_index.
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1.5.2. UNDERSTANDING TIRE PRESSURE AND LOAD LIMITS Tire inflation pressure is the level of air in the tire that provides it with load-carrying capacity and affects the overall performance of the trailer. The tire inflation pressure is a number that indicates the amount of air pressure– measured in pounds per square inch (psi) or kilopascals (kpa) –a tire requires to be properly inflated.
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1.5.5. TIRE SIZE To maintain tire safety, purchase new tires that are the same size as the trailer's original tires or another size recommended by the manufacturer. Look at the tire information placard, the owner's manual, or the sidewall of the tire you are replacing to find this information. If you have any doubt about the correct size to choose, consult with your dealer. 1.5.6.
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1.5.9.2. Information on Light Truck Tires Please refer to the diagram below. Tires for light trucks have other markings besides those found on the sidewalls of passenger tires. LT - indicates the tire is for light trucks or trailers. ST - indicates the tire is for trailer use only. Max. Load Dual kg (lbs) at kPa (psi) Cold - indicates the maximum load and tire pressure when the tire is used as a dual, that is, when four tires are put on each axle. Max.