FX60/FXT60 Tier 4 Operator’s Manual CMW® Issue 2.
FX60/FXT60 Tier 4 Operator’s Manual Overview - 1 Overview Chapter Contents Serial Number Location . . . . . . . . . . . . . . . . . . . . . . 2 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Equipment Modification . . . . . . . . . . . . . . . . . . . . . 3 FX60 Unit Components. . . . . . . . . . . . . . . . . . . . . . . 3 • 800 gallon tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 • 1200 gallon tank . . . . . . . . . . . .
FX60/FXT60 Tier 4 Operator’s Manual Overview - 2 Serial Number Location Serial Number Location Record serial numbers and date of purchase in spaces provided. FX60 serial number is located as shown. Date of manufacture Date of purchase FX60 serial number (shown) Engine serial number Blower serial number Water pump serial number Trailer serial number Intended Use The FX60 is a self-contained vacuum excavation unit capable of vacuuming a wide variety of nonhazardous, non-flammable liquid and solid debris.
FX60/FXT60 Tier 4 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.
Overview - 4 FX60/FXT60 Tier 4 Operator’s Manual FX60 Unit Components 1200-Gal (4542-L) Tank 1. Inlet valve 8. Antifreeze tank 2. Vacuum tank 9. Vacuum hose reel 3. Primary shutoff valve 10. Water tanks 4. Operator’s station 11. Vacuum filter/secondary shutoff valve 5. Power pack 12. Drain/Outlet valve 6. Potholing tools 13. Hose reel - wash pump 7. Water lance 14.
FX60/FXT60 Tier 4 Operator’s Manual Overview - 5 FXT60 Unit Components FXT60 Unit Components 500-Gal (1893-L) Tank 1. Inlet valve 9. Tool storage (optional) 2. Cyclonic filter 10. Water tank 3. Vacuum tank 11. Antifreeze tank 4. Primary shutoff valve 12. Hose reel 5. Vacuum filter/secondary shutoff valve 13. Tool storage 6. Vacuum boom (optional) 14. Water lance 7. Power pack 15. Drain/Outlet valve 8.
Overview - 6 FX60/FXT60 Tier 4 Operator’s Manual FXT60 Unit Components 800-Gal (3028-L) Tank 1. Inlet valve 8. Operator’s station 2. Cyclonic filter 9. Tool storage (optional) 3. Vacuum tank 10. Antifreeze tank 4. Water tanks 11. Vacuum hose reel 5. Primary shutoff valve 12. Tool storage 6. Vacuum boom (optional) 13. Water lance 7. Power pack 14.
FX60/FXT60 Tier 4 Operator’s Manual Overview - 7 FCC Statement FCC Statement U.S. This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. Changes or modifications not expressly approved by The Charles Machine Works, Inc. could void the user’s authority to operate the equipment.
FX60/FXT60 Tier 4 Operator’s Manual Overview - 8 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. 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.
FX60/FXT60 Tier 4 Operator’s Manual Foreword - 9 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.
Foreword - 10 FX60/FXT60 Tier 4 Operator’s Manual FX60/FXT60 Tier 4 Operator’s Manual This manual covers the following models: FX60 Tier 4, FXT60 Tier 4. Issue number 2.0/OM-11/14 Part number 053-2754 Copyright 2014 by The Charles Machine Works, Inc. , Ditch Witch, and CMW are registered trademarks of The Charles Machine Works, Inc. This product is covered by the following patent: U.S. 8,066,140; other U.S. patents pending.
FX60/FXT60 Tier 4 Operator’s Manual Contents - 11 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 9 part number, revision level, and publication date of this manual, and factory contact information Safety 11 machine safety alerts and emergency procedures Controls 31 machine controls, gauges, and indicators and how to use them Operation Overview 51 an overview for c
Contents - 12 FX60/FXT60 Tier 4 Operator’s Manual Service Record 147 a record of major service performed on the machine Appendix additional information about Ditch CMW® 149 Witch® equipment
FX60/FXT60 Tier 4 Operator’s Manual Safety - 13 Safety Chapter Contents Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Emergency Procedures . . . . . . . . . . . . . . . . . . . . . 15 • Electric Strike Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 • If an Electric Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 • If a Gas Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety - 14 FX60/FXT60 Tier 4 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.
FX60/FXT60 Tier 4 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. 274-050 Before operating any equipment, review emergency procedures and check that all safety precautions have been taken. EMERGENCY SHUTDOWN - Turn ignition switch to stop position or push remote engine stop button (if equipped). Electric Strike Description Electric shock.
Safety - 16 FX60/FXT60 Tier 4 Operator’s Manual Emergency Procedures If an Electric Line is Damaged Ditch Witch®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.
FX60/FXT60 Tier 4 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. 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 order and degree of action will depend on the situation. • Immediately shut off engine(s), if this can be done safely and quickly.
Safety - 18 FX60/FXT60 Tier 4 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.
FX60/FXT60 Tier 4 Operator’s Manual Safety - 19 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.
Safety - 20 FX60/FXT60 Tier 4 Operator’s Manual FX60T4 Machine Safety Alerts FX60T4 Machine Safety Alerts Power Unit Hot parts may cause burns. Do not touch until cool 1 or wear gloves. 275-355 (2-P) Lift point. See Transport chapter for more information. 2 3 4 CMW® Read operator’s manual. Know how to use all controls. Your safety is at stake. 273-475 Exposure to high noise levels may cause hearing loss. Wear hearing protection.
FX60/FXT60 Tier 4 Operator’s Manual Safety - 21 FX60T4 Machine Safety Alerts 5 6 Incorrect boom procedures could result in serious injury or death. Lock boom before transporting or tilting. 270-1982 Flying objects thrown by machine may strike people. Wear safety glasses and hard hat. 275-193 Equipment can be operated by remote control. 7 Stay away. 270-5739 Moving parts could cut off hand or foot. Stay away.
Safety - 22 FX60/FXT60 Tier 4 Operator’s Manual FX60T4 Machine Safety Alerts 800 Gallon Tanks 1 Do not get boom near power lines. Death or serious injury will occur. Keep required distance between boom and power lines. Use a spotter. 270-1983 Lift point. See Transport chapter for more information. 2 3 4 CMW® Crushing weight can cause death or serious injury. Pin door lock on linkage before servicing. 270-5216 Crushing weight. Place cylinder lock on extended cylinder and secure.
FX60/FXT60 Tier 4 Operator’s Manual Safety - 23 FX60T4 Machine Safety Alerts Moving parts could cut off hand or foot. Stay away. 5 6 275-184, 273-437 Contents under pressure. Relieve pressure before opening. Death or injury could occur. 270-2732 Vacuum can suffocate. Keep hose end away from 7 8 9 10 11 face. 273-205 Fire or explosion possible. Do not vacuum flammable or combustible substances. 273-483 Pressurized fluid or air could pierce skin and cause severe injury.
Safety - 24 FX60/FXT60 Tier 4 Operator’s Manual FX60T4 Machine Safety Alerts 1200 Gallon Tank 1 2 3 Fire or explosion possible. Do not vacuum flammable or combustible substances. 273-483 Do not get boom near power lines. Death or serious injury will occur. Keep required distance between boom and power lines. Use a spotter. 270-1983 Crushing weight could cause death or serious injury. Stay away. 275-326 Moving parts could cut off hand or foot. Stay away.
FX60/FXT60 Tier 4 Operator’s Manual Safety - 25 FX60T4 Machine Safety Alerts 5 6 7 Pressurized fluid or air could pierce skin and cause severe injury. Refer to operator’s manual for proper use. 270-6035 Contents under pressure. Relieve pressure before opening. Death or injury could occur. 270-2732 Confined space will cause suffocation. Use proper procedures for entering or stay away. 273-200 Lift point. See Transport chapter for more information.
Safety - 26 FX60/FXT60 Tier 4 Operator’s Manual FXT60T4 Machine Safety Alerts FXT60T4 Machine Safety Alerts Power Unit Lift point. See Transport chapter for more information. 1 2 3 CMW® Read operator’s manual. Know how to use all controls. Your safety is at stake. 273-475 Exposure to high noise levels may cause hearing loss. Wear hearing protection.
FX60/FXT60 Tier 4 Operator’s Manual Safety - 27 FXT60T4 Machine Safety Alerts 4 5 Incorrect boom procedures could result in serious injury or death. Lock boom before transporting or tilting. 270-1982 Flying objects thrown by machine may strike people. Wear safety glasses and hard hat. 275-193 Equipment can be operated by remote control. 6 Stay away. 270-5739 Moving parts could cut off hand or foot. Stay away. 7 275-184, 273-437 Hot parts may cause burns.
Safety - 28 FX60/FXT60 Tier 4 Operator’s Manual FXT60T4 Machine Safety Alerts Tanks 1 Do not get boom near power lines. Death or serious injury will occur. Keep required distance between boom and power lines. Use a spotter. 270-1983 Lift point. See Transport chapter for more information. 2 3 4 CMW® Crushing weight can cause death or serious injury. Pin door lock on linkage before servicing. 270-5216 Crushing weight. Place cylinder lock on extended cylinder and secure.
FX60/FXT60 Tier 4 Operator’s Manual Safety - 29 FXT60T4 Machine Safety Alerts Moving parts could cut off hand or foot. Stay away. 5 6 275-184, 273-437 Contents under pressure. Relieve pressure before opening. Death or injury could occur. 270-2732 Vacuum can suffocate. Keep hose end away from 7 8 9 10 11 face. 273-205 Fire or explosion possible. Do not vacuum flammable or combustible substances. 273-483 Pressurized fluid or air could pierce skin and cause severe injury.
FX60/FXT60 Tier 4 Operator’s Manual Safety - 30 FX Filters and Cyclones Safety Alerts FX Filters and Cyclones Safety Alerts 1 2 1 1 2 2 FX_Filters_&_Cyclones.eps 1 Contents under pressure. Relieve pressure before opening. Death or injury could occur. 270-2732 Use breathing protection when exposed to silica 2 CMW® dust.
FX60/FXT60 Tier 4 Operator’s Manual Controls - 31 Controls Chapter Contents Power Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 • Controls and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 • Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 800 Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 • Tethered Controller . . . . . . . . . . . . . . . . . . . . .
Controls - 32 FX60/FXT60 Tier 4 Operator’s Manual Power Pack Power Pack Controls and Connectors 1. Hydraulic function switch 7. Throttle 2. Water pump switch 8. Hydraulic return connector 3. Water pressure gauge 9. Hydraulic flow control 4. Water pressure control 10. Hydraulic supply connector 5. Light switch 11. Flow direction control 6. Ignition switch 12.
FX60/FXT60 Tier 4 Operator’s Manual Controls - 33 Power Pack Item Description 1. Hydraulic function switch To direct hydraulic power to the optional boom function, press top. Notes To direct hydraulic power to the door function, move to center position. To direct hydraulic power to the tank tilt function, press bottom. 2. Water pump switch H To turn on water pump, press top. To turn off water pump, press bottom. c00ic062t.eps 3.
FX60/FXT60 Tier 4 Operator’s Manual Controls - 34 Power Pack Item Description 5. Light switch To turn on, press top. Notes To turn off, press bottom. c00ic258h.eps 6. Ignition switch To start engine, insert key and turn clockwise. IMPORTANT: When engine is on, blower operates and vacuum is present at tank inlet. To stop engine, turn key counterclockwise. 7. Throttle To increase engine speed, rotate clockwise. To decrease engine speed, rotate counterclockwise. 8.
FX60/FXT60 Tier 4 Operator’s Manual Controls - 35 Power Pack Item Description Notes 10. Hydraulic supply connector To operate hydraulic power tools with power pack hydraulic system, connect hydraulic supply hose to connector. IMPORTANT: Connect return hose before connecting supply hose. 11. Flow direction control To operate in reverse flow mode, turn counterclockwise. Use reverse flow to unload tank contents to another tank. Operate in reverse flow mode only when drain/ outlet valve is open.
Controls - 36 FX60/FXT60 Tier 4 Operator’s Manual Power Pack Display 1. Hydraulic fluid temperature indicator 7. Engine oil pressure indicator 2. Blower temperature indicator 8. Diagnostics menu button 3. Engine speed (RPM) 9. Hourmeter 4. Diagnostic message indicator 10. Settings menu button 5. Wait-to-start indicator 11. Electrical system voltage 6. Engine coolant temperature indicator 12.
FX60/FXT60 Tier 4 Operator’s Manual Controls - 37 Power Pack Item Description Notes 1. Hydraulic fluid temperature indicator Indicates hydraulic fluid temperature is above 215°F (102°C). Engine will stop. Indicates blower discharge temperature is above 335°F (168°C). Engine will stop. 2. Blower temperature indicator Check hydraulic fluid level. 1. Check for air flow obstructions. 2. Let blower cool before restarting. 3. Engine speed (RPM) 4. Diagnostic message indicator Displays engine RPM.
FX60/FXT60 Tier 4 Operator’s Manual Controls - 38 Power Pack Item Description Notes 6. Engine coolant temperature indicator Indicates cooling system fluid is overheated. Engine will stop. 1. Let engine cool. 2. Check cooling system fluid level. c00ic120h.eps 7. Engine oil pressure indicator Indicates engine oil pressure is low. Engine will stop. 1. Check oil level. Also lights briefly when engine is started. 8. Diagnostics menu button Press button below icon to go to the Diagnostics menu. 9.
FX60/FXT60 Tier 4 Operator’s Manual Controls - 39 800 Tanks 800 Tanks Tethered Controller 1 2 j08om082h.eps Item Description Notes Tethered tank control To lift and lower tank, set hydraulic function switch to the tank position, then Note: The vacuum boom uses a different tethered controller. See page 47 and page 49. • To lift tank, press UP. • To lower tank, press DOWN. IMPORTANT: These functions are also included on the wireless control module. c00ic174h.
FX60/FXT60 Tier 4 Operator’s Manual Controls - 40 800 Tanks Machine Controls 1. Inlet valve 4. Drain/Outlet valve 2. Water tank drain 5. Antifreeze tank supply valve 3. Water tank supply valve 6. Vacuum gauge Item Description 1. Inlet valve To close valve (stop suction), rotate up. To open valve (start suction), rotate down.
FX60/FXT60 Tier 4 Operator’s Manual Controls - 41 800 Tanks Item Description 2. Water tank drain To drain tank, open valve. Notes Close valve when tank is empty. 3. 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. 4.
FX60/FXT60 Tier 4 Operator’s Manual Controls - 42 1200 Tank 1200 Tank Tank Controls 1. Tank door lock 4. Tank lift control 2. Tank door handle 5. Tank door lift control 3. Door seal pressure gauge 6. Door seal control Item Description 1. Tank door lock To lock vacuum tank door, turn clockwise until it stops. To unlock door, turn counterclockwise.
FX60/FXT60 Tier 4 Operator’s Manual Controls - 43 1200 Tank Item Description Notes 2. Tank door handle To engage tank door, push and turn 90° clockwise. IMPORTANT: To disengage tank door, turn 90° counterclockwise and pull. 3. Door seal pressure gauge Displays door seal pressure reading. Door is fully sealed when reading reaches 2400 psi (165 bar). 4. Tank lift control To raise vacuum tank, push up. • Tank door must be unlocked before tank door handle will work.
FX60/FXT60 Tier 4 Operator’s Manual Controls - 44 1200 Tank Machine Controls 1. Inlet valve 5. Water tank drain 2. Vacuum hose reel control 6. Drain/Outlet valve 3. Water tank supply valve 7. Vacuum gauge 4. Antifreeze tank supply valve 8. Vacuum filter drain Item Description 1. Inlet valve To close valve (stop suction), rotate up. To open valve (start suction), rotate down.
FX60/FXT60 Tier 4 Operator’s Manual Controls - 45 1200 Tank Item Description 2. Vacuum hose reel control To wind vacuum hose, push up. Notes To unwind vacuum hose, pull down. 3. Water tank supply valve To open valve (send water from the water tank through the pump and water lance), rotate counterclockwise. To close valve (stop water flow), rotate clockwise. 4. Antifreeze tank supply valve To open valve (send antifreeze through pump and water lance), rotate counterclockwise.
FX60/FXT60 Tier 4 Operator’s Manual Controls - 46 1200 Tank Item Description 6. Drain/Outlet valve To drain tank, rotate down. To close drain, rotate up. 7. Vacuum gauge Displays blower vacuum reading in inches of mercury. Vacuum relief valve opens when vacuum reaches 16” (406 mm). 8. Vacuum filter drain To drain vacuum filter canister, rotate up. To close drain, rotate down.
FX60/FXT60 Tier 4 Operator’s Manual Controls - 47 Vacuum Boom (optional) Vacuum Boom (optional) 5 4 3 2 1 j35om053h.eps 1. Boom latch 4. Boom retract 2. Boom up 5. Boom extend 3. Boom down IMPORTANT: The vacuum boom can be controlled with the wireless control module or the tethered controller. Item Description 1. Boom latch Pull cable to open latch and release boom from saddle. Notes Push boom into latch to lock boom into saddle.
FX60/FXT60 Tier 4 Operator’s Manual Controls - 48 Vacuum Boom (optional) Item Description Notes 2. Boom up To raise boom, press. NOTICE: Do not use boom to raise or lower objects. To stop movement, release. 3. Boom down To lower boom, press. To stop movement, release. 4. Boom retract To retract boom, press. To stop movement, release. 5. Boom extend To extend boom, press. To stop movement, release. CMW® NOTICE: Do not use boom to raise or lower objects.
FX60/FXT60 Tier 4 Operator’s Manual Controls - 49 Wireless Control Module Wireless Control Module Read operator’s manual. Know how to use all controls. Your safety is at stake. 273-475 To help avoid injury: Keep unit in sight when controlling tank or boom with wireless control module. Item Description 1. Light key To toggle dome and option work light on and off, press. 2. Boom/Tank selector switch To activate tank and door controls, move to Notes To activate boom controls, move to 3.
FX60/FXT60 Tier 4 Operator’s Manual Controls - 50 Wireless Control Module Item Description Notes 5. Receiver power off key To turn off receiver, press. The receiver does not shut off automatically. To preserve batteries, turn off receiver when not in use. 6. Door open key To open vacuum tank door, press. 7. Door close key To close vacuum tank door, press. 8. Tank up key To raise vacuum tank, press. 9. Tank down key To lower vacuum tank, press. 10. Boom up key To raise boom, press.
FX60/FXT60 Tier 4 Operator’s Manual Operation Overview - 51 Operation Overview Chapter Contents Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Setting Up at Jobsite . . . . . . . . . . . . . . . . . . . . . . . 52 Vacuuming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Potholing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Leaving Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Storing Equipment . . . . . . . . . . .
Operation Overview - 52 FX60/FXT60 Tier 4 Operator’s Manual Planning Planning 1. Gather information about jobsite (page 56). 2. Inspect jobsite (page 57). 3. Check supplies and prepare equipment (page 59). Setting Up at Jobsite 1. Prepare jobsite (page 58). 2. Position vacuum excavation unit. 3. Leave unit hitched to towing vehicle or properly stabilized. 4. Block trailer wheels. Vacuuming 1. Connect hoses (page 66). 2. Start unit (page 69). 3. Position optional vacuum boom (page 70). 4.
FX60/FXT60 Tier 4 Operator’s Manual Operation Overview - 53 Potholing Potholing 1. Connect hoses (page 66). 2. Start unit (page 69). 3. Pothole (page 72). 4. Disconnect hoses (page 83). 5. Drain tank (page 74). Leaving Jobsite 1. Rinse unit and tools (page 83). 2. Stow tools (page 84). Storing Equipment 1. For cold weather storage, antifreeze vacuum excavation unit (page 82). 2. For long-term storage, disconnect battery disconnect switch (page 35).
Operation Overview - 54 FX60/FXT60 Tier 4 Operator’s Manual Storing Equipment CMW®
FX60/FXT60 Tier 4 Operator’s Manual Prepare - 55 Prepare Chapter Contents Gather Information . . . . . . . . . . . . . . . . . . . . . . . . . 56 • Arrange for Traffic Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 • Prepare for Working Near Existing Utilities . . . . . . . . . . . . . . . . . . . . . .56 • Plan for Emergency Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Inspect Jobsite . . . . . . . . . . . . . . . . . . . . . . . . .
Prepare - 56 FX60/FXT60 Tier 4 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.
FX60/FXT60 Tier 4 Operator’s Manual Prepare - 57 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 digging. Also contact any utilities that do not participate in the One-Call service..
FX60/FXT60 Tier 4 Operator’s Manual Prepare - 58 Prepare Jobsite Prepare Jobsite Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. 274-050 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.
FX60/FXT60 Tier 4 Operator’s Manual Prepare - 59 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.
Prepare - 60 FX60/FXT60 Tier 4 Operator’s Manual Check Supplies and Prepare Equipment Prepare Equipment Fluid Levels • fuel • hydraulic fluid • engine coolant • battery charge • engine oil • blower oil Condition and Function • filters (air, oil, hydraulic) • belts • hydraulic pump • blower • tires • hoses and valves • couplers and fittings • water tanks CMW®
FX60/FXT60 Tier 4 Operator’s Manual Transport - 61 Transport Chapter Contents Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 • Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 • Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 Haul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 • Inspect Trailer . . . . . . . . . .
FX60/FXT60 Tier 4 Operator’s Manual Transport - 62 Lift Lift Crushing weight could cause death or serious injury. Stay away. 275-326 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 3000 lb (1360 kg). Use top lift point as shown.
FX60/FXT60 Tier 4 Operator’s Manual Transport - 63 Haul Tank Use crane capable of supporting the weight shown below. Use top lift point (1) as shown. Use end lift point (2) to drain tank if machine is disabled. 800 gallon 2500 lb ( kg) kg 1200 gallon 3000 lb (1360 kg) NOTICE: • Relieve pressure in tank before storing or transporting. • Only lift empty water or spoils tanks. • Do not lift tank by vacuum boom, if installed. Haul Crushing weight could cause death or serious injury. Stay away.
Transport - 64 FX60/FXT60 Tier 4 Operator’s Manual 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).
FX60/FXT60 Tier 4 Operator’s Manual Vacuum and Pothole - 65 Vacuum and Pothole Chapter Contents Connect Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Determine Tank Fill Level . . . . . . . . . . . . . . . . . . . 67 • 800-gal Vacuum Tank on T18S Trailer . . . . . . . . . . . . . . . . . . . . . . . . . .67 • 1200-gal Vacuum Tank on BT26 Trailer . . . . . . . . . . . . . . . . . . . . . . . . .68 Start Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vacuum and Pothole - 66 FX60/FXT60 Tier 4 Operator’s Manual Connect Hoses Connect Hoses 1. Remove vacuum hoses from storage. If using 1200: • Disconnect hose end from hose catch. • Insert hose through rollers (2). • Pull vacuum hose reel control (1) down to unwind hose. • Disconnect hose end (3) from hose reel. 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.
FX60/FXT60 Tier 4 Operator’s Manual Vacuum and Pothole - 67 Determine Tank Fill Level (FX60 Trailer Only) Determine Tank Fill Level (FX60 Trailer Only) 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.
FX60/FXT60 Tier 4 Operator’s Manual Vacuum and Pothole - 68 Determine Tank Fill Level (FX60 Trailer Only) 1200-gal Vacuum Tank on BT26 Trailer Material Maximum Vacuum Tank Fill Level Water tank fill level CMW® full (500 gal) empty (0 gal) wood chips (dry) 100% 100% snow (dry) 100% 100% water 94% 100% light weight mud (8-10 lb/gal) 87% 100% earth (dry, loose) 82% 100% caliche 75% 100% earth, loam 75% 100% medium weight mud (10-12 lb/gal) 71% 99% limestone (crushed) 61% 85%
FX60/FXT60 Tier 4 Operator’s Manual Vacuum and Pothole - 69 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 (for 1200 gallon), connect a -08 hose with a minimum working pressure rating of 3000 psi (207 bar) from return/tank (1) to pressure (2) connections on power pack. 1. Open tank inlet valve. NOTICE: Avoid idling engine with inlet valve closed. 2.
FX60/FXT60 Tier 4 Operator’s Manual Vacuum and Pothole - 70 Position Vacuum Boom Position Vacuum Boom The vacuum boom is optional equipment. Contact your Ditch Witch® dealer to add this option. Procedure Do not get boom near power lines. Death or serious injury will occur. Keep required distance between boom and power lines. Use a spotter. 270-1983 Read operator’s manual. Know how to use all controls. Your safety is at stake. 273-475 To help avoid injury: • Latch boom before tilting tank.
FX60/FXT60 Tier 4 Operator’s Manual Vacuum and Pothole - 71 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 can suffocate. Keep hose end away from face. 273-205 Fire or explosion possible. Do not vacuum flammable or combustible substances. 273-483 Read operator’s manual. Know how to use all controls. Your safety is at stake.
FX60/FXT60 Tier 4 Operator’s Manual Vacuum and Pothole - 72 Pothole Pothole EMERGENCY SHUTDOWN: Turn ignition switch to STOP. 1. Start engine. Vacuum can suffocate. Keep hose end away from face. 273-205 Fire or explosion possible. Do not vacuum flammable or combustible substances. 273-483 2. Open water tank valve. NOTICE: Avoid idling engine with inlet valve closed. 3. Move water pump switch to on. 4. Open inlet valve. 5. Position tool over area to be excavated and begin pothole.
FX60/FXT60 Tier 4 Operator’s Manual Vacuum and Pothole - 73 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. 274-050 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.
FX60/FXT60 Tier 4 Operator’s Manual Vacuum and Pothole - 74 Drain Tank Drain Tank EMERGENCY SHUTDOWN: Turn ignition switch to STOP. 1. Ensure that unit is hitched to vehicle. See “Hitch Trailer” on page 64. 2. Haul unit to approved dumping area. Read operator’s manual. Know how to use all controls. Your safety is at stake. 273-475 To help avoid injury: • Do not unhitch unit from tow vehicle before or during dumping. A freestanding unit can become unstable when tilting tank.
FX60/FXT60 Tier 4 Operator’s Manual Vacuum and Pothole - 75 Drain Tank 9. If further draining is necessary, open tank door. See “Open/Close Tank Door” on page 78. Crushing weight could cause death or serious injury. Stay away. 275-326 To help avoid injury: Use tools (provided with unit) if unit must be serviced with tank door up. 10. Tilt tank up. Allow tank to drain completely. 11. Connect water pressure hose to water lance. 12. Turn water pump switch on. Adjust water pressure. 13.
FX60/FXT60 Tier 4 Operator’s Manual Vacuum and Pothole - 76 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. Read operator’s manual. Know how to use all controls. Your safety is at stake. 273-475 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.
FX60/FXT60 Tier 4 Operator’s Manual Vacuum and Pothole - 77 Unload to Another Tank 4. Open offboard tank inlet valve. Move valve handle counterclockwise to engage “reverse flow” mode and start engine. Material will flow into offboard tank. 5. Increase throttle as desired to transfer material. 6. When transfer is complete, throttle down completely and turn off engine. Close FX tank drain/outlet valve. 7. Close offboard tank inlet valve and disconnect hose from offboard tank inlet valve. 8.
FX60/FXT60 Tier 4 Operator’s Manual Vacuum and Pothole - 78 Open/Close Tank Door Open/Close Tank Door Crushing weight. Place cylinder lock on extended cylinder and secure. 273-231 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. IMPORTANT: Depressurize tank before emptying cyclonic canister, cleaning filter, clearing hoses or opening any doors. 800 Tank: Open 1.
FX60/FXT60 Tier 4 Operator’s Manual Vacuum and Pothole - 79 Open/Close Tank Door 1200 Tank: Open 1. Push door seal control to SEAL. 2. Turn tank door lock counterclockwise. 3. Pull door seal control to RELEASE. 4. Turn door handle to DISENGAGE and pull out. 5. Push door lift control to OPEN. 6. Ensure door lift latch (1) engages properly. Door lift latch (1) should be fully seated on pin (2). NOTICE: If door latch is not fully seated on pin, door will close and possibly injure someone. Close 1.
Vacuum and Pothole - 80 FX60/FXT60 Tier 4 Operator’s Manual Open/Close Tank Door CMW®
FX60/FXT60 Tier 4 Operator’s Manual Complete the Job - 81 Complete the Job Chapter Contents Antifreeze Fluid Excavation Unit . . . . . . . . . . . . . 82 • Add Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 • Reclaim Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 Rinse Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Complete the Job - 82 FX60/FXT60 Tier 4 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. 7.
FX60/FXT60 Tier 4 Operator’s Manual Complete the Job - 83 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. 273-200 To help avoid injury: Enter tank only if necessary. Follow U.S. Department of Labor guidelines for entering confined spaces. Crushing weight can cause death or serious injury.
Complete the Job - 84 FX60/FXT60 Tier 4 Operator’s Manual Stow Tools Stow Tools Make sure optional vaccum boom, potholing tools, water lance, and other tools are properly stowed. If using 1200, failure to stow tools as indicated could result in damage to water tank. 1. 2-in-1 potholing tool 2. Basic potholing tool 3.
FX60/FXT60 Tier 4 Operator’s Manual Service - 85 Service Chapter Contents Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Recommended Lubricants/Service Key . . . . . . . . 88 Each Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 10 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 25 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FX60/FXT60 Tier 4 Operator’s Manual Service - 86 Service Precautions Service Precautions Read operator’s manual. Know how to use all controls. Your safety is at stake. 273-475 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. IMPORTANT: Service illustrations show unit configured with 1200-gal (4542-L) tank unless indicated otherwise.
FX60/FXT60 Tier 4 Operator’s Manual Service - 87 Service Precautions Working Under Raised Tank Door Crushing weight can cause death or serious injury. Pin door lock on linkage before servicing. 270-5216 If using 800: 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. j35om074h.eps Welding Precaution NOTICE: Welding can damage electronics.
FX60/FXT60 Tier 4 Operator’s Manual Service - 88 Recommended Lubricants/Service Key Recommended Lubricants/Service Key Item Description DEO Diesel engine oil meeting or exceeding Deutz specification DQC III- LA. NOTICE: This unit is shipped from the factory with API CJ-4 DEO meeting Deutz specification DQC II-LA. Change oil initially at 250 hours. • Engine must use low sulfated ash, phosphorous, and sulfur (low (SAPS) oil. • See viscosity chart.
FX60/FXT60 Tier 4 Operator’s Manual Service - 89 Recommended Lubricants/Service Key Engine Oil Temperature Chart Temperature range anticipated before next oil change See engine manual for more information about oil viscosity and operation in arctic conditions.
Service - 90 FX60/FXT60 Tier 4 Operator’s Manual Recommended Lubricants/Service Key Approved Fuel 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 15ppm/ 15 mg/kg sulfur content) in this unit.
FX60/FXT60 Tier 4 Operator’s Manual Service - 91 Each Use Each Use Location Task Notes Trailer Check torque of hitch bolts and verify proper hitch height 200 ft•lb (271 N•m) Check tire pressure and lug nut torque Check lights and reflectors Trailer Check Torque of Hitch Bolts and Verify Proper Hitch Height Check torque of hitch bolts. Torque varies by trailer model. Refer to “Specifications” on page 129. Verify that hitch is at the proper height to avoid adding excess load on axle and wheels.
Service - 92 FX60/FXT60 Tier 4 Operator’s Manual Each Use Check Lights and Reflectors Check lights and reflectors for correct operation and cleanliness. j33om013h.
FX60/FXT60 Tier 4 Operator’s Manual Service - 93 10 Hour 10 Hour Location Task Vacuum System Check engine oil level Notes Drain fuel/water separator Inspect belts (water pump, blower and fan) Check coolant level Check air filter service indicator Check hydraulic fluid level THF Check hydraulic hoses Check blower oil level SGL Check blower Check water pump oil level Check water pump NDO Check water pump regulator Clean water pump filter Clean vacuum air filter Drain vacuum air filter canister C
Service - 94 FX60/FXT60 Tier 4 Operator’s Manual 10 Hour Vacuum System Check Engine Oil Level Check engine oil at dipstick (1) before operation and every 10 hours thereafter. Check with unit on level surface and at least 15 minutes after stopping engine. Add DEO at fill (2) as necessary to keep oil level at highest line on dipstick. Drain Fuel/Water Separator Drain water out of filter every 10 hours. To drain, place loose end of drain hose into approved container.
FX60/FXT60 Tier 4 Operator’s Manual Service - 95 10 Hour Check Coolant Level Check coolant level, with engine cool, at coolant expansion tank every 10 hours. Maintain coolant level at fill line. If low, add approved coolant. NOTICE: • The use of non-approved coolant may lead to engine damage or premature engine failure and will void engine warranty. • See “Approved Coolant” on page 90 for list of approved coolants. To fill: 1. Slowly add coolant at expansion tank to fill line. 2.
FX60/FXT60 Tier 4 Operator’s Manual Service - 96 10 Hour Check Hydraulic Fluid Level With frame level, check oil at indicator every 10 hours. Add THF at fill as necessary. Clean dust from cap by blowing with low-pressure air. IMPORTANT: Use a ladder or other means to access hydraulic fluid fill. Check Hydraulic Hoses Check hoses every 10 hours for wear or damage. Replace as needed. Pressurized fluid or air could pierce skin and cause severe injury. Refer to operator’s manual for proper use.
FX60/FXT60 Tier 4 Operator’s Manual Service - 97 10 Hour Check Blower Oil Level With frame level, check blower oil at sight glass (2) every 10 hours. Add SGL at breather (1) as necessary to maintain oil level at halfway point on sight glass (2). Do not overfill. Check Blower Check blower every 10 hours for unusual noise or vibration. If malfunction is detected: 1. Stop engine. 2. Consult blower repair manual. Check Water Pump Oil Level With frame level, check water pump oil at dipstick every 10 hours.
FX60/FXT60 Tier 4 Operator’s Manual Service - 98 10 Hour Check Water Pump Check water pump unit every 10 hours for leaks, loose fittings, unusual noise or vibration. Repair if necessary. 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: • Before using system, check that all connections are tight and all lines are undamaged. • Use a piece of cardboard or wood, rather than hands, to search for leaks.
FX60/FXT60 Tier 4 Operator’s Manual Service - 99 10 Hour Check Water Pump Regulator Check for proper operation of regulator every 10 hours. To check: 1. Start engine. 2. Connect water pressure hose to water lance. 3. Move water pressure switch to on. 4. Squeeze water lance handle. Water pump should engage. 5. Release water lance handle. Water pump should disengage. If pump does not engage and disengage with movement of water lance handle, water pump control system is not functioning properly.
FX60/FXT60 Tier 4 Operator’s Manual Service - 100 10 Hour Clean Vacuum Air Filter Use breathing protection when exposed to silica dust. 270-4952 Clean filter every 10 hours or as needed. To clean filter: 1. Remove filter from canister. 2. Run low pressure water into inside of filter. NOTICE: Do not use high pressure water to clean filter. Filter will be damaged. 3. Allow filter to dry completely before returning to canister. j35om013h.
FX60/FXT60 Tier 4 Operator’s Manual Service - 101 10 Hour Drain Vacuum Air Filter Canister (1200) Drain filter canister at drain (1) every 10 hours or as needed. Drain when water is visible in sight glass (2). 2 1 j35om042h.eps 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. j35om015h.
Service - 102 FX60/FXT60 Tier 4 Operator’s Manual 10 Hour Debris Tank Check Vacuum Tank Hoses Check hoses every 10 hours for wear or damage. Replace as needed. j35om041h.eps Check Strobe Light Check strobe light for proper function every 10 hours. When ignition is on, strobe light should be flashing. Repair if necessary. j35om016h.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.
FX60/FXT60 Tier 4 Operator’s Manual Service - 103 10 Hour Check Tank Deflector Check tank deflector every 10 hours for buildup, wear, or damage. Clean or replace as needed. j35om022h.eps 800 j35om050h.
FX60/FXT60 Tier 4 Operator’s Manual Service - 104 25 Hour 25 Hour Location Task Notes Vacuum System Change water pump oil Initial service, NDO Vacuum System 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 (2) while oil is warm. • Add NDO at fill (1) until oil is at full mark on dipstick.
FX60/FXT60 Tier 4 Operator’s Manual Service - 105 50 Hour 50 Hour Location Task Vacuum System Check water pump belt tension Notes Check blower belt tension Inspect cooling fan Check radiator Check blower relief valve Check water pressure hoses Check vacuum air filter and hoses Debris Tank Vacuum Boom Lube door lock screw 1200 tank Lube tank pivot pins 800 tanks Lube boom pivot Boom is optional equipment Vacuum System Check Water Pump Belt Tension Check belt every 10 hours for correct tensio
Service - 106 FX60/FXT60 Tier 4 Operator’s Manual 50 Hour Check Blower Belt Tension Check belt every 10 hours for correct tension, damage or wear. Replace worn belt. Tighten as needed. See “Adjust Blower Belt Tension” on page 117. Inspect Cooling Fan Check for cracks, loose rivets, and bent or loose blades. Check mounting screws and tighten if needed. Check Radiator Check radiator for dirt, grass, and other foreign matter every 50 hours. Clean out with compressed air or spray wash if required.
FX60/FXT60 Tier 4 Operator’s Manual Service - 107 50 Hour Check Blower Relief Valve Check relief valve for proper operation every 50 hours. To check: 1. Ensure that vacuum inlet valve and drain valve are both closed. 2. Start engine. Vacuum will start to build. 3. When vacuum goes over relief, check for suction at the bottom of the relief air filter. If suction is not present, stop engine and check relief valve. Check Water Pressure Hoses Check hoses every 50 hours for wear or damage. Replace as needed.
Service - 108 FX60/FXT60 Tier 4 Operator’s Manual 50 Hour Debris Tank Lube Door Lock Screw (1200 tank) Lube every 50 hours with MPG. j35om048h.eps Lube Tank Pivot Pins (800 tanks) Lube two pins every 50 hours with MPG. j35om020h.eps Vacuum Boom Lube Boom Pivot Lube six zerks every 50 hours with MPG. j35om021h.
FX60/FXT60 Tier 4 Operator’s Manual Service - 109 100 Hour 100 Hour Location Task Notes Vacuum System Change hydraulic fluid filter Initial service Change water pump oil NDO Lube blower HTG Debris Tank Check tank deflector Check tank mounting bolts Vacuum Boom Check structure Vacuum System Change Hydraulic Fluid Filter (Initial Service) Use provided wrench to change hydraulic fluid filter after first 100 hours. Replace filters every 1000 hours thereafter.
Service - 110 FX60/FXT60 Tier 4 Operator’s Manual 100 Hour Lube Blower Wipe two zerks clean and lube every 100 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. Debris Tank Check Tank Mounting Bolts 800 Tanks Check vacuum tank mounting bolts (shown, on both sides) every 100 hours for looseness and damage. Tighten or replace as needed. j35om071h.
FX60/FXT60 Tier 4 Operator’s Manual Service - 111 250 Hour Vacuum Boom Check Structure Check boom deflector every 100 hours. Replace as needed. 250 Hour Location Task Notes Vacuum System change engine oil and filter DEO, initial and if using API CJ-4 or ACEA E6/E9 oil Inspect air intake system Vacuum System Change Engine Oil and Filter Change oil and filter after 250 hours and every 250 hours if using oil meeting API CJ-4 or ACEA E6/E9. See page 88 for more information about DEO specifications.
FX60/FXT60 Tier 4 Operator’s Manual Service - 112 500 Hour Inspect Air Intake System Inspect intake piping for cracked hoses, loose clamps, or punctures. Tighten or replace parts as necessary. 500 Hour Location Task Notes Vacuum System Change engine oil and filter DEO; ONLY if using DQC IIILA oil Change fuel filters and clean filter screen Vacuum System Change Engine Oil and Filter Change oil and filter every 500 hours ONLY if using oil meeting Deutz DQC III- LA.
FX60/FXT60 Tier 4 Operator’s Manual Service - 113 1000 Hour Change Fuel Filters Replace primary and secondary fuel filters and clean filter screen every 500 hours for normal service. See parts manual or contact your Ditch Witch® dealer for correct replacement filter. 1000 Hour Location Task Notes Vacuum System Change blower oil SGL Change hydraulic fluid THF Vacuum System Change Blower Oil Change oil every 1000 hours. Change oil more frequently if working in dusty conditions.
FX60/FXT60 Tier 4 Operator’s Manual Service - 114 2000 Hour Change Hydraulic Fluid Drain hydraulic fluid (2) and add (1) THF every 1000 hours. Change fluid every 500 hours if jobsite temperature exceeds 100°F (38°C) more than 50% of the time. 2000 Hour Location Task Notes Vacuum System Change coolant DEAC Vacuum System Change Coolant Drain cooling system at drain (1) every two years or 2000 hours. Add approved coolant at expansion tank (2) to fill line.
FX60/FXT60 Tier 4 Operator’s Manual Service - 115 As Needed As Needed Location Task Vacuum System Change air filter Notes Change water pump filter Adjust blower belt tension Lube blower for longterm storage Change blower relief air filter Replace water pump belt Replace blower belt Replace fan belt Empty cyclonic separator canister Debris Tank Lube reverse flow 4-way valve MPG Change wireless control module batteries 3 AA Clean primary shutoff valve Clean secondary shutoff valve Trailer 1200
Service - 116 FX60/FXT60 Tier 4 Operator’s Manual As Needed Vacuum System Change Air Filter 1 Change air filter element when red band on filter minder (1) is visible. Push button to reset indicator. 2 To replace air filter: 5 2. Remove the primary (4) and secondary (5) filters from the canister (6). 4 3. Wipe out the canister (6) and cover (3) with a damp cloth. 4. Install the new secondary and primary filters by hand with a slight turn and firm push to seat the filters in the canister. 3 6 1.
FX60/FXT60 Tier 4 Operator’s Manual Service - 117 As Needed Adjust Blower Belt Tension 1. Turn off engine and remove key. 2. Loosen jam nut (3), pulley nut (1, alternate view 1B) and idler mount bolt (2, alternate view 2B) only enough that components can slide. 3. Rotate adjustment screw (4) using hand tools. 4. Tighten pulley nut. 5. Check belt tension at access hole (5). Using ultrasonic meter: • New belt: 97-100 Hz • Used belt: 90-93 Hz Using force/deflection: • New belt: 7 lb (31.
Service - 118 FX60/FXT60 Tier 4 Operator’s Manual 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.
FX60/FXT60 Tier 4 Operator’s Manual Service - 119 As Needed Lube Reverse Flow 4-Way Valve Lube reverse flow 4-way valve at zerk (shown) with MPG as needed. Also open left access panel of power unit and lube zerk on other side of valve. Change Wireless Control Module Batteries Change batteries in wireless control module as needed. Unit requires 3 AA batteries. To change: 1. Insert 3 AA batteries into the slots on the back of the battery adapter case housing as indicated on the case. 2.
Service - 120 FX60/FXT60 Tier 4 Operator’s Manual As Needed Debris Tank Clean Primary Shutoff Valve Clean primary shutoff valve as needed. Replace primary shutoff valve as needed. 2 1 To clean: 1. Open tank door. See “Open/Close Tank Door” on page 78. 2. Spray valve housing inside vacuum tank with high-pressure water. 3. Store water pressure hose. j35om027h.eps 4. Close tank door. See “Open/Close Tank Door” on page 78. To remove: 1. Loosen three wingnuts (1) and pull out valve housing (2). 2.
FX60/FXT60 Tier 4 Operator’s Manual Service - 121 As Needed Clean Secondary Shutoff Valve (1200 Tank) Clean secondary shutoff valve as needed. Replace secondary shutoff valve as needed. To clean: 1. Loosen wingnuts and open water trap door. 1 2. Remove filter canister lid and remove filter element. 2 3. Drain water from element housing. 4. Spray valve housing and rubber seat inside water trap housing with high-pressure water. j35om067h.eps 5. Disconnect water pressure hose and store properly. 6.
FX60/FXT60 Tier 4 Operator’s Manual Service - 122 As Needed Trailer Check Battery Check battery as needed. Keep battery clean and terminals free of corrosion. To clean: 1. Turn battery disconnect switch, if equipped, 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. j35om008h.eps 5. Check for signs of internal corrosion in cables. 6.
FX60/FXT60 Tier 4 Operator’s Manual Service - 123 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.
Service - 124 FX60/FXT60 Tier 4 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.
FX60/FXT60 Tier 4 Operator’s Manual Service - 125 200 Mile 200 Mile 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. j35om023h.eps 4. Rotate starwheel the other direction until drum turns with slight drag.
FX60/FXT60 Tier 4 Operator’s Manual Service - 126 10,000 Mile 10,000 Mile Location Task Truck Check mounting bolts and springs Notes Check accessory mounting bolts Truck Check Mounting Bolts and Springs Check mounting bolts and springs (shown, underneath and both sides) every 10,000 miles for looseness and damage. Springs (1) should be 3” (76 mm). Loosen or tighten bolt to adjust spring length. Tighten all other indicated hardware to 240 ft•lb (325 N•m). 1 j39om013w.
FX60/FXT60 Tier 4 Operator’s Manual Service - 127 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. j35om025h.
Service - 128 FX60/FXT60 Tier 4 Operator’s Manual 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 4 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.
FX60/FXT60 Tier 4 Operator’s Manual Specifications - 129 FX60-800 Specifications FX60-800 Dimensions U.S. Metric L Length 263 in 6.7 m H Height 92 in 2.3 m W Width 97.5 in 2.5 m Trailer width 100.5 in 2.5 m Dry weight * 10,700 lb 4853 kg Weight with all tanks filled with water * 18,900 lb 8573 kg * Options included on weight calculation: boom, reverse flow, cyclonic filter, heater, and 200-gallon water tank on a T18S trailer. Vac Tank U.S.
Specifications - 130 FX60/FXT60 Tier 4 Operator’s Manual FX60-800 Engine U.S. Metric Deutz TD2.9L4, diesel, Tier 4, turbocharged Cooling medium liquid Injection direct Number of cylinders 4 Displacement 178 in3 2.9 L Bore 3.62 in 92 mm Stroke 4.
FX60/FXT60 Tier 4 Operator’s Manual Specifications - 131 FX60-800 Battery SAE res. cap. 195 min; SAE cold crank @ 0°F (-18°C) 925A, 12V Vacuum system U.S. Metric Drive type belt Displacement 1020 cfm 28.9 m3/min Maximum vacuum 16 in Hg 405 mm Hg Filter type washable polyester Filter area 130 ft2 12 m2 Suction hose size 4 in 102 mm Water pump system U.S. Metric Maximum pressure 3000 psi 207 bar Flow 5.5 gpm 21 L/min Hose reel capacity with water lance 50 ft 15.
Specifications - 132 FX60/FXT60 Tier 4 Operator’s Manual FX60-800 T18S Trailer U.S. Metric Clearance (at jack foot pad) 12 in 305 mm Adj. coupler height 17-26 in 432-660 mm Width between fenders 80.5 in 2m Width outside fenders 100.5 in 2.6 m Number of axles 2 Coupler (square mount drawbar) 3 in or 2.5 in Type of brakes electric Lug nut torque 300 ft•lb 407 N•m Hitch bolt torque 200 ft•lb 271 N•m Electrical system 12V DC 215/75R-17.5, H16TL 125 psi 8.
FX60/FXT60 Tier 4 Operator’s Manual Specifications - 133 FX60-1200 FX60-1200 Dimensions U.S. Metric L Length 245 in 6.2 m H Height 99 in 2.5 m W Width 100.5 in 2.55 m Dry weight 12,060 lb 5420 kg Weight with all tanks filled with water * 25,400 lb 11 520 kg * Options included on weight calculation: boom and heater on a T26S trailer. Tank U.S. Metric Capacity 1200 gal 4542 L Length 106 in 2.7 m Diameter 60 in 1.
Specifications - 134 FX60/FXT60 Tier 4 Operator’s Manual FX60-1200 Engine U.S. Metric Deutz TD2.9L4, diesel, Tier 4, turbocharged Cooling medium liquid Injection direct Number of cylinders 4 Displacement 178 in3 2.9 L Bore 3.62 in 92 mm Stroke 4.
FX60/FXT60 Tier 4 Operator’s Manual Specifications - 135 FX60-1200 Battery SAE res. cap. 195 min; SAE cold crank @ 0°F (-18°C) 925A, 12V Vacuum system U.S. Metric Drive type belt Displacement 1020 cfm 28.9 m3/min Maximum vacuum 16 in Hg 405 mm Hg Filter type washable polyester Filter area 130 ft2 12 m2 Suction hose size 4 in 102 mm Water pump system U.S. Metric Maximum pressure 3000 psi 207 bar Flow 5.5 gpm 21 L/min Hose reel capacity with water lance 100 ft 30.
Specifications - 136 FX60/FXT60 Tier 4 Operator’s Manual FX60-1200 T26S Trailer U.S. Metric Clearance (at jack foot pad) 12 in 305 mm Adj. coupler height 18-27 in 457-686 mm Width between fenders 50 in 1.3 m Width outside fenders 100.5 in 2.6 m Number of axles 2 Coupler (square mount drawbar) 3 in or 2.5 in Type of brakes electric Lug nut torque 190-210 ft•lb 258-285 N•m Hitch bolt torque 300 ft•lb 407 N•m Electrical system 12V DC ST235/85R16, F 95 psi 6.
FX60/FXT60 Tier 4 Operator’s Manual Specifications - 137 FXT60-500 FXT60-500 Dimensions U.S. Metric L Overall length 214 in 5.4 m L1 Length sitting on truck frame 178 in 4.5 m H Height with boom 93 in 2.4 m H1 Height without boom 79 in 2m W Overall width 96 in 2.4 m W1 Width sitting on truck frame 34 in 864 mm Dry weight 6175 lb 2801 kg Weight with all tanks filled with water 12,013 lb 5449 kg Truck Information U.S.
Specifications - 138 FX60/FXT60 Tier 4 Operator’s Manual FXT60-500 Vac Tank U.S. Metric Capacity 500 gal 1893 L Length 62 in 1.6 m Diameter 50 in 1.3 m Drain valve size 6 in 152 mm Inlet valve size 4 in 102 mm Engine U.S. Metric Deutz TD2.9L4, diesel, Tier 4, turbocharged Cooling medium liquid Injection direct Number of cylinders 4 Displacement 178 in3 2.9 L Bore 3.62 in 92 mm Stroke 4.
FX60/FXT60 Tier 4 Operator’s Manual Specifications - 139 FXT60-500 Vacuum system U.S. Metric Drive type belt Displacement 1020 cfm 28.8 m3/min Maximum vacuum 16 in Hg 406 mm Hg Filter type washable polyester Filter area 130 ft2 12 m2 Suction hose size 4 in 102 mm Water system U.S. Metric Maximum pressure 3000 psi 207 bar Flow 5.5 gpm 21 L/min Hose reel capacity (locking) 50 ft 15.
Specifications - 140 FX60/FXT60 Tier 4 Operator’s Manual FXT60-800 FXT60-800 Dimensions U.S. Metric L Overall length 214 in 5.4 m L1 Length sitting on truck frame 178 in 4.5 m H Height with boom 93 in 2.4 m H1 Height without boom 79 in 2m W Overall Width 96 in 2.4 m W1 Width sitting on truck frame 34 in 864 mm Dry weight 6700 lb 3039 kg Weight with all tanks filled with water 16,708 lb 7578.6 kg Truck Information U.S. Metric 33000 lb 14968.
FX60/FXT60 Tier 4 Operator’s Manual Specifications - 141 FXT60-800 Vac Tank U.S. Metric Capacity 800 gal 3028 L Length 98 in 2.5 m Diameter 50 in 1.3 m Drain valve size 6 in 152 mm Inlet valve size 4 in 102 mm Engine U.S. Metric Deutz TD2.9L4, diesel, Tier 4, turbocharged Cooling medium liquid Injection direct Number of cylinders 4 Displacement 178 in3 2.9 L Bore 3.62 in 92 mm Stroke 4.
Specifications - 142 FX60/FXT60 Tier 4 Operator’s Manual FXT60-800 Vacuum system U.S. Metric Drive type belt 2-Lobe blower displacement 1020 cfm 28.9 m3/min Maximum vacuum 16 in Hg 405 mm Hg Filter type washable polyester Filter area 130 ft2 12 m2 Suction hose size 4 in 102 mm Water system U.S. Metric Maximum pressure 3000 psi 207 bar Flow 5.5 gpm 21 L/min Hose reel capacity (locking) 50 ft 15.
FX60/FXT60 Tier 4 Operator’s Manual Support - 143 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.
FX60/FXT60 Tier 4 Operator’s Manual Warranty - 144 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.
FX60/FXT60 Tier 4 Operator’s Manual Service Record - 147 Service Record Service Performed Date Hours CMW®
Service Record - 148 FX60/FXT60 Tier 4 Operator’s Manual Service Performed Date CMW® Hours
FX60/FXT60 Operator’s Manual Appendix - 149 Appendix Chapter Contents Tire Safety Information CMW®
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.
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.
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.
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.
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.
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.
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.
