HP FM5 - Manual

FM5 Operator’s Manual Foreword - 5 CMW 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...

Foreword - 6 FM5 Operator’s Manual CMW FM5 Operator’s Manual Issue number 1.1/OM-11/03 Part number 054-121 Copyright 2003 by The Charles Machine Works, Inc. , Ditch Witch, CMW, AutoCrowd, Modularmatic, Jet Trac, Roto Witch, Subsite, Fluid Miser, Perma-Soil, Power Pipe, Super Witch, Super Witch II, P...

FM5 Operator’s Manual Contents - 7 CMW Contents Overview machine serial number, information about the type of work this machine is designed to perform, basic machine components, and how to use this manual 1 Foreword part number, revision level, and publication date of this manual, and factory contac...

FM5 Operator’s Manual Safety - 9 CMW Safety Chapter Contents Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Safety Alert Classifications . . . . . . . . . . . . . . . . . . 11 Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Emergency Proced...

Safety - 10 FM5 Operator’s Manual Guidelines CMW Guidelines Follow these guidelines before operating any jobsite equipment: • Complete proper training and read operator’s manual before using equipment. • Contact One-Call (888-258-0808) and any utility companies which do not subscribe to One-Call. Ha...

FM5 Operator’s Manual Safety - 11 Safety Alert Classifications CMW 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 an...

Safety - 12 FM5 Operator’s Manual Safety Alerts CMW Safety Alerts Electric shock. Contacting electric lines will cause death or serious injury. Know location of lines and stay away. Deadly gases. Lack of oxygen or presence of gas will cause sickness or death. Provide ventilation. Jobsite hazards cou...

Safety - 14 FM5 Operator’s Manual Emergency Procedures CMW Emergency Procedures Before operating any equipment, review emergency procedures and check that all safety precautions have been taken. Electric Strike Description When working near electric cables, remember the following: • Electricity foll...

FM5 Operator’s Manual Safety - 15 Emergency Procedures CMW 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 situat...

Safety - 16 FM5 Operator’s Manual Emergency Procedures CMW If a Gas Line is Damaged 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. • Remove ...

FM5 Operator’s Manual Controls - 17 CMW Controls Chapter Contents Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Fluid Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Controls - 18 FM5 Operator’s Manual Engine CMW Engine 1. Choke 2. Fuel shutoff valve 3. Throttle 4. Tachometer/Hourmeter 5. Rope start Item Description Notes 1. Choke To help start cold engine, close valve. This valve regulates air/fuel mixture. 2. Fuel shutoff valve When transporting unit to or fro...

Controls - 20 FM5 Operator’s Manual Fluid Mixing CMW Fluid Mixing 1. Drain plug 2. Tank discharge valve 3. Circulation valve 4. Hopper valve 5. Mixing jet valve 6. Discharge valve Item Description Notes 1. Drain plug To drain fluid from tank, remove plug. IMPORTANT: Install plug before filling tank.

FM5 Operator’s Manual Operation Overview - 23 CMW Operation Overview Chapter Contents Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Setting Up at Jobsite . . . . . . . . . . . . . . . . . . . . . . . 24 Mixing Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . ...

Operation Overview - 24 FM5 Operator’s Manual Planning CMW Planning 1. Gather information about jobsite (page 28). 2. Inspect jobsite (page 28). 3. Check supplies and prepare equipment (page 30). Setting Up at Jobsite 1. Prepare jobsite (page 29). 2. Position fluid unit and connect to drilling unit....

FM5 Operator’s Manual Operation Overview - 25 Mixing Fluid CMW Mixing Fluid 1. Verify that hopper throat is not plugged before mixing. 2. Fill fluid tank with water. Allow room for additives. 3. Open circulation valve and tank discharge valve. 4. Start engine and run at half throttle or higher. 5. O...

Operation Overview - 26 FM5 Operator’s Manual Transferring Fluid CMW Transferring Fluid 1. Connect hose from mixing pump to drilling unit. 2. Open hopper and discharge valves. 3. Adjust engine throttle to give desired flow rate to drilling unit. • Half throttle is recommended for most drilling situa...

FM5 Operator’s Manual Prepare - 27 CMW Prepare Chapter Contents Gather Information . . . . . . . . . . . . . . . . . . . . . . . . . 28 • Arrange for Traffic Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 • Prepare for Working Near Existing Utilities . . . . . . . . ...

Prepare - 28 FM5 Operator’s Manual Gather Information CMW 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, conta...

FM5 Operator’s Manual Prepare - 29 Prepare Jobsite CMW Prepare Jobsite Install Fluid Unit Consider Load Requirements Installation Tips • Drill holes through trailer cross members to provide adequate connection to trailer structure, not just deck boards. • Use high-quality, properly-sized mounting ha...

Prepare - 30 FM5 Operator’s Manual Check Supplies and Prepare Equipment CMW 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 classif...

FM5 Operator’s Manual Transport - 31 CMW Transport Chapter Contents Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 • Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 • Procedure . . . . . . . . . . . ....

Transport - 32 FM5 Operator’s Manual Lift CMW Lift Points Lifting points are identified by lifting decals. Lifting at other points is unsafe and can damage machinery. Procedure Tank Use crane capable of supporting the equipment’s size and weight. See “Specifications” on page 49 or measure and weigh ...

FM5 Operator’s Manual Transport - 33 Haul CMW Haul Inspect Trailer • Check hitch for wear and cracks. Lubricate if needed. • Check battery for 12V charge. • Inspect lights for cleanliness and correct operation. Inspect reflectors and replace if needed. • Check tire pressure. Check lug nut torque wit...

Transport - 34 FM5 Operator’s Manual Haul CMW Unhitch Trailer 1. Stop tow vehicle and trailer on level ground. 2. Put manual transmission into first or reverse gear or automatic transmission into park. Turn off ignition. Set parking brake. 3. Block trailer wheels. 4. To unhitch trailer from tow vehi...

FM5 Operator’s Manual Drilling Fluid Concepts - 35 CMW Drilling Fluid Concepts Chapter Contents Recommended Products . . . . . . . . . . . . . . . . . . . . 36 Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Polymer . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

Drilling Fluid Concepts - 36 FM5 Operator’s Manual Recommended Products CMW Recommended Products For productive drilling and equipment protection, use these recommended Baroid ® products, available from your Ditch Witch dealer. • Soda ash • Quik-Gel™ dry powder bentonite (p/n 259-804) • E-Z Mud™ liq...

FM5 Operator’s Manual Drilling Fluid Concepts - 37 Polymer CMW Polymer This drilling fluid additive provides excellent lubrication and increases viscosity in average soils and heavy clay. In swelling clay, polymer can reduce swelling that traps pipe in the bore. There are two types of polymer: • lon...

Drilling Fluid Concepts - 38 FM5 Operator’s Manual Mixtures CMW Mixtures Bentonite does not mix well in water containing polymer. To use both, mix bentonite first, then add polymer. When adding other products follow the order listed below. General mixing order 1. Soda ash 2. Bentonite 3. Polymer 4. ...

FM5 Operator’s Manual Drilling Fluid Concepts - 39 Mixtures CMW Basic Fluid Recipes Soil type Mixture/100 gal (378 L) of water Notes fine sand 35 lb (16 kg) Bore-Gel coarse sand 35 lb (16 kg) Bore-Gel.5 lb (225 g) No-Sag Add .5 lb (225 g) of Quik-Trol for additional filtrate control fine sand below ...

Drilling Fluid Concepts - 40 FM5 Operator’s Manual Drilling Fluid Requirements CMW Drilling Fluid Requirements 1. Determine drilling conditions and choose appropriate drilling fluid mix. 2. Estimate amount of supplies needed and check availability. • Drilling fluid • Water supply. If more water than...

FM5 Operator’s Manual Complete the Job - 41 CMW Complete the Job Chapter Contents Rinse Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Complete the Job - 42 FM5 Operator’s Manual Rinse Equipment CMW Rinse Equipment Spray water onto equipment to remove dirt and mud. Disconnect Disconnect and store hoses and cables.

FM5 Operator’s Manual Service - 43 CMW Service Chapter Contents Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Recommended Lubricants/Service Key . . . . . . . . 44 10 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 20 Hour . . . . . . . . . . ...

Service - 44 FM5 Operator’s Manual Precautions CMW Precautions Recommended Lubricants/Service Key Proper lubrication and maintenance protects Ditch Witch equipment from damage and failure. Service intervals listed are for minimum requirements. In extreme conditions, service machine more frequently. ...

FM5 Operator’s Manual Service - 45 10 Hour CMW Engine Oil Temperature Chart 10 Hour Check Engine Oil Check engine oil at dipstick (shown) before operation and every 10 hours thereafter. Check with unit on level surface and at least 15 minutes after stopping engine. Add GEO at fill as necessary to ke...

Service - 46 FM5 Operator’s Manual 20 Hour CMW 20 Hour Change Engine Oil (Initial Service) Change oil after first 20 hours. Pull drain plug and drain crankcase while oil is still warm. Refill at fill neck with 2.3 pt (1.1 L) of GEO. 50 Hour Grease Pump Lube grease fitting with NLGI #1 every 50 hours...

FM5 Operator’s Manual Service - 47 100 Hour CMW 100 Hour Change Engine Oil Change oil every 100 hours. Pull drain plug and drain crankcase while oil is still warm. Refill at fill neck with 2.3 pt (1.1 L) of GEO. Change Air Filter Change foam air filter element every 100 hours. Do not allow dirt to f...

FM5 Operator’s Manual Specifications - 49 CMW Specifications Dimensions U.S. Metric A Length 123 in 3.1 m B Height 53 in 1.3 m C Width 25.6 in 650 mm Weight, empty 660 lb 299 kg Weight, with full tank (water) 3164 lb 1435 kg Performance U.S. Metric Maximum flow rate at 26 viscosity 160 gpm 606 L/min...

FM5 Operator’s Manual Support - 51 Procedure CMW 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 o...

Warranty - 52 FM5 Operator’s Manual CMW Warranty Ditch Witch Equipment and Parts Limited Warranty Policy Subject to the limitations 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 Charl...

FM5 Operator’s Manual Service Record - 55 CMW Service Record Service Performed Date Hours