FM5 Operator’s Manual CMW® Issue 1.
FM5 Operator’s Manual Overview - 1 Overview Chapter Contents Serial Number Location . . . . . . . . . . . . . . . . . . . . . . 2 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 • Bulleted Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 • Numbered Lists . . . . . . . . . . . . . .
Overview - 2 FM5 Operator’s Manual Serial Number Location Serial Number Location Record serial numbers and date of purchase in spaces provided. Fluid unit serial number is located as shown. Item date of manufacture date of purchase fluid unit serial number trailer serial number engine serial number Intended Use The FM5 is a self-contained drilling fluid unit capable of mixing up to 300 gal (1136 L) of drilling fluid per tank and transferring fluid under pressure to the drilling unit.
FM5 Operator’s Manual Overview - 3 Unit Components Unit Components 1. tank 3. engine 2. hopper 4. pump About This Manual This manual contains information for the proper use of this machine. See the beige Operation Overview pages for basic operating procedures. Cross references such as “See page 50” will direct you to detailed procedures. Bulleted Lists Bulleted lists provide helpful or important information or contain procedures that do not have to be performed in a specific order.
Overview - 4 CMW FM5 Operator’s Manual
FM5 Operator’s Manual Foreword - 5 Foreword This manual is an important part of your equipment. It provides safety information and operation instructions to help you use and maintain your Ditch Witch equipment. Read this manual before using your equipment. Keep it with the equipment at all times for future reference. If you sell your equipment, be sure to give this manual to the new owner. If you need a replacement copy, contact your Ditch Witch dealer.
FM5 Operator’s Manual Foreword - 6 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, Pierce Airrow, The Underground, and The Underground Authority Worldwide are registered trademarks of The Charles Machine Works, Inc.
FM5 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 17 machine controls, gauges, and indicators and how to use them Operation Overview 23 an overview for completing a job
Contents - 8 CMW FM5 Operator’s Manual
FM5 Operator’s Manual Safety - 9 Safety Chapter Contents Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Safety Alert Classifications . . . . . . . . . . . . . . . . . . 11 Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Emergency Procedures . . . . . . . . . . . . . . . . . . . . . 14 • Electric Strike Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 • If an Electric Line is Damaged . . . . . . . . . . . .
Safety - 10 FM5 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 One-Call (888-258-0808) and any utility companies which do not subscribe to One-Call. Have all underground pipes and cables located and marked before operating equipment. If you damage a utility, contact utility company.
FM5 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.
FM5 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. Deadly gases. Lack of oxygen or presence of gas will cause sickness or death. Provide ventilation. Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. Crushing weight could cause death or serious injury.
FM5 Operator’s Manual Safety - 13 Safety Alerts Fire or explosion possible. Fumes could ignite and cause burns. No smoking, no flame, no spark. Moving traffic - hazardous situation. Death or serious injury could result. Avoid moving vehicles, wear high visibility clothing, post appropriate warning signs. 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.
Safety - 14 FM5 Operator’s Manual Emergency Procedures Emergency Procedures 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 When working near electric cables, remember the following: • Electricity follows all paths to ground, not just path of least resistance.
FM5 Operator’s Manual Safety - 15 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. • Contact utility company to shut off power.
Safety - 16 FM5 Operator’s Manual Emergency Procedures 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 any ignition source(s), if this can be done safely and quickly. • Warn others that a gas line has been cut and that they should leave the area. • Leave jobsite as quickly as possible.
FM5 Operator’s Manual Controls - 17 Controls Chapter Contents Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Fluid Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FM5 Operator’s Manual Controls - 18 Engine Engine 1. Choke 4. Tachometer/Hourmeter 2. Fuel shutoff valve 5. Rope start 3. Throttle 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 from jobsite, or anytime machine is parked, close valve. This valve separates the fuel tank from the engine. Before starting engine, open valve.
FM5 Operator’s Manual Controls - 19 Engine Item Description Notes 3. Throttle To increase engine speed, move lever away from fuel tank. IMPORTANT: Increasing engine speed also increases pump flow. To decrease engine speed, move lever toward fuel tank. 4. Rope start To start engine, pull rope. 5. Tachometer/Hourmeter Displays engine rpm when engine is running. Displays engine operating time when engine is not running. Fuel shut-off valve open for this control to function.
FM5 Operator’s Manual Controls - 20 Fluid Mixing Fluid Mixing 1. Drain plug 4. Hopper valve 2. Tank discharge valve 5. Mixing jet valve 3. Circulation 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 Controls - 21 Fluid Mixing Item Description Notes 2. Tank discharge valve To allow flow from tank to fluid pump, open valve. IMPORTANT: Close valve only when disconnecting hose to fluid pump. To stop flow from tank to fluid pump, turn off engine. 3. Circulation valve To circulate fluid while mixing, open valve. See “Operation Overview” on page 23 for information about how to use this control. To stop circulation, close valve. 4.
Controls - 22 FM5 Operator’s Manual Fluid Mixing CMW
FM5 Operator’s Manual Operation Overview - 23 Operation Overview Chapter Contents Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Setting Up at Jobsite . . . . . . . . . . . . . . . . . . . . . . . 24 Mixing Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Transferring Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Operating in Cold Weather . . . . . . . . . . . . . . . . . . 26 Leaving Jobsite . . . . . . . . . . . . . . . . . . . . . . .
Operation Overview - 24 FM5 Operator’s Manual Planning 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. See drilling unit operator’s manual. IMPORTANT: Leave unit hitched to towing vehicle or properly stabilized. 3. Block trailer wheels.
FM5 Operator’s Manual Operation Overview - 25 Mixing Fluid Mixing Fluid Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. NOTICE: • Wear personal protective equipment including hard hat, safety eye wear, and hearing protection. • Do not wear jewelry or loose clothing. 1. Verify that hopper throat is not plugged before mixing. 2. Fill fluid tank with water. Allow room for additives. 3.
Operation Overview - 26 FM5 Operator’s Manual Transferring Fluid Transferring Fluid Electric shock. Contacting electric lines will cause death or serious injury. Know location of lines and stay away. NOTICE: If electrical strike occurs while fluid hose is connected to drilling unit, fluid system will also become electrified. 1. Connect hose from mixing pump to drilling unit. 2. Open hopper and discharge valves.
FM5 Operator’s Manual Prepare - 27 Prepare Chapter Contents Gather Information . . . . . . . . . . . . . . . . . . . . . . . . . 28 • Arrange for Traffic Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 • Prepare for Working Near Existing Utilities . . . . . . . . . . . . . . . . . . . . . .28 • Plan for Emergency Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 Inspect Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prepare - 28 FM5 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.
FM5 Operator’s Manual Prepare - 29 Prepare Jobsite Prepare Jobsite Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. NOTICE: • If jobsite classification is in question or if the possibility of unmarked electric utilities exists, classify jobsite as electric. • Cutting high voltage cable can cause electrocution. Expose lines by hand before digging. • All vegetation near operator’s station must be removed.
FM5 Operator’s Manual Prepare - 30 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.
FM5 Operator’s Manual Transport - 31 Transport Chapter Contents Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 • Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 • Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Haul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 • Inspect Trailer . . . . . . . . . . . . . . . . .
FM5 Operator’s Manual Transport - 32 Lift Lift Crushing weight. If load falls or moves it could kill or crush you. Use proper procedures and equipment or stay away. Points Lifting points are identified by lifting decals. Lifting at other points is unsafe and can damage machinery. Procedure Tank Use crane capable of supporting the equipment’s size and weight. See “Specifications” on page 49 or measure and weigh equipment before lifting.
FM5 Operator’s Manual Transport - 33 Haul Haul Crushing weight. If load falls or moves it could kill or crush you. Use proper procedures and equipment or stay away. 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 with a torque wrench. Adjust if needed.
Transport - 34 FM5 Operator’s Manual Haul 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 vehicle, reverse “Hitch Trailer” steps.
FM5 Operator’s Manual Drilling Fluid Concepts - 35 Drilling Fluid Concepts Chapter Contents Recommended Products . . . . . . . . . . . . . . . . . . . . 36 Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Polymer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Bentonite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Mixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 • General mixing order . . . . . . . . .
FM5 Operator’s Manual Drilling Fluid Concepts - 36 Recommended Products Recommended Products For productive drilling and equipment protection, use these recommended Baroid® products, available from your Ditch Witch dealer.
FM5 Operator’s Manual Drilling Fluid Concepts - 37 Polymer Polymer This drilling fluid additive provides excellent lubrication and increases viscosity in average soils and heavy clay. In swelling clay, polymer can reduce swelling that traps pipe in the bore. There are two types of polymer: • long chain such as Baroid EZ-Mud • medium chain such as Baroid Quik-Trol Bentonite Bentonite is a dry powder.
FM5 Operator’s Manual Drilling Fluid Concepts - 38 Mixtures 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. NOTICE: • If chemicals are added in the wrong order, they will not mix properly and will form clumps. • If tank contains bentonite/polymer mix and more drilling fluid is needed, completely empty tank and start with fresh water before mixing another batch.
FM5 Operator’s Manual Drilling Fluid Concepts - 39 Mixtures Basic Fluid Recipes Soil type Mixture/100 gal (378 L) of water Notes fine sand 35 lb (16 kg) Bore-Gel coarse sand 35 lb (16 kg) Bore-Gel .5 lb (225 g) No-Sag Add .5 lb (225 g) of Quik-Trol for additional filtrate control fine sand below water table 40 lb (18 kg) Bore-Gel .75 lb (340 g) Quik-Trol Add .5 - 1 gal (2-4 L) of Dinomul in high torque situations coarse sand below water table 40 lb (18 kg) Bore-Gel .75 lb (340 g) Quik-Trol .
Drilling Fluid Concepts - 40 FM5 Operator’s Manual Drilling Fluid Requirements Drilling Fluid Requirements 1. Determine drilling conditions and choose appropriate drilling fluid mix. 2. Estimate amount of supplies needed and check availability. • Drilling fluid • Water supply. If more water than can be carried with the unit will be needed, arrange to transport additional water. • Bentonite and/or polymer 3. Check water quality. • Use meter or pH test strips to test pH of water. If pH is below 9.
FM5 Operator’s Manual Complete the Job - 41 Complete the Job Chapter Contents Rinse Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Complete the Job - 42 FM5 Operator’s Manual Rinse Equipment Rinse Equipment Spray water onto equipment to remove dirt and mud. Disconnect Disconnect and store hoses and cables.
FM5 Operator’s Manual Service - 43 Service Chapter Contents Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Recommended Lubricants/Service Key . . . . . . . . 44 10 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 20 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 100 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FM5 Operator’s Manual Service - 44 Precautions Precautions Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly. NOTICES: • Unless otherwise instructed, all service should be performed with engine off. • Refer to engine manufacturer’s manual for engine maintenance instructions. • Refer to trailer operator’s manual for trailer service instructions.
FM5 Operator’s Manual Service - 45 10 Hour Engine Oil Temperature Chart Temperature range anticipated before next oil change 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 keep oil level at highest line on dipstick.
Service - 46 FM5 Operator’s Manual 20 Hour 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. Grease cavity is full when grease escapes from grease cylinder relief valve.
FM5 Operator’s Manual Service - 47 100 Hour 100 Hour Location Task Notes change engine oil regular service change air filter 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 fall into carburetor.
Service - 48 FM5 Operator’s Manual 100 Hour CMW
FM5 Operator’s Manual Specifications - 49 Specifications W L H j11om015h.eps 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 Mixing hopper capacity 1 ft3 28 L Suction time for 50 lb (22.
Specifications - 50 Engine FM5 Operator’s Manual U.S. Metric Honda GX160, gasoline Cooling medium air Number of cylinders 1 Displacement 9.9 in3 162 cm3 Bore 2.7 in 69 mm Stroke 1.8 in 46 mm * Maximum tilt angle fore & aft 35° * Maximum tilt angle side 35° Flywheel power @ 3600 rpm 5.5 hp 4.1 kW * Exceeding these operating angles will cause engine damage. This DOES NOT IMPLY machine is stable to maximum angle of safe engine operation. Fluid Capacities U.S. Metric Fuel tank .
FM5 Operator’s Manual Support - 51 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.
FM5 Operator’s Manual Warranty - 52 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 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 SK500 attachments).
FM5 Operator’s Manual Service Record - 55 Service Record Service Performed Date Hours CMW
Service Record - 56 Service Performed CMW FM5 Operator’s Manual Date Hours
