Ditch Witch FX20 User Manual

FX20

Operator’s Manual

CMW

Issue 1.1

053-1270

FX20 Operator’s Manual Overview - 1

Overview

Chapter Contents

Serial Number Location . . . . . . . . . . . . . . . . . . . . . . 2

Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Operator Orientation. . . . . . . . . . . . . . . . . . . . . . . . . 4

About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 4

• Bulleted Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

• Numbered Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

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Overview - 2 FX20 Operator’s Manual

Serial Number Location

Record serial numbers and date of purchase in spaces provided. FX20 serial number is located as shown.

Date of manufacture Date of purchase FX20 serial number (shown) Engine serial number Blower serial number Water pump serial number Trailer serial number

Intended Use

The FX20 is a self-contained vacuum excavation unit capable of vacuuming a wide variety of nonhazardous, non-flammable liquid and solid debris. It is designe d to perform efficient soft excavation, including exposing utilities for visual verification and/or potholing, and is intended for operation in ambient temperatures from 0° to 115°F (-18° to 46°C). Use in any other way is considered contrary to the intended use.

The FX20 should be operated, serviced, and repaired only by persons familiar with its particular characteristics and acquainted with the relevant safety procedures.

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FX20 Operator’s Manual Overview - 3

Unit Components

1. Cyclonic filter reservoir

2. Cyclonic filter

3. Air pre-filter

4. Blower

5. Water tank

6. Blower silencer

7. Potholing tools

8. Door prop

9. Vacuum tank

10. Vacuum filter

11. Antifreeze tank

12. Battery

13. Water pump

14. Operator’s station

15. Engine

16. Fuel tank

17. Wash wand

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Overview - 4 FX20 Operator’s Manual

Operator Orientation

1. Rear of unit

2. Left of unit

Right and left sides of machine are determined by facing towing vehicle.

3. Front of unit

4. Right of unit

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.

Bulleted Lists

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

Numbered Lists

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

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FX20 Operator’s Manual Foreword - 5

Reporting Safety Defects (Trailer-Mounted Units)

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 equipmen t at all times for future reference. If you sell your equipment, be sure to give this manual to the new owner.

If you need a replacement copy, contact your Ditch Witch dealer. If you need assistance in locating a dealer, visit our website at www.ditchwitch.com or write to the following address:

The Charles Machine Works, Inc. Attn: Marketing Department PO Box 66 Perry, OK 73077-0066 USA

The descriptions and specifications in this manual are subject to change without notice. The Charles Machine Works, Inc. reserves the right to improve equipment. Some product improvements may have taken place after this manual was publishe d. For the latest information on Ditch Witch equipment, see your Ditch Witch dealer.

Thank you for buying and using Ditch Witch equipment.

Reporting Safety Defects (Trailer-Mounted Units)

If you believe that your vehicle has a defect which could cau se a cr ash o r co uld ca use injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying the Product Safety Coordinator at The Charles Machine Works, Inc.

If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in any individual problems between you, your Ditch Witch dealer, or The Charles Machine Works, Inc.

To contact NHTSA you may either call the Auto Safety Hotline toll-free at 1-888-327-4236 (TTY: 1-800424-9153), go to http://www.safercar.gov, or write to:

Administrator NHTSA 1200 New Jersey Avenue S.E. Washington, DC 20590

You can also obtain other information about motor vehicle safety from http://www.safe rcar.gov.

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Foreword - 6 FX20 Operator’s Manual

FX20

Operator’s Manual

Issue number 1.1/OM-6/08

Part number 053-1270

by The Charles Machine Works, Inc.

, Ditch Witch, CMW, AutoCrowd, Jet Trac, Roto Witch, Subsite, Fluid Miser, Power Pipe, Super Witch, Pierce Airrow, The Underground, The Underground Authority Worldwide, and Zahn are registered trademarks of The Ch ar les Mac hin e Works, Inc.

U.S. patents pending.

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FX20 Operator’s Manual Contents - 7

Content s

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

Foreword

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

Safety

machine safety alerts and emergency procedures

Controls

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

Operation Overview

an overview for completing a job with this machine: planning, setting up, vacuuming, potholing, and restoring the jobsite; with cross references to detailed procedures

Prepare

procedures for inspecting and classifying the jobsite, and preparing the jobsite for work

Transport

procedures for lifting and hauling

Vacuum and Pothole

procedures for removing debris and potholing utility locations

Complete the Job

procedures for restoring the jobsite and rinsing and storing equipment

Service

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

Specifications

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

Support

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

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Contents - 8 FX20 Operator’s Manual

Service Record

a record of major service performed on the machine

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FX20 Operator’s Manual Safety - 9

Safety

Chapter Contents

Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Safety Alert Classifications . . . . . . . . . . . . . . . . . . 11

Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Emergency Procedures . . . . . . . . . . . . . . . . . . . . . 15

• Electric Strike Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

• If an Electric Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

• If a Gas Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

• If a Fiber Optic Cable is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

• If Machine Catches on Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

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Safety - 10 FX20 Operator’s Manual

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.

• Classify jobsite based on its hazards and use cor rect tools and machin ery, safety equipment, and work

methods for jobsite.

• Mark jobsite clearly and keep spectators away.

• Wear personal protective equipment.

• Review jobsite hazards, safety and emergency procedures, and individual responsibilities with all

personnel before work begins. Safety videos are available from your Ditch Witch dealer.

• Replace missing or damaged safety shields and safety signs.

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

• Do not operate unit where flammable gas may be present.

• Contact your Ditch Witch dealer if you have any question about operation, ma intenance, or equipment

use.

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FX20 Operator’s Manual Safety - 11

Safety Alert Classifications

These classifications and the icons defined on the following pages work together to alert you to situations which could be harmful to you, jobsite bystanders or your equipment. When you see these words and icons in the book or on the machine, carefully read and follow all instructions. YOUR SAFETY IS AT STAKE.

Watch for the three safety alert levels: DANGER, WARNING and CAUTION. Learn what each level means.

indicates an imminently hazardous situation which, if not avoided, will result in death or

serious injury.

indicates a potentially hazardous situation which, if not avoided, could result in death or

serious injury.

indicates a potentially hazardous situation which, if not avoided, may result in minor or

moderate injury.

Watch for two other words: NOTICE and IMPORTANT. NOTICE can keep you from doing something that might damage the machine or someone's property. It

can also alert you against unsafe practices.

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

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Safety - 12 FX20 Operator’s Manual

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.

Confined space will cause suffocation. Use proper procedures for entering

or stay away.

Vacuum will suffocate. Maintain distance between face and vacuum inlets.

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

Crushing weight could cause death or seriou s injur y. Use

proper procedures and equipment or stay away.

Moving parts could cut off hand or foot. Stay away.

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FX20 Operator’s Manual Safety - 13

Safety Alerts

Explosion possible. Serious injury or equipment damage could occur.

Follow directions carefully .

Incorrect procedures could result in death, injury, or property damage.

Learn to use equipment correctly.

Improper control function could cause death or serious injury. If control does

not work as described in instructions, stop machine and have it serviced.

Fire or explosion possible. Fumes could ignite and cause burns. No

smoking, no flame, no spark.

Moving traffic - hazardous situation. Death or serious injury could result.

Avoid moving vehicles, wear high visibility clothing, post appropriate warning signs.

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Safety - 14 FX20 Operator’s Manual

Safety Alerts

Hot pressurized cooling system fluid could cause serious burns. Allow to

cool before servicing.

Flying objects may cause injury. Wear hard hat and safety glasses.

Hot parts may cause burns. Do not touch until cool.

Exposure to high noise levels may cause hearing loss. Wear hearing

protection.

Fall possible. Slips or trips may result in injury. Keep area clean.

Battery acid may cause burns. Avoid contact.

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

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FX20 Operator’s Manual Safety - 15

Emergency Procedures

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

Before operating any equipment, review emergency proc edures and check that all safety precau tions have been taken.

EMERGENCY SHUTDOWN - Turn ignition switch to stop position or push remote e ngine stop button ( if equipped).

Electric Strike Description

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

Know location of lines and stay away.

When working near electric cables, remember the following:

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

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

• Low voltage current can injure or kill. Almost one-third of work-related electrocutions result from contact with less than 440 volts.

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

• power outage

•smoke

•explosion

• popping noises

• arcing electricity

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

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Safety - 16 FX20 Operator’s Manual

Emergency Procedures

If an Electric Line is Damaged

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

• Warn people nearby that an electric strike has occurred. Instruct them to leave the area and contact utility.

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

• Do not allow anyone to touch equipment.

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

• LEAVE AREA.

• Contact utility company to shut off power.

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

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FX20 Operator’s Manual Safety - 17

Emergency Procedures

If a Gas Line is Damaged

Fire or explosion possible. Fumes could ignite and cause burns. No

smoking, no flame, no spark.

Explosion possible. Serious injury or equipment damage could occur.

Follow directions carefully.

If you suspect a gas line has been damaged, take the following actions. The order and degree of action will depend on the situation.

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

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

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

• Leave jobsite as quickly as possible.

• Immediately call your local emergency phone number and utility company.

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

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

If a Fiber Optic Cable is Damaged

Do not look into cut ends of fiber optic or unidentified cable. Vision damage can occur.

If Machine Catches on Fire

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

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

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

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

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Safety - 18 FX20 Operator’s Manual

Emergency Procedures

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FX20 Operator’s Manual Controls - 19

Controls

Chapter Contents

Engine/Operator’s Station . . . . . . . . . . . . . . . . . . . 20

Machine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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Controls - 20 FX20 Operator’s Manual

Engine/Operator’s Station

Engine/Operator ’s Station

1. Throttle

2. Choke

3. Ignition switch

4. Water pressure gauge

Item Description Notes

1. Throttle To increase engine speed,

move left. To decrease engine speed,

move right.

2. Choke To choke cold engine, move left.

To operate normally, move right.

5. Hourmeter

6. Water pump switch

7. Auxiliary outlet

8. Water pressure control

NOTICE: Set engine speed to full throttle before turning off engine.

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FX20 Operator’s Manual Controls - 21

Engine/Operator’s Station

Item Description Notes

3. Ignition switch T o star t engine, insert key and

turn clockwise. To stop engine, turn key

counterclockwise.

4. Water pressure gauge Displays water pressure when water pressure switch is on and water lance is in use.

5. Hourmeter Displays engine operating time.

6. Water pump switch To turn on water pump, press top.

IMPORTANT: When engine is on, blower operates and vacuum is present at tank inlet.

NOTICE: Set engine speed to full throttle before turning off engine.

Hourmeter runs when ignition switch is on.

Use these times to schedule service.

To turn off water pump, move to center position.

To bypass low water indication, press bottom.

7. Auxiliary outlets To operate work lights or other 12V devices, plug into outlet.

Use bypass to feed antifreeze into system when freshwater tank is empty. See “Add Antifreeze” on page 52.

Outlet has power only when ignition switch is on.

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Controls - 22 FX20 Operator’s Manual

Engine/Operator’s Station

Item Description Notes

8. Water pressure control To increase water pressure,

turn clockwise. To decrease water pressure,

turn counterclockwise.

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FX20 Operator’s Manual Controls - 23

Machine Controls

1. Debris tank sight glass

2. Inlet valve

3. Cyclonic filter sight glass

4. Battery disconnect switch

5. Vacuum gauge

Item Description Notes

1. Debris tank sight glass

2. Inlet valve To close valve (stop suction),

rotate up. To open valve (start suction),

rotate down.

3. Cyclonic filter sight

glass

6. Tank door handle

7. Drain valve

8. Water tank drain valve

9. Antifreeze tank supply valve

10. Water tank supply valve

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Controls - 24 FX20 Operator’s Manual

Machine Controls

Item Description Notes

4. Battery disconnect

To connect, turn clockwise.

switch

To disconnect, turn counterclockwise.

5. Vacuum gauge Displays blower vacuum reading in inches of mercury. Vacuum relief valve opens when vacuum reaches 15” (381 mm).

6. Tank door handle To close tank door, turn clockwise several times.

To open tank door, turn counterclockwise several times.

IMPORTANT: Use battery disconnect switch when servicing, welding, and during long-term storage.

IMPORTANT: Do not push on door when closing with handle.

c00ic176h.eps

7. Drain valve To drain tank, rotate down. To close drain, rotate up.

8. Water t ank supply va lve 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.

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IMPORTANT: Water tank supply

valve or antifreeze supply valve must be open when pump is running or pump will be damaged.

FX20 Operator’s Manual Controls - 25

Machine Controls

Item Description Notes

9. Antifreeze tank supply

valve

10. Water tank drain valve To drain tank, open valve.

To open valve (send antifreeze through pump and water lance), rotate counterclockwise.

To close valve (stop antifreeze flow), rotate clockwise.

Close valve when tank is empty.

IMPORTANT:

• Water tank supply valve or antifreeze supply valve must be open when pump is running or pump will be damaged.

• Close supply valve when using antifreeze valve.

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Controls - 26 FX20 Operator’s Manual

Machine Controls

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FX20 Operator’s Manual Operation Overview - 27

Operation Overview

Chapter Contents

Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Setting Up at Jobsite . . . . . . . . . . . . . . . . . . . . . . . 28

Vacuuming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Potholing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Leaving Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Storing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 29

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Operation Overview - 28 FX20 Operator’s Manual

Planning

1. Gather information about jobsite (page 32).

2. Inspect jobsite (page 33).

3. Check supplies and prepare equipment (page 35).

Setting Up at Jobsite

1. Prepare jobsite (page 34).

2. Position vacuum excavation unit.

3. Leave unit hitched to towing vehicle or properly stabilized if trailer-mounted unit.

4. Block trailer wheels if trailer-mounted unit.

Vacuuming

1. Connect hoses (page 44).

2. Start unit (page 44).

3. Remove debris (page 45).

4. Disconnect hoses.

5. Drain tank (page 48).

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FX20 Operator’s Manual Operation Overview - 29

Potholing

1. Connect hoses (page 44).

2. Start unit (page 44).

3. Pothole (page 46).

4. Disconnect hoses.

5. Drain tank (page 48).

Leaving Jobsite

1. Rinse unit and tools (page 53).

2. Stow tools (page 53).

Storing Equipment

1. For cold weather storage, antifreeze vacuum excavation unit (page 52) .

2. For long-term storage, disconnect battery disconnect switch (page 23).

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+ 70 hidden pages