FX25
Operator’s
Manual
CMW
®
Issue 2.1
053-2379
FX25 Operator’s Manual Overview - 1
Overview
Chapter Contents
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . 2
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Equipment Modification . . . . . . . . . . . . . . . . . . . . . 3
Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operator Orientation. . . . . . . . . . . . . . . . . . . . . . . . . 4
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 4
• Bulleted Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
• Numbered Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CMW
Overview - 2 FX25 Operator’s Manual
j32om001h.jpg
Serial Number Location
Serial Number Location
Record serial numbers and date of purchase in spaces provided. FX25 serial number is located as shown.
j32om001h.jpg
Date of manufacture
Date of purchase
FX25 serial number (shown)
Engine serial number
Blower serial number
Water pump serial number
Trailer serial number
Intended Use
The FX25 is a self-contained vacuum excavation unit capable of vacuuming a wide variety of nonhazardous, non-flammable liquid and solid debris. It is designed to perform efficient soft excavation,
including exposing utilities for visual verification and/or potholing. The optional reverse flow system allows
for spoils transfer to another tank. The FX25 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 FX25 should be operated, serviced, and repaired only by persons familiar with its particular
characteristics and acquainted with the relevant safety procedures.
CMW
FX25 Operator’s Manual Overview - 3
1
2
33445
6
7
8
10
9
11
12
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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. Modification of equipment should only be made by
competent personnel possessing knowledge of applicable standards, regulations, equipment design
functionality/requirements and any required specialized testing.
Unit Components
j32om002h.eps
1
7
2
9
8
10
5
11
6
12
1. Inlet valve
2. Primary shut-off valve
3. Vacuum tank
4. Water tank
5. Operator’s station
6. Power pack
7. Hose reel
8. Potholing tools
9. Tool storage
10. Antifreeze tank
11. Vacuum filter
12. Drain/Outlet valve
CMW
Overview - 4 FX25 Operator’s Manual
1
2
3
4
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Operator Orientation
Operator Orientation
1. Front of unit
2. Right of unit
Right and left sides of machine are determined by
facing towing vehicle.
3. Rear of unit
4. Left of unit
4
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1
2
3
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.
CMW
FX25 Operator’s Manual Foreword - 5
Reporting Safety Defects
Foreword
This manual is an important part of your equipment. It provides safety information and operation
instructions to help you use and maintain your Ditch Witch equipment.
Read this manual before using your equipment. Keep it with the equipment at all times for future reference.
If you sell your equipment, be sure to give this manual to the new owner.
If you need a replacement copy, contact your Ditch Witch dealer. 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 published. 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
If you believe that your vehicle has a defect which could cause a crash or could cause 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.safercar.gov.
CMW
Foreword - 6 FX25 Operator’s Manual
Works, Inc.
FX25
Operator’s Manual
Issue number 2.1/OM-4/13
Part number 053-2379
Copyright 2011, 2012, 2013
by The Charles Machine Works, Inc.
, Ditch Witch, and CMW are registered trademarks of The Charles Machine
U.S. patents pending.
CMW
FX25 Operator’s Manual Contents - 7
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
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
1
5
9
19
29
33
39
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
43
57
61
99
105
CMW
Contents - 8 FX25 Operator’s Manual
Service Record
a record of major service performed on the machine
Appendix
additional information about Ditch Witch equipment
109
111
CMW
FX25 Operator’s Manual Safety - 9
Safety
Chapter Contents
Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Safety Alert Classifications . . . . . . . . . . . . . . . . . . 11
Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Emergency Procedures . . . . . . . . . . . . . . . . . . . . . 15
• Electric Strike Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
• If an Electric Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
• If a Gas Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
• If a Fiber Optic Cable is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
• If Machine Catches on Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CMW
Safety - 10 FX25 Operator’s Manual
Guidelines
Guidelines
Follow these guidelines before operating any jobsite equipment:
• Complete proper training and read operator’s manual before using equipment.
• Contact your local One-Call (811 in USA) or the One-Call referral number (888-258-0808 in USA and
Canada) to have underground utilities located before digging. Also contact any utilities that do not
participate in the One-Call service. Mark proposed path with white paint prior to contacting One-Call or
utilities.
• Classify jobsite based on its hazards and use correct tools and machinery, 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, maintenance, or equipment
use.
CMW
FX25 Operator’s Manual Safety - 11
Safety Alert Classifications
Safety Alert Classifications
These classifications and the icons defined on the following pages work together to alert you to situations
which could be harmful to you, jobsite bystanders or your equipment. When you see these words and
icons in the book or on the machine, carefully read and follow all instructions. YOUR SAFETY IS AT
STAKE.
Watch for the three safety alert levels: DANGER, WARNING and CAUTION. Learn what each level
means.
indicates a hazardous situation that, if not avoided, will result in death or serious injury.
This signal word is to be limited to the most extreme situations.
indicates a hazardous situation that, if not avoided, could result in death or serious injury.
indicates a hazardous situation that, if not avoided, could result in minor or moderate
injury.
Watch for two other words: NOTICE and IMPORTANT.
NOTICE indicates information considered important, but not hazard-related (e.g., messages relating to
property damage).
IMPORTANT can help you do a better job or make your job easier in some way.
CMW
Safety - 12 FX25 Operator’s Manual
Safety Alerts
Safety Alerts
Electric shock. Contacting electric lines will cause death or serious injury.
Know location of lines and stay away.
Confined space will cause suffocation. Use proper procedures for entering
or stay away.
Vacuum will suffocate. Maintain distance between face and vacuum inlets.
correct equipment and work methods. Use and maintain proper safety
equipment.
proper procedures and equipment or stay away.
Explosion possible. Serious injury or equipment damage could occur.
Follow directions carefully.
Jobsite hazards could cause death or serious injury. Use
Crushing weight could cause death or serious injury. Use
Moving parts could cut off hand or foot. Stay away.
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Incorrect procedures could result in death, injury, or property damage.
Learn to use equipment correctly.
FX25 Operator’s Manual Safety - 13
Safety Alerts
Improper control function could cause death or serious injury. If control does
not work as described in instructions, stop machine and have it serviced.
Fire or explosion possible. Fumes could ignite and cause burns. No
smoking, no flame, no spark.
Avoid static electricity when fueling. Ultra Low Sulfur Diesel (ULSD) poses a
greater static ignition hazard than earlier diesel formulations. Avoid death or serious injury
from fire or explosion. Consult with your fuel system supplier to ensure the delivery system
is in compliance with fueling standards for proper grounding and bonding practices.
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 FX25 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).
Breathing crystalline silica dust may cause lung disease. Cutting, drilling, or
working materials such as concrete, sand, or rock containing quartz may result in exposure
to silica dust. Use dust control methods or appropriate breathing protection when exposed
to silica dust.
CMW
FX25 Operator’s Manual Safety - 15
Emergency Procedures
Emergency Procedures
Jobsite hazards could cause death or serious injury. Use
correct equipment and work methods. Use and maintain proper safety
equipment.
Before operating any equipment, review emergency procedures and check that all safety precautions have
been taken.
EMERGENCY SHUTDOWN - Turn ignition switch to stop position or push remote engine stop button (if
equipped).
Electric Strike Description
Electric shock. 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. Many 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.
CMW
Safety - 16 FX25 Operator’s Manual
Emergency Procedures
If an Electric Line is Damaged
If you suspect an electric line has been damaged and you are on truck or trailer, DO NOT MOVE.
Remain on truck or trailer and take the following actions. The order and degree of action will depend on the
situation.
• Warn people nearby that an electric strike has occurred. Instruct them to leave the area and contact
utility.
• Do not allow anyone into area until given permission by utility company.
• 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. The ground surface may be electrified so take small shuffle steps with feet close
together to reduce the hazard of being shocked from one foot to the other.
• Contact utility company to shut off power.
• Do not return to area or allow anyone into area until given permission by utility company.
CMW
FX25 Operator’s Manual Safety - 17
Emergency Procedures
If a Gas Line is Damaged
Fire or explosion possible. Fumes could ignite and cause burns. No
smoking, no flame, no spark.
Explosion possible. Serious injury or equipment damage could occur.
Follow directions carefully.
If you suspect a gas line has been damaged, take the following actions. The order and degree of action will
depend on the situation.
• Immediately shut off engine(s), if this can be done safely and quickly.
• 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.
CMW
Safety - 18 FX25 Operator’s Manual
Emergency Procedures
If a Fiber Optic Cable is Damaged
Do not look into cut ends of fiber optic or unidentified cable. Vision damage can occur.
If Machine Catches on Fire
Perform emergency shutdown procedure and then take the following actions. The order and degree of
action will depend on the situation.
• Immediately move battery disconnect switch (if equipped and accessible) to disconnect position.
• 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.
CMW
FX25 Operator’s Manual Controls - 19
Controls
Chapter Contents
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Operator’s Station . . . . . . . . . . . . . . . . . . . . . . . . . 21
Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CMW
Controls - 20 FX25 Operator’s Manual
Engine
Engine
1
2
3
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1. Fuel level sight glasses
2. Throttle
Item Description Notes
1. Fuel level sight glasses Monitor sight glasses to
determine fuel level.
2. Throttle To increase engine speed,
move to right.
To decrease engine speed,
move to left.
3. Choke To help start cold engine, pull
knob.
When engine has warmed,
push in completely.
4. Ignition switch To start engine, insert key and
turn clockwise.
To stop engine, turn key
counterclockwise.
4
3. Choke
4. Ignition switch
IMPORTANT: Run engine at full
throttle during operation.
IMPORTANT:
• When engine is on, blower
operates and vacuum is present
at tank inlet.
CMW
• All indicators should light briefly at
startup.
FX25 Operator’s Manual Controls - 21
2
3
4
5
6
7
8
9
1
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Operator Station
Operator Station
1
5
4
3
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1. Flow direction control (optional)
2. Water pressure gauge
3. Auxiliary outlet
4. Hourmeter
5. Battery disconnect switch
2
6
7
9
6. Hydraulic function switch
7. Water pressure switch
8. Water pressure control
9. Tethered tank control outlet
8
Item Description Notes
1. Flow direction control To operate in reverse flow
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mode, turn counterclockwise.
To operate in vacuum mode,
turn clockwise.
Use optional reverse flow to unload
tank contents to another tank.
Operate in reverse flow mode only
when drain/outlet valve is open.
CMW
Controls - 22 FX25 Operator’s Manual
Operator Station
Item Description Notes
2. Water pressure gauge Displays water pressure
when water pressure switch
is on and spray wand is in
use.
3. Auxiliary outlet To operate work lights or
other 12V devices, plug into
outlet.
4. Hourmeter Displays engine operating
time.
c00ic112t.eps
5. Battery disconnect
To connect, turn clockwise.
switch
To disconnect, turn
counterclockwise.
Outlet has power only when ignition
switch is on.
Hourmeter runs when engine is
running.
Use these times to schedule service.
IMPORTANT: Use battery disconnect
switch when servicing, welding, and
during long-term storage.
CMW
_
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+
_
+
FX25 Operator’s Manual Controls - 23
Operator Station
Item Description Notes
6. Hydraulic function
switch
To operate the vacuum boom
option, press top.
To operate hydraulic door lift,
move to center position.
To operate hydraulic tank tilt,
press bottom.
7. Water pressure control To increase water pressure,
turn clockwise.
To decrease water pressure,
turn counterclockwise.
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8. Water pressure switch To turn on water pump, press
top.
To turn off water pump, move
to center position.
c00ic114t.eps
9. Tethered tank control
outlet
To bypass low water
indication, press bottom.
Water pump will operate for
60 seconds.
Connection for tethered tank
control.
Use bypass to feed antifreeze into
system when freshwater tank is
empty. See “Add Antifreeze” on
page 58.
CMW
Controls - 24 FX25 Operator’s Manual
Operator Station
Item Description Notes
Tethered tank control To lift and lower tank, set
hydraulic function switch to
the tank position, then
• To lift tank, press UP.
U P
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DOWN
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• To lower tank, press
DOWN.
To open and close tank door,
set hydraulic function switch
to the door position, then
• To open door, press UP.
• To close door, press
DOWN.
NOTICE: When opening and closing
door, stand in a position with a full
view of the door.
CMW
FX25 Operator’s Manual Controls - 25
1
2
7
4
3
6
5
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Machine
Machine
j32om005h.eps
1
7
2
3
6
5
4
1. Inlet valve
2. Water tank supply valve
3. Water tank drain
4. Drain/Outlet valve
Item Description Notes
1. Inlet valve To close valve (stop suction),
rotate up.
To open valve (start suction),
rotate down.
5. Reverse flow gauge (optional)
6. Antifreeze tank supply valve
7. Vacuum gauge
NOTICE: Do not idle engine with inlet
valve closed.
CMW
Controls - 26 FX25 Operator’s Manual
Machine
Item Description Notes
2. Water tank supply valve To open valve (send water
from the water tank through
the pump and water lance),
rotate counterclockwise.
To close valve (stop water
flow), rotate clockwise.
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3. Water tank drain To drain tank, open valve.
Close valve when tank is
empty.
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4. Drain/Outlet valve To drain tank, rotate down.
To close drain, rotate up.
IMPORTANT: Water tank supply
valve or antifreeze supply valve must
be open when pump is running or
pump will be damaged.
5. Reverse flow gauge Displays reverse flow
pressure.
CMW
FX25 Operator’s Manual Controls - 27
Machine
Item Description Notes
6. Antifreeze tank supply
valve
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7. Vacuum gauge Displays blower vacuum
To open valve (send
antifreeze through pump and
water lance), rotate
counterclockwise.
To close valve (stop
antifreeze flow), rotate
clockwise.
reading in inches of mercury.
Vacuum relief valve opens
when vacuum reaches 15”
(381 mm).
IMPORTANT: Water tank supply
valve or antifreeze supply valve must
be open when pump is running or
pump will be damaged.
CMW
Controls - 28 FX25 Operator’s Manual
Machine
CMW
FX25 Operator’s Manual Operation Overview - 29
Operation Overview
Chapter Contents
Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Setting Up at Jobsite . . . . . . . . . . . . . . . . . . . . . . . 30
Vacuuming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Potholing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Leaving Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Storing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 31
CMW
Operation Overview - 30 FX25 Operator’s Manual
Planning
Planning
1. Gather information about jobsite (page 34).
2. Inspect jobsite (page 35).
3. Check supplies and prepare equipment (page 37).
Setting Up at Jobsite
1. Prepare jobsite (page 36).
2. Position vacuum excavation unit (page 30).
3. Leave unit hitched to towing vehicle or properly stabilized if trailer-mounted unit.
4. Block trailer wheels if trailer-mounted unit.
Vacuuming
1. Connect hoses (page 44).
2. Start unit (page 47).
3. Remove debris (page 48).
4. Disconnect hoses.
5. Drain tank (page 51) or unload to another tank (page 53).
CMW
FX25 Operator’s Manual Operation Overview - 31
Potholing
Potholing
1. Connect hoses (page 44).
2. Start unit (page 47).
3. Pothole (page 49).
4. Disconnect hoses.
5. Drain tank (page 51).
Leaving Jobsite
1. Rinse unit and tools (page 59).
2. Stow tools (page 59).
Storing Equipment
1. For cold weather storage, antifreeze vacuum excavation unit (page 58).
2. For long-term storage, disconnect battery disconnect switch (page 22).
CMW
Operation Overview - 32 FX25 Operator’s Manual
Storing Equipment
CMW
FX25 Operator’s Manual Prepare - 33
Prepare
Chapter Contents
Gather Information . . . . . . . . . . . . . . . . . . . . . . . . . 34
• Arrange for Traffic Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
• Prepare for Working Near Existing Utilities . . . . . . . . . . . . . . . . . . . . . 34
• Plan for Emergency Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Inspect Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Prepare Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
• Prepare Excavation Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Check Supplies and Prepare Equipment . . . . . . . 37
• Assemble Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
• Check Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
• Prepare Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
CMW
Prepare - 34 FX25 Operator’s Manual
Gather Information
Gather Information
A successful job begins before the excavation. The first step in planning is reviewing information already
available about the job and jobsite.
Arrange for Traffic Control
If working near a road or other traffic area, contact local authorities about safety procedures and
regulations.
Prepare for Working Near Existing Utilities
If jobsite may contain electrical lines, wear protective boots and gloves meeting the following standards:
• Boots must have high tops and meet the electric hazard protection requirements of ASTM F2413 or
ASTM F1117, when tested at 14,000 volts. Tuck legs of pants completely inside boots.
• Gloves must have 17,000 AC maximum use voltage, according to ASTM specification D120.
If working around higher voltage, use gloves and boots with appropriately higher ratings.
Plan for Emergency Services
Have the telephone numbers for local emergency and medical facilities on hand. Check that you will have
access to a telephone.
CMW
FX25 Operator’s Manual Prepare - 35
Inspect Jobsite
Inspect Jobsite
• Follow U.S. Department of Labor regulations on excavating and trenching (Part 1926, Subpart P) and
other similar regulations.
• Contact your local One-Call (811 in USA) or the One-Call referral number (888-258-0808 in USA and
Canada) to have underground utilities located before working. Also contact any utilities that do not
participate in the One-Call service.
• Inspect jobsite and perimeter for evidence of underground hazards, such as:
– “Buried utility” notices
– Utility facilities without overhead lines
– Gas or water meters
– Junction boxes
– Drop boxes
– Light poles
– Manhole covers
– Sunken ground
• Mark location of all buried utilities and obstructions.
CMW
Prepare - 36 FX25 Operator’s Manual
Prepare Jobsite
Prepare Jobsite
Jobsite hazards could cause death or serious injury. Use
correct equipment and work methods. Use and maintain proper safety
equipment.
To help avoid injury:
• If jobsite classification is in question or if the possibility of unmarked electric utilities exists, classify
jobsite as electric.
• Cutting high voltage cable can cause electrocution. Expose lines by hand before using unit.
• All vegetation near operator’s station must be removed. Contact with trees, shrubs, or weeds during
electrical strike could result in electrocution.
Prepare Excavation Point
• Clear the area to be excavated. Remove rocks or branches too large for vacuum hose.
• If excavating fluids while drill string is moving, clear area of trees, shrubs, and weeds.
• Select a solid area to stand on while excavating.
CMW
FX25 Operator’s Manual Prepare - 37
Check Supplies and Prepare Equipment
Check Supplies and Prepare Equipment
Assemble Accessories
Fire Extinguisher
If required, mount a fire extinguisher near the power unit but away from possible points of ignition. The fire
extinguisher should always be classified for both oil and electric fires. It should meet legal and regulatory
requirements.
Lighting Kit
If you will need additional light, plug lighting kit into provided outlet. Contact your Ditch Witch dealer for
further information.
Check Supplies
• water and additional hoses
• fuel
• keys
• spray lubricant
• personal protective equipment, such as hard hat and safety glasses
CMW
Prepare - 38 FX25 Operator’s Manual
Check Supplies and Prepare Equipment
Prepare Equipment
Fluid Levels
• fuel
• battery
• engine oil
• blower oil
Condition and Function
• filters (air, oil)
• belts
• blower
• tires
• hoses and valves
• couplers and fittings
• water tanks
• trailer parking brake (trailer-mounted unit)
CMW
FX25 Operator’s Manual Transport - 39
Transport
Chapter Contents
Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
• Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
• Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Haul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
• Inspect Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
• Hitch Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
• Unhitch Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
CMW
Transport - 40 FX25 Operator’s Manual
j32om006h.eps
Lift
Lift
Crushing weight. If load falls or moves it could kill or crush you. Use
proper procedures and equipment or stay away.
Points
Lifting points are identified by lifting decals. Lifting at other points is unsafe
and can damage machinery.
Procedure
Power Pack
Use a crane capable of supporting 1500 lb (680 kg).
Attach lifting device to corners and lift as shown.
Tank
Use crane capable of supporting the 2000 lb (907 kg).
Use top lift point (1) as shown. Use end lift point (2) to
drain tank if machine is disabled.
NOTICE:
• Relieve pressure in tank before storing or
transporting.
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1
2
• Only lift empty water or spoils tanks.
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CMW
FX25 Operator’s Manual Transport - 41
Haul
Haul
Crushing weight. If load falls or moves it could kill or crush you. Use
proper procedures and equipment or stay away.
To help avoid injury:
• Do not haul or move trailer unless tank is fully lowered and horizontal. Damage to machine or injury
to personnel could occur.
• Do not travel on roads with reducer or any other fitting installed on tank outlet valve. Fitting will
extend beyond the rear impact guard and will not be legal for operation on roadways.
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.
• Ensure trailer brakes are adjusted to come on in synchronization with tow vehicle brakes.
• Check ramps (if equipped) and trailer bed for cracks.
CMW
Transport - 42 FX25 Operator’s Manual
TrailerHitchAdjust_T9.eps
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). Attach left chain to right side of
tow vehicle and vice versa to cradle hitch. Do
not connect to pintle hook or hitch ball.
5. Connect breakaway switch cable to tow
vehicle. Do not connect to pintle hook or hitch
ball.
6. Plug trailer electrical connector into tow
vehicle connector.
7. Use jack crank to raise jack base and stow.
TrailerHitchAdjust_T9.eps
8. Remove wheel blocks.
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.
CMW
FX25 Operator’s Manual Vacuum and Pothole - 43
Vacuum and Pothole
Chapter Contents
Connect Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Determine Tank Fill Level . . . . . . . . . . . . . . . . . . . 45
• 500-gal Vacuum Tank on T9S Trailer . . . . . . . . . . . . . . . . . . . . . . . . . 45
• 500-gal Vacuum Tank on T12S Trailer . . . . . . . . . . . . . . . . . . . . . . . . 46
Start Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
• Standard Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Remove Debris . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
• Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Pothole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Drain Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Unload to Another Tank . . . . . . . . . . . . . . . . . . . . 53
Open/Close Tank Door . . . . . . . . . . . . . . . . . . . . . 55
CMW
Vacuum and Pothole - 44 FX25 Operator’s Manual
Connect Hoses
Connect Hoses
1. Remove vacuum hoses from storage.
2. If potholing, remove 2-in-1 potholing tool or basic potholing tool from storage.
3. Connect hoses. Secure all locking clamps.
4. Ensure drain/outlet valve is closed.
5. If potholing, connect water pressure hose.
2-in-1 Tool Basic Tool
CMW
FX25 Operator’s Manual Vacuum and Pothole - 45
Determine Tank Fill Level
Determine Tank Fill Level
Use these reference charts to help determine how full of various materials the vacuum tank can be without
overloading trailer. Exceeding the maximum fill level will overload the trailer.
Never exceed the trailer capacity. You can exceed the vacuum tank lifting capacity if you drain the tank
down to the lifting capacity before lifting tank.
To use these charts, first select the appropriate table based on trailer and vacuum tank size. Next find the
material being excavated. If the material being excavated is not listed, find a material with similar density.
Then, determine the maximum fill level based on the amount of water in the water tank.
IMPORTANT: For all materials, the vacuum tank should be no more than half full when lifting the tank.
500-gal Vacuum Tank on T9S Trailer
Material Maximum Vacuum Tank
Fill Level
Water tank fill level full (80 gal) empty (0 gal)
wood chips (dry) 100% 100%
snow (dry) 100% 100%
water 95% 100%
light weight mud (8-10 lb/gal) 88% 100%
earth (dry, loose) 83% 95%
caliche 76% 87%
earth, loam 76% 87%
medium weight mud (10-12 lb/gal) 72% 83%
limestone (crushed) 62% 71%
asphalt 59% 68%
sand (dry) 59% 68%
earth (wet, excavated) 59% 68%
heavy weight mud (12-15 lb/gal) 59% 67%
gravel (dry) 58% 66%
shale, riprap 56% 65%
sand (wet) 46% 52%
CMW
Vacuum and Pothole - 46 FX25 Operator’s Manual
Determine Tank Fill Level
500-gal Vacuum Tank on T12S Trailer
Material Maximum Vacuum Tank
Fill Level
Water tank fill level full (200 gal) empty (0 gal)
wood chips (dry) 100% 100%
snow (dry) 100% 100%
water 100% 100%
light weight mud (8-10 lb/gal) 100% 100%
earth (dry, loose) 100% 100%
caliche 94% 100%
earth, loam 94% 100%
medium weight mud (10-12 lb/gal) 89% 100%
limestone (crushed) 77% 100%
asphalt 73% 95%
sand (dry) 73% 95%
earth (wet, excavated) 73% 95%
heavy weight mud (12-15 lb/gal) 72% 94%
gravel (dry) 71% 92%
shale, riprap 70% 91%
sand (wet) 56% 73%
CMW
FX25 Operator’s Manual Vacuum and Pothole - 47
Start Unit
Start Unit
EMERGENCY SHUTDOWN: Turn ignition switch to STOP.
Standard Procedure
IMPORTANT: If power pack is not connected to external tank
control valves, connect a -04 hose with a minimum working
pressure rating of 3000 psi (207 bar) from pressure (1) to power
beyond (2) connections on power pack.
2
1
2
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1. Open tank inlet valve.
1
NOTICE: Avoid idling engine with inlet valve closed.
2. If equipped with reverse flow, ensure vacuum is in “vacuum” mode before starting.
3. Insert key.
4. Turn key clockwise. See page 20 for more information.
CMW
Vacuum and Pothole - 48 FX25 Operator’s Manual
Remove Debris
Remove Debris
EMERGENCY SHUTDOWN: Turn ignition switch to STOP.
Procedure
1. Position vacuum hose in area to be excavated.
2. Start engine.
Vacuum will suffocate. Maintain distance between face and
vacuum inlets.
Fire or explosion possible. Do not vacuum flammable or
combustible substances.
Incorrect procedures could result in death, injury, or property
damage. Learn to use equipment correctly.
To help avoid injury: Do not excavate hazardous or toxic materials. Unit is designed to excavate
only soil cuttings, drilling fluids, and other non-toxic waste.
3. Open inlet valve.
NOTICE: Avoid idling engine with inlet valve closed.
4. Use sight glasses to monitor debris level in tank. Vacuum will shut off when tank is full but always heed
trailer and tank lifting capacities as indicated on page 45. Engine will remain running.
CMW
FX25 Operator’s Manual Vacuum and Pothole - 49
Pothole
Pothole
EMERGENCY SHUTDOWN: Turn ignition switch to STOP.
1. Start engine.
Vacuum will suffocate. Maintain distance between face and
vacuum inlets.
Fire or explosion possible. Do not vacuum flammable or
combustible substances.
2. Open inlet valve.
NOTICE: Avoid idling engine with inlet valve closed.
3. Open water tank valve.
4. Move water pump switch to on.
5. Position tool over area to be excavated and begin pothole.
Electric shock. Contacting electric lines will cause death or serious
injury. Know location of lines and stay away.
To help avoid injury: Do not direct water lance at overhead lines. Water conducts electricity.
2-in-1 Tool Basic Tool
• Squeeze water pressure lever to start
water pressure.
• Work pressurized water in a rocking or
circular motion to loosen and excavate soil
until hole is at the desired diameter and
depth.
• First use water lance to loosen soil.
• Work tool in a rocking or circular motion to
excavate soil.
• Use water lance and tool alternately until
hole is at the desired diameter and depth.
CMW
Vacuum and Pothole - 50 FX25 Operator’s Manual
Pothole
6. Adjust water pressure as needed to match soil conditions and/or material of utility being exposed.
Jobsite hazards could cause death or serious injury. Use correct
equipment and work methods. Use and maintain proper safety equipment.
To help avoid injury: Test water pressure on a sample of the utility line material to be exposed.
Adjust pressure until no damage occurs to the material. High pressure water can cut utility lines.
7. Ensure that water sprays from nozzle in a fan pattern. If it does not, nozzle may be clogged and pump
will not function properly. Clean or replace nozzle as necessary.
8. When freshwater tank is empty, stop operation and turn water pump switch to off.
NOTICE: Do not continue to operate with freshwater tank empty. Running water pump with no
water will damage pump.
CMW
FX25 Operator’s Manual Vacuum and Pothole - 51
Drain Tank
Drain Tank
EMERGENCY SHUTDOWN: Turn ignition switch to STOP.
1. Ensure that unit is hitched to vehicle. See “Hitch Trailer” on page 42.
2. Haul unit to approved dumping area.
Incorrect procedures could result in death, injury, or property
damage. Learn to use equipment correctly.
To help avoid injury:
• Do not unhitch unit from tow vehicle before or during dumping. A freestanding unit can
become unstable when tilting tank.
• Do not unlatch door with tank tilted up.
• Do not unlatch vacuum boom (optional) with tank tilted up.
Breathing crystalline silica dust may cause lung disease. Cutting,
drilling, or working materials such as concrete, sand, or rock containing quartz may
result in exposure to silica dust. Use dust control methods or appropriate breathing
protection when exposed to silica dust.
NOTICE: Do not drive with tank or door raised.
3. Open drain/outlet valve and inlet valve.
4. Allow tank to drain in the horizontal position until
tank is approximately half drained. Monitor sight
glasses.
5. When tank is half drained, start engine and run at
low idle.
6. Tilt tank up to help flush solids from tank.
7. Lower tank to the full horizontal position.
8. Close drain/outlet valve and inlet valve.
CMW
Vacuum and Pothole - 52 FX25 Operator’s Manual
Drain Tank
9. If further draining is necessary, open tank door. See “Open/Close Tank Door” on page 55.
Crushing weight could cause death or serious injury. Use proper
procedures and equipment or stay away.
To help avoid injury: Use tools (provided with unit) if unit must be serviced with
tank door up.
10. Tilt tank up fully. Allow tank to drain completely.
11. Connect water pressure hose to water lance.
12. Turn water pump switch on. Adjust water pressure.
13. Use water lance to thoroughly rinse inside of tank
and around door seal.
Confined space
will cause suffocation. Use
proper procedures for entering
or stay away.
To help avoid injury: Enter tank only if
necessary. Follow U.S. Department of Labor
guidelines for entering confined spaces.
14. Return tank to the fully lowered horizontal position.
15. Close tank door. See “Open/Close Tank Door” on page 55.
CMW
FX25 Operator’s Manual Vacuum and Pothole - 53
Unload to Another Tank
Unload to Another Tank
Optional reverse flow mode can be used to transfer vacuumed material to another tank or disposal site.
Incorrect procedures could result in death, injury, or property damage.
Learn to use equipment correctly.
To help avoid injury:
• Keep unit in “vacuum” mode unless pressure is needed.
• Restrain hose prior to pressurization. Unrestrained hose may cause property damage, injury or
death.
• Do not open fitting cams or valves when tank is pressurized. Flying debris, plugs and doors can
cause injury or death.
• Do not open tank door while tank is pressurized.
• Do not use pressure to clear clogs in vacuum hose.
IMPORTANT: Check relief valve as shown
before each use.
j33om059h.eps
1. Throttle down completely and turn off engine. Securely connect transfer hose to FX tank. Ensure drain/
outlet valve on FX tank is closed.
2. Securely connect other end of transfer hose to offboard tank. Ensure inlet valve on offboard tank is
closed and tank is vented.
3. Open FX tank drain/outlet valve. Material will flow into transfer hose.
4. Open offboard tank inlet valve.
CMW
Vacuum and Pothole - 54 FX25 Operator’s Manual
Unload to Another Tank
5. Move valve handle counterclockwise to engage “reverse flow” mode and start engine. Material will flow
into offboard tank.
6. Increase throttle as desired to transfer material.
7. When transfer is complete, throttle down completely and turn off engine. Close FX tank drain/outlet
valve.
8. Close offboard tank inlet valve and disconnect hose from offboard tank inlet valve.
9. Move handle clockwise to “vacuum” mode and turn on engine.
10. Open FX tank drain/outlet valve. Material will empty from transfer hose.
11. Close FX tank drain/outlet valve, throttle down and turn off engine.
12. Disconnect transfer hose from FX tank.
CMW
FX25 Operator’s Manual Vacuum and Pothole - 55
Open/Close Tank Door
Open/Close Tank Door
Open
Crushing weight could cause death or serious injury. Use proper
procedures and equipment or stay away.
To help avoid injury: Use tools (provided with unit) if unit must be serviced with tank
door up.
To help avoid injury: Do not raise tank with door held closed only by vacuum. Door may suddenly
open and possibly injure someone.
NOTICE: Do not drive with tank or door raised.
IMPORTANT: Depressurize tank before emptying cyclonic canister, cleaning filter, clearing hoses or
opening any doors.
1. If using optional reverse flow mode, turn off engine and ensure handle is down (in “vacuum” mode).
2. If tank is tilted, lower tank fully before opening door.
3. Open tank inlet valve.
4. Set hydraulic function switch to door position.
5. Press OPEN on tethered control.
Close
Incorrect procedures could result in death, injury, or property damage.
Learn to use equipment correctly.
1. Press CLOSE on tethered control until the linkage on both sides of the tank is fully collapsed.
2. Close tank inlet valve.
CMW
Vacuum and Pothole - 56 FX25 Operator’s Manual
Open/Close Tank Door
CMW
FX25 Operator’s Manual Complete the Job - 57
Complete the Job
Chapter Contents
Antifreeze Fluid Excavation Unit . . . . . . . . . . . . . 58
• Add Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
• Reclaim Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Rinse Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Stow Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
CMW
Complete the Job - 58 FX25 Operator’s Manual
Antifreeze Fluid Excavation Unit
Antifreeze Fluid Excavation Unit
Add Antifreeze
Follow these steps for overnight or long-term storage of unit during cold weather.
1. Fill antifreeze tank with a propylene-glycol based antifreeze.
2. Ensure that water tank valve is closed.
3. Open antifreeze tank valve.
4. Connect water pressure hose to water lance.
5. Start engine.
6. Move water pump switch to on. If freshwater tank is empty, move to bypass.
7. Squeeze water lance handle and run until antifreeze runs through the water lance.
8. Move water pump switch to off.
9. Close antifreeze tank supply valve.
10. Turn ignition switch to off.
11. Drain water tank completely.
Reclaim Antifreeze
1. Turn water pressure down.
2. Move water pump switch to on.
3. Put end of water lance in antifreeze tank.
4. Squeeze water lance handle and run until water comes out of lance.
5. Move water pump switch to off.
CMW
FX25 Operator’s Manual Complete the Job - 59
Rinse Equipment
Rinse Equipment
Spray water onto equipment to remove dirt and mud. Use water lance. Thoroughly rinse inside of tank and
around door seal.
Confined space will cause suffocation. Use proper procedures for
entering or stay away.
To help avoid injury: Enter tank only if necessary. Follow U.S. Department of Labor guidelines for
entering confined spaces.
NOTICE: Do not spray water onto operator’s console. Electrical components could be damaged. Wipe
down instead.
Disconnect
Disconnect and store the following hoses and cables (if used):
• vacuum hoses
• water pressure hose
Stow Tools
Make sure potholing tools, water lance, and other tools are properly stowed.
CMW
Complete the Job - 60 FX25 Operator’s Manual
Stow Tools
CMW
FX25 Operator’s Manual Service - 61
Service
Chapter Contents
Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . 62
Recommended Lubricants/Service Key . . . . . . . 64
Each Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
10 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
100 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
As Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
200 Mile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3,000 Mile. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
12,000 Mile. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
CMW
Service - 62 FX25 Operator’s Manual
FX_Tank_Raised.eps
Service Precautions
Service Precautions
Incorrect procedures could result in death, injury, or property damage.
Learn to use equipment correctly.
To help avoid injury:
• Unless otherwise instructed, all service should be performed with engine off.
• Refer to engine manufacturer’s manual for engine maintenance instructions.
Working Under Raised Debris Tank
Crushing weight could cause death or serious injury. Use proper
procedures and equipment or stay away.
To help avoid injury: Use tools (provided with unit) if hydraulic system must be serviced
with tank tilted up.
1. Raise vacuum tank.
2. Remove cylinder lockout tool.
3. Place channel of lock around extended cylinder
and secure.
4. Lower vacuum tank until load is supported by
cylinder lockout tool.
FX_Tank_Raised.eps
CMW
FX25 Operator’s Manual Service - 63
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Service Precautions
Working Under Raised Tank Door
Crushing weight could cause death or serious injury. Use proper
procedures and equipment or stay away.
To help avoid injury: Use tools (provided with unit) if unit must be serviced with tank
door up.
1. Locate door lock tools in tool storage area and bring
to rear of tank.
2. Raise tank door completely.
3. Pin door lock tools into place as shown.
4. Lower tank lid until load is supported by door lock
tools.
Welding Precaution
NOTICE: Welding can damage electronics.
• Disconnect battery to prevent damage to battery. Do not turn off battery disconnect switch with
engine running, or alternator and other electronic devices may be damaged.
• Connect welder ground clamp close to welding point and make sure no electronic components are
in the ground path.
• Always disconnect the Engine Control Unit ground connection from the frame, harness connections
to the ECU, and other electronic components prior to welding on machine or attachments.
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Washing Precaution
NOTICE: Water can damage electronics. When cleaning equipment, do not spray electrical components
with water.
CMW
Service - 64 FX25 Operator’s Manual
Recommended Lubricants/Service Key
Recommended Lubricants/Service Key
Item Description
GEO Gasoline engine oil meeting API service classification CF-4 or E1-96 and SAE viscosity
recommended by engine manufacturer (SAE 15W40)
SGL Synthetic gear oil (ISO 100), cmw p/n 256-044
MPG Multipurpose grease meeting ASTM D217 and NLGI 5
HTG High temperature, NLGI #2 premium grade, petroleum-based grease with high
temperature resistance and good mechanical stability
NDO 30W non-detergent oil
THF Tractor hydraulic fluid, similar to Phillips 66 HG, Mobilfluid 423, Chevron Tractor
Hydraulic Fluid, Texaco TDH Oil, or equivalent
DOT DOT 3 or 4 brake fluid
Check level of fluid or lubricant
Check condition
Filter
Change, replace, adjust, service or test “Fluid capacities” on page 101
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.
Use only recommended lubricants. Fill to capacities listed in “Specifications” on page 99.
For more information on engine lubrication and maintenance, see your engine manual.
NOTICE:
• Use only genuine Ditch Witch parts, filters, approved lubricants, TJC, and approved coolants to
maintain warranty.
• Use the “Service Record” on page 109 to record all required service to your machine.
CMW
FX25 Operator’s Manual Service - 65
Recommended Lubricants/Service Key
Engine Oil Temperature Chart
SAE 30
SAE 10W-30
SAE 5W-30
Synthetic SAE 5W-30
-20
F
-30 -20
C
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Temperature range anticipated before next oil change
IMPORTANT: If temperature is below 40°F (4°C), using SAE 30 will result in hard starting. If
temperature is above 80°F (27°C), using 10W-30 can cause increased oil consumption. Check oil level
more frequently.
0
20
10 0 10 20 30 40
40
60
80 100
CMW
Service - 66 FX25 Operator’s Manual
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Each Use
Each Use
Location Task Notes
Trailer Check torque of hitch bolts 200 ft•lb (271 N•m)
Check hydraulic brake actuator bolts If equipped
Check hydraulic brake fluid level If equipped; DOT 3 or 4
Check trailer battery
Check tire pressure and lug nut torque
Check lights and reflectors
Trailer
Check Hitch Bolts
Check that trailer hitch bolts are properly
tightened. Torque varies by trailer model. Refer to
“Specifications” beginning on page 99.
Check Hydraulic Brake Actuator Bolts
Check hydraulic brake actuator bolts. Tighten if
loose.
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CMW
FX25 Operator’s Manual Service - 67
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Each Use
Check Hydraulic Brake Fluid Level
Check hydraulic brake fluid level at master
cylinder each use. Fluid should be visible at top of
master cylinder. Add DOT 3 or DOT 4 brake fluid
and bleed brakes as needed. See page 92.
j32om011h.eps
Check Trailer Battery
Check battery connections for wear or corrosion.
Keep connections clean and tight. Batteries
supplied by factory are maintenance-free. Service
replacement batteries according to
manufacturer’s instructions.
Check Trailer Tire Pressure and
Lug Nut Torque
Check tire pressure (2) and lug nut (1) torque.
See below for correct pressure and torque. To
verify trailer model, see the certification plate
located on the trailer tongue.
Trailer Pressure Torque
T9S/
T12SE
80 psi
(5.5 bar)
95 ft•lb
(129 N•m)
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1
2
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CMW
Service - 68 FX25 Operator’s Manual
j33om013h.eps
Each Use
Check Trailer Lights and Reflectors
Check lights and reflectors for correct operation
and cleanliness.
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CMW
FX25 Operator’s Manual Service - 69
10 Hour
10 Hour
Location Task Notes
VACUUM
SYSTEM
DEBRIS
TANK
Check engine air filter service indicator
Check engine oil level GEO
Check hydraulic hoses
Check hydraulic fluid level THF
Check blower oil level SGL
Check blower belt tension
Check water pump oil level NDO
Clean water pump filter
Check tension of water pump belts
Clean vacuum air filter
Check spray nozzle
Drain cyclonic separator canister
Check strobe light
Check vacuum tank door seals/fittings
Check tank deflector
CMW
Service - 70 FX25 Operator’s Manual
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10 Hour
Vacuum System
Check Engine Air Filter
Check air filter every 10 hours. Press dust ejector
valve to release dust. Change air filter elements
when air filter restriction indicator (1) reaches the
red zone.
NOTICE: Only open the air filter canister when
air restriction is indicated. Change the elements,
do not attempt to clean them.
• Compressed air or water may damage filter
element.
• Tapping filter elements to loosen dirt may
damage the element.
.To change:
1. Remove air filter cover and remove element.
2. Wipe inside of housing and wash cover.
3. Insert new element.
4. Replace cover.
Check Engine Oil Level
While engine oil is warm, check oil level at dipstick
(2) every 10 hours. Add GEO at fill (1) as necessary
to keep oil level at highest line on dipstick.
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2
1
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CMW
FX25 Operator’s Manual Service - 71
10 Hour
Check Hydraulic Hoses
Fluid or air pressure could pierce skin and cause injury or death. Stay
away.
To help avoid injury: Escaping pressurized fluid can cause injury or pierce skin and poison.
• Before disconnecting a hydraulic line, turn engine off and operate all controls to relieve pressure.
Lower, block, or support any raised component with a hoist. Cover connection with heavy cloth and
loosen connector nut slightly to relieve residual pressure. Catch all fluid in a container.
• 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.
• Wear protective clothing, including gloves and eye protection.
• If you are injured, seek immediate medical attention from a doctor familiar with this type of injury.
Check hydraulic hoses for leaks every 10 hours.
CMW
Service - 72 FX25 Operator’s Manual
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10 Hour
Check Hydraulic Fluid Level
DC Units
Check hydraulic fluid level every 10 hours. Maintain
fluid level at 3/4 tank when engine is off and fluid is
cool. Add THF at hydraulic fluid fill (shown) as
necessary.
Gear Pump Units
Check hydraulic fluid level at cap (shown) every 10
hours. Maintain fluid level at 2” (51 mm) from top of
tank when engine is off and fluid is cool. Add THF
at hydraulic fluid fill (shown) as necessary.
Check Blower Oil Level
With frame level, check blower oil at sight glass
(3) every 10 hours. Add SGL at fill (2) as
necessary to maintain oil level at halfway point on
sight glass (3). Do not overfill.
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2
3
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CMW
FX25 Operator’s Manual Service - 73
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10 Hour
Check Blower Belt Tension
Check belt every 10 hours for correct tension,
damage or wear. Idler pulley tensioner should be
set to 70 lb of force. Verify that the indication
marks on tensioner are in the same position as
initially set, or apply 10 lb of force to the belt and
check that deflection is .25-.375” (6-10 mm).
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Check Water Pump Oil Level
With frame level, check water pump oil at sight
glass (2) every 10 hours. Add NDO at fill (1) as
necessary to keep oil at halfway mark on sight
glass.
Clean Water Pump Filter
Clean water pump filter every 10 hours and
replace as needed.
1. Open filter housing.
2. Remove element and rinse housing
thoroughly with water.
3. Inspect element for signs of collapse and for
brittle or broken rubber seals on the ends of
the element. Replace as needed. See
page 89.
1
2
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4. Replace element and close filter housing.
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CMW
Service - 74 FX25 Operator’s Manual
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10 Hour
Check Water Pump Belt Tension
Check belt every 10 hours for correct tension,
damage or wear. Contact your Ditch Witch dealer
for adjustment or belt replacement.
To check
1. Turn ignition to STOP and remove key.
2. Apply moderate thumb pressure to belt
between pulleys.
3. Belt is properly tensioned when deflection is
.125-.25” (3-6 mm).
Clean Vacuum Air Filter
Breathing
crystalline silica dust may cause
lung disease. Cutting, drilling, or
working materials such as
concrete, sand, or rock
containing quartz may result in exposure to
silica dust. Use dust control methods or
appropriate breathing protection when
exposed to silica dust.
Clean filter every 10 hours or as needed.
To clean filter:
2
4
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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.
CMW
FX25 Operator’s Manual Service - 75
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2
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10 Hour
Check Spray Nozzle
Check spray nozzle every 10 hours. Ensure that
water sprays from nozzle in a fan pattern. Clean
or replace nozzle as necessary.
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Drain Cyclonic Separator Canister
IMPORTANT: Depressurize tank before
emptying cyclonic canister, cleaning filter,
clearing hoses or opening any doors.
Drain canister at drain (2) every 10 hours or when
water is visible in sight glass
1
2
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CMW
Service - 76 FX25 Operator’s Manual
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10 Hour
Debris Tank
Check Strobe Light
Check strobe light for proper function every 10
hours. When ignition is on, strobe light should be
flashing. Repair if necessary.
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Check Vacuum Tank Door Seals and
Fittings
Check door seal every 10 hours for wear or
damage. Repair if necessary. Check for leaks
and loose fittings every 10 hours. Repair or
replace if necessary.
Check Tank Deflector
Check tank deflector every 10 hours for buildup,
wear, or damage. Clean or replace as needed.
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CMW
FX25 Operator’s Manual Service - 77
50 Hour
50 Hour
Location Task Notes
VACUUM
SYSTEM
DEBRIS
TANK
Change engine oil and filter Initial service, GEO
Change fuel filters Initial service
Check battery
Check water pressure hoses
Check vacuum relief valve
Lube blower bearings
Change water pump oil Initial service, NDO
Lube tank pivot pins
CMW
Service - 78 FX25 Operator’s Manual
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50 Hour
Vacuum System
Change Engine Oil and Filter
(Initial Service)
Change engine oil and filter after 50 hours, and
every 100 hours thereafter. Drain oil (4), change
filter (3), and add 2.5 qt (2.3 L) of GEO at fill (2).
IMPORTANT: Use oil specified in temperature
chart found in “Recommended Lubricants/
Service Key” on page 64.
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2
4
3
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Change Fuel Filter (Initial)
Replace filter after the first 50 hours of operation,
and every 100 hours thereafter.
1. Remove filter.
2. Install new filter. Apply fuel oil thinly over the
gasket and hand-tighten.
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CMW
FX25 Operator’s Manual Service - 79
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50 Hour
Check Battery
Keep battery clean and free of corrosion. Apply
coat of grease to cable clamps after cleaning.
In cold weather, battery loses some starting ability.
Closely watch voltmeter for signs of battery
discharge.
If battery will not hold charge, see your Ditch Witch
dealer for replacement battery.
IMPORTANT: Use battery disconnect switch
when servicing, welding, and during long-term
storage.
Check Water Pressure Hoses
Check hoses every 50 hours for wear or damage.
Replace as necessary.
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Check Vacuum 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.
4. If suction is not present, stop engine and
change relief valve.
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CMW
Service - 80 FX25 Operator’s Manual
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50 Hour
Lube Blower Bearings
Wipe two zerks clean and lube every 50 hours
with HTG. Inject grease into zerk until clean
grease comes out of relief fittings.
NOTICE: Do not inject grease too quickly.
Drive shaft seal damage could occur.
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Change Water Pump Oil
Change oil after the first 50 hours of operation
and every 100 hours thereafter. Change oil more
frequently if working in dusty conditions.
• Drain at drain plug (3) while oil is warm.
• Add NDO at fill (1) until oil is at halfway mark
on sight glass (2).
1
3
2
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CMW
FX25 Operator’s Manual Service - 81
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50 Hour
Debris Tank
Lube Tank Pivot Pins
Lube two pins every 50 hours with MPG.
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CMW
Service - 82 FX25 Operator’s Manual
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100 Hour
100 Hour
Location Task Notes
VACUUM
SYSTEM
DEBRIS
TANK
Change engine oil and filter GEO
Change fuel filters
Change blower oil initial service, SGL
Change hydraulic fluid DC unit initial service, THF
Change water pump oil NDO
Check tank deflector
Check tank mounting bolts
Vacuum System
Change Engine Oil and Filter
(Regular Service)
Change engine oil and filter every 100 hours. Drain
oil (4), change filter (3), and add 2.5 qt (2.3 L) of
GEO at fill (2).
IMPORTANT: Use oil specified in temperature
chart found in “Recommended Lubricants/
Service Key” on page 64.
2
4
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3
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CMW
FX25 Operator’s Manual Service - 83
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100 Hour
Change Fuel Filter
Replace filter every 100 hours.
1. Remove filter.
2. Install new filter. Apply fuel oil thinly over the
gasket and hand-tighten.
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Change Blower Oil
2
Change oil after the first 100 hours of operation,
and every 1000 hours thereafter. Change oil more
frequently if working in dusty conditions.
• Drain at drain plug (4) while oil is warm.
• Add SGL at fill (2) until oil is at halfway point
on sight glass (3).
Change Hydraulic Fluid (DC Units)
Change hydraulic fluid after the first 100 hours, and
every 1000 hours thereafter. Drain hydraulic fluid
(2), add THF at hydraulic fluid fill (1) and check
level.
4
3
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2
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CMW
Service - 84 FX25 Operator’s Manual
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100 Hour
Change Water Pump Oil
Change oil after the first 25 hours of operation
and every 100 hours thereafter. Change oil more
frequently if working in dusty conditions.
• Drain at drain plug (3) while oil is warm.
• Add NDO at fill (1) until oil is at halfway mark
on sight glass (2).
Debris Tank
Check Tank Mounting Bolts
Check vacuum tank mounting bolts (shown, both
sides) every 100 hours for looseness and damage.
Tighten or replace as needed.
1
3
2
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CMW
FX25 Operator’s Manual Service - 85
1
2
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250-Hour
250-Hour
Location Task Notes
VACUUM
SYSTEM
Change hydraulic fluid gear pump unit initial service,
Vacuum System
Change Hydraulic Fluid (Gear Pump
Units)
Change hydraulic fluid after the first 250 hours, and
every 1000 hours thereafter. Drain hydraulic fluid
(2), remove and clean strainer, add THF at
hydraulic fluid fill (1) and check level.
THF
1
2
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CMW
Service - 86 FX25 Operator’s Manual
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1000 Hour
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.
• Drain at drain plug (4) while oil is warm.
• Add SGL at fill (2) until oil is at halfway point
on sight glass (3).
2
4
3
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CMW
FX25 Operator’s Manual Service - 87
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1
2
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1000 Hour
Change Hydraulic Fluid
DC Units
Change hydraulic fluid every 1000 hours. Drain
hydraulic fluid (2), add THF at hydraulic fluid fill (1)
and check level.
1
2
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G
1
ear Pump Units
Change hydraulic fluid every 1000 hours. Drain
hydraulic fluid (2), remove and clean strainer, add
THF at hydraulic fluid fill (1) and check level.
2
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CMW
Service - 88 FX25 Operator’s Manual
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2000 Hour
2000 Hour
Location Task Notes
VACUUM
SYSTEM
Replace water pump belts
Replace blower belt
Vacuum System
Replace Water Pump Belts
Replace belt every 2000 hours.
Replace Blower Belt
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Replace belt every 2000 hours.
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CMW
FX25 Operator’s Manual Service - 89
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As Needed
As Needed
Location Task Notes
VACUUM
SYSTEM
DEBRIS
TANK
TRAILER Add surge brake fluid DOT 3 or 4
Change water pump filter
Lube blower for longterm storage
Change blower relief air filter
Empty cyclonic filter canister
Clean primary shutoff valve
Vacuum System
Change Water Pump Filter
1. Open filter housing.
2. Remove element and rinse housing
thoroughly with clean water.
3. Install new element and close filter housing.
Lube Blower for Long-term Storage
Lubricate blower before long-term storage to help
prevent rust and siezing.
1. Remove filter.
2. Start engine.
3. Spray light oil into port and run unit for 1-2
minutes.
4. Turn off engine.
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CMW
Service - 90 FX25 Operator’s Manual
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2
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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.
Empty Cyclonic Separator Canister
IMPORTANT: Depressurize tank before
emptying cyclonic canister, cleaning filter,
clearing hoses or opening any doors.
Empty cyclonic separator canister (2) as needed.
Open door and dump tank. Clean out cyclone
through upper access door (1) as needed.
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2
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CMW
FX25 Operator’s Manual Service - 91
2
3
1
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As Needed
Debris Tank
Clean Primary Shut-off Valve
Clean primary shut-off valve as needed. Replace
primary shut-off valve as needed.
To clean:
1
1. Open tank door. See “Drain Tank” on page 51.
2. Spray valve housing inside vacuum tank with
high-pressure water.
3. Store water pressure hose.
4. Close tank door. See “Drain Tank” on
page 51.
To remove:
1. Loosen three wingnuts (1) and pull out valve housing (2).
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2
3
2. Remove ball (3).
3. Clean ball and housing with high-pressure water.
4. Replace ball and housing.
5. Tighten wingnuts.
CMW
Service - 92 FX25 Operator’s Manual
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As Needed
Trailer
Add Surge Brake Fluid
Add surge brake fluid at cap (1) as needed and
bleed brakes.
1. Remove lever guide and flat emergency lever
spring by removing two 5/16” hex head bolts
and lock washers.
2. Using short strokes, pull forward on
emergency lever (2) until brake fluid in master
cylinder stops bubbling.
3. Attach bleeder hose to bleeder valve on one
wheel and submerge other end of hose into a
transparent container partially filled with brake
fluid.
4. Loosen bleeder valve one turn and use emergency lever to pump master cylinder. Continue to pump
the lever until bubbles no longer appear in brake fluid in container.
NOTICE: Check fluid level in master cylinder every 4-5 strokes and add fluid as necessary to
keep master cylinder at least half full while bleeding brakes.
5. When bubbles stop, close bleeder valve and repeat process on remaining wheels.
6. After all wheels have been bled, fill master cylinder and attach cap securely.
7. Install emergency lever spring and lever guide using hex head bolts and lock washers.
12
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8. Test brakes.
• Pull emergency lever forward until it locks into its second notch.
• Attempt to rotate all wheels in forward direction.
• If any wheel rotates, adjust brakes.
CMW
FX25 Operator’s Manual Service - 93
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200 Mile
200 Mile
Location Task Notes
Trailer Adjust electric brakes Initial
Adjust hydraulic brakes Initial
Trailer
Adjust Electric Brakes (Initial)
Adjust brakes after 200 miles (320 km).
1. Place adequate jack stands under frame rails
and remove wheels.
2. Remove cover from adjusting slot on bottom
of backing plate.
3. Rotate adjuster starwheel with screwdriver or
brake spoon to expand brake shoes. Adjust
until drum is very difficult to turn by hand.
4. Rotate starwheel the other direction until drum
turns with slight drag.
5. Replace adjusting slot cover and replace
wheel.
6. Repeat procedure for all remaining brakes.
7. Remove jack stands and lower wheels to ground.
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CMW
Service - 94 FX25 Operator’s Manual
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200 Mile
Adjust Hydraulic Brakes (Initial)
Adjust hydraulic brakes after 200 miles (320 km).
Crushing weight could cause death or serious injury. Use proper
procedures and equipment or stay away.
1. Use a jack and suitable jack stands to raise
wheels so that wheels can be rotated by
hand.
2. Rotate wheel forward by hand to reposition
free backing primary brake shoe.
3. Remove adjusting plug from backing plate at
wheel.
4. Use a slender screwdriver or similar tool to
push the adjuster screw spring (1) away from
the adjuster assembly.
1
2
5. At the same time, use a brake adjusting tool
to tighten adjuster assembly (2). Adjust until
brake linings become tight enough that wheel
cannot be turned by hand, then back off 11
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clicks for brakes that have not been used, and
15 clicks for brakes already burnished in.
6. Rotate wheel forward by hand. Wheel should rotate freely.
7. Replace adjusting plug in backing plate.
8. Repeat adjustment procedure at each wheel. To ensure even braking, make sure that all wheels have
approximately the same amount of drag.
CMW
FX25 Operator’s Manual Service - 95
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3000 Mile
3000 Mile
Location Task Notes
Trailer Adjust electric brakes
Adjust hydraulic brakes
Trailer
Adjust Electric Brakes
Adjust brakes every 3000 miles (5000 km).
1. Place adequate jack stands under frame rails
and remove wheels.
2. Remove cover from adjusting slot on bottom
of backing plate.
3. Rotate adjuster starwheel with screwdriver or
brake spoon to expand brake shoes. Adjust
until drum is very difficult to turn by hand.
4. Rotate starwheel the other direction until drum
turns with slight drag.
5. Replace adjusting slot cover and replace
wheel.
6. Repeat procedure for all remaining brakes.
7. Remove jack stands and lower wheels to ground.
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CMW
Service - 96 FX25 Operator’s Manual
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3000 Mile
Adjust Hydraulic Brakes
Adjust hydraulic brakes every 3000 miles (5000 km).
Crushing weight could cause death or serious injury. Use proper
procedures and equipment or stay away.
1. Use a jack and suitable jack stands to raise
wheels so that wheels can be rotated by
hand.
1
2. Rotate wheel forward by hand to reposition
free backing primary brake shoe.
3. Remove adjusting plug from backing plate at
wheel.
4. Use a slender screwdriver or similar tool to
push the adjuster screw spring (1) away from
the adjuster assembly.
2
5. At the same time, use a brake adjusting tool
to tighten adjuster assembly (2). Adjust until
brake linings become tight enough that wheel
cannot be turned by hand, then back off 11
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clicks for brakes that have not been used, and
15 clicks for brakes already burnished in.
6. Rotate wheel forward by hand. Wheel should rotate freely.
7. Replace adjusting plug in backing plate.
8. Repeat adjustment procedure at each wheel. To ensure even braking, make sure that all wheels have
approximately the same amount of drag.
CMW
FX25 Operator’s Manual Service - 97
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12,000 Mile
12,000 Mile
Location Task Notes
Trailer Inspect brake shoes and linings
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.
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CMW
Service - 98 FX25 Operator’s Manual
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12,000 Mile
Adjust and Lubricate Bearings
1. Place adequate jack stands under frame rails
and remove wheels.
2. Unscrew grease cap (11) while holding the
hub stationary.
3. Bend locking tang (14) down from outer
spindle nut (13) and remove spindle nut (3).
4. Remove tang washer, unscrew inner spindle
nut and remove spindle washer (16).
5. Remove hub from spindle. Do not drop outer
bearing cone.
2
3
4
8
9
16
13
14
13
11
6. Pry seal (2) from hub and remove inner
bearing cone (3).
7. Inspect brake drum for excessive wear or heavy scoring.
Condition Recommended Action
Brake drum worn more than .020” (.5 mm). Remachine drum surface
Brake drum worn out of round more than .015” (.39 mm).
Brake drum has scoring and other wear greater than .090” (2.29 mm) Replace drum
8. Clean all grease from bearing cups (4,8), cones (9,3), hardware, and hub bore using suitable solvent.
Dry components with lint free cloth.
9. Inspect bearing cups and cones for pitting, spalling, and corrosion. Replace if damaged.
10. Pack all cones using an extreme pressure, water resistant lithium complex grease. Apply light coating
of grease to bearing cones.
11. Install the bearing and washer into the hub. Thread on the inner nut, rotate the hub, and tighten the nut
until the hub will not rotate. This requires a minimum of 100 ft•lb (136 N•m) of torque.
12. Loosen the nut to remove preload torque.
13. Hand tighten the nut and back it off 1/4 to 3/4 of a turn.
14. Place tang washer on spindle and bend one tang inward over the nut. This will keep the inner nut from
turning while torque is applied to the outer nut.
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15. Install the outer nut. Ensure that inner nut does not turn. Bend two tangs from the tang washer over the
outer flats to secure.
16. Install cap with o-ring and plug installed. Rotate the hub and check bearing adjustment. Allowable end
play is .001-.010” (.025-.25 mm).
CMW
FX25 Operator’s Manual Specifications - 99
L
W
H
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500
Specifications
500
L
W
H
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Dimensions U.S. Metric
L Length, T9S or T9SH trailer 200 in 5.1 m
H Height 86 in 2.3 m
W Width 96 in 2.2 m
Weight: suction only unit
Dry 4805 lb 2180 kg
Full 8870 lb 4023 kg
Weight: suction and water unit
Dry 4930 lb 2236 kg
Full water tank, empty vac tank 5665 lb 2570 kg
Empty water tank, full vac tank 9120 lb 4137 kg
Full water tank, full vac tank 9765 lb 4430 kg
NOTICE: Do not transport vac system and T9S, T9SH trailer with full water tank and full vac tank. Doing
so will exceed the trailer’s rated Gross Motor Vehicle Weight.
CMW
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