Ditch Witch FXT50 User Manual
FX50
Operator’s
Manual
CMW
®
Issue 1.0
053-2545
FX50 Operator’s Manual Overview - 1
Overview
Chapter Contents
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . 2
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Equipment Modification . . . . . . . . . . . . . . . . . . . . . 3
Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operator Orientation. . . . . . . . . . . . . . . . . . . . . . . . . 6
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 6
• Bulleted Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
• Numbered Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CMW
Overview - 2 FX50 Operator’s Manual
Serial Number Location
Serial Number Location
Record serial numbers and date of purchase in spaces provided. FX50 serial number is located as shown.
j36om071w.eps
Date of manufacture
Date of purchase
FX50 serial number (shown)
Engine serial number
Blower serial number
Water pump serial number
Trailer serial number
Intended Use
The FX50 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 FX50 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 FX50 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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FX50 Operator’s Manual Overview - 3
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2
33445
6
7
8
10
9
11
12
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
300-Gallon Tank
1
7
2
8
5
9
10
11
6
1312
j36om075w.eps
1. Inlet valve
2. Vacuum tank
3. Primary shut-off valve
4. Water tank
5. Operator’s station
6. Power unit
7. Hose reel
8. Potholing tools
9. Tool storage
10. Antifreeze tank
11. Vacuum filter
12. Cyclonic separator
13. Drain/outlet valve
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Overview - 4 FX50 Operator’s Manual
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2
3
4
5
6
7
8
10
9
11
12
j
Unit Components
800-Gallon Tank
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1
7
2
9
8
3
10
11
4
5
6
1312
1. Inlet valve
2. Vacuum tank
3. Primary shut-off valve
4. Water tank
5. Operator’s station
6. Power unit
7. Hose reel
8. Potholing tools
9. Tool storage
10. Antifreeze tank
11. Vacuum filter
12. Cyclonic separator
13. Drain/outlet valve
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FX50 Operator’s Manual Overview - 5
Unit Components
1200-Gal (4542-L)Tank
234 51
j36om077w.eps
1. Inlet valve
2. Vacuum tank
3. Primary shutoff valve
4. Operator’s station
5. Power unit
6. Potholing tools
7. Water lance
76
8 10
9
11
1213
8. Antifreeze tank
9. Water tanks
10. Vacuum filter/secondary shutoff valve
11. Drain/Outlet valve
12. Hose reel
13. Tool storage
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Overview - 6 FX50 Operator’s Manual
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2
3
4
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
j36om003w.eps
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.
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FX50 Operator’s Manual Foreword - 7
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 Charles Machine Works, Inc, Attn: Product Safety Coordinator.
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 1-800-424-9393 (366-0123 in
Washington, DC area) or write to:
NHTSA
U.S. Department of Transportation
400 7th Street SW (NSA-11)
Washington, DC 20590
You can also obtain other information about motor vehicle safety from the Hotline.
CMW
Foreword - 8 FX50 Operator’s Manual
Works, Inc.
FX50
Operator’s Manual
Issue number 1.0/OM-9/12
Part number 053-2545
Copyright 2012
by The Charles Machine Works, Inc.
, Ditch Witch, and CMW are registered trademarks of The Charles Machine
U.S. patents pending.
CMW
FX50 Operator’s Manual Contents - 9
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
7
11
21
37
41
47
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
51
69
73
115
127
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Contents - 10 FX50 Operator’s Manual
Service Record
a record of major service performed on the machine
Appendix
Information regarding tire safety
131
133
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FX50 Operator’s Manual Safety - 11
Safety
Chapter Contents
Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Safety Alert Classifications . . . . . . . . . . . . . . . . . . 13
Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Emergency Procedures . . . . . . . . . . . . . . . . . . . . . 17
• Electric Strike Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
• If an Electric Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
• If a Gas Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
• If a Fiber Optic Cable is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
• If Machine Catches on Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Safety - 12 FX50 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.
• 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.
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FX50 Operator’s Manual Safety - 13
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.
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Safety - 14 FX50 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.
FX50 Operator’s Manual Safety - 15
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.
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 - 16 FX50 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.
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FX50 Operator’s Manual Safety - 17
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.
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Safety - 18 FX50 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.
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FX50 Operator’s Manual Safety - 19
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.
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Safety - 20 FX50 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.
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FX50 Operator’s Manual Controls - 21
Controls
Chapter Contents
Power Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
• Controls and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
• Gauges and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
• Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
• Tethered Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
• Machine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Vacuum Boom (optional) . . . . . . . . . . . . . . . . . . . . 34
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Controls - 22 FX50 Operator’s Manual
Power Pack
Power Pack
Controls and Connectors
23
1
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1. Hydraulic function switch
2. Auxiliary outlet switch
3. Throttle
4
5
6
4. Water pressure switch
5. Ignition switch
6. Water pressure control
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FX50 Operator’s Manual Controls - 23
Power Pack
Item Description Notes
1. Hydraulic function
switch
2. Auxiliary outlet switch To turn on, press top.
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3. Throttle To increase engine speed,
To direct hydraulic power to
the optional boom function,
press top.
To direct hydraulic power to
the door function, move to
center position.
To direct hydraulic power to
the tank tilt function, press
bottom.
To turn off, press bottom.
push up.
IMPORTANT: Keep switch in off
position unless in use.
To decrease engine speed,
pull down.
4. Water pressure switch To turn on water pump, press
top.
To turn off water pump, move
to center position.
To bypass low water
indication, press bottom.
Water pump will operate for
60 seconds.
Use bypass to feed antifreeze into
system when freshwater tank is
empty. See “Add Antifreeze” on
page 70.
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Controls - 24 FX50 Operator’s Manual
Power Pack
Item Description Notes
5. Ignition switch To start engine, insert key and
turn clockwise.
To stop engine, turn key
counterclockwise.
6. Water pressure control To increase water pressure,
turn clockwise.
To decrease water pressure,
turn counterclockwise.
IMPORTANT:
• When engine is on, blower
operates and vacuum is present
at tank inlet.
• All indicators should light briefly at
startup.
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FX50 Operator’s Manual Controls - 25
Power Pack
Gauges and Indicators
23
1
4
5
6
1. Water pressure gauge
2. Fuel gauge
3. Hourmeter
Item Description Notes
1. Water pressure gauge Displays water pressure
when water pressure switch
is on and water lance is in
use.
4. Engine oil pressure indicator
5. Engine oil temperature indicator
6. Cold start wait indicator
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Controls - 26 FX50 Operator’s Manual
Power Pack
Item Description Notes
2. Fuel gauge Displays fuel level in tank. NOTICE: Use low sulfur or ultra low
sulfur diesel fuel only.
In temperatures below 32° F
(0° C), use #1 diesel fuel.
Tank holds 19 gal (72 L).
3. Hourmeter Displays engine operating
time.
4. Engine oil pressure
indicator
Indicates engine oil pressure
is too low.
Also lights briefly when
engine is started.
4. Engine oil temperature
indicator
Indicates engine oil
temperature is too high.
Hourmeter runs when ignition switch
is on.
Use these times to schedule service.
Engine will stop.
1. Check oil level.
2. Check for leaks before starting
engine.
3. If pressure is still low, consult
engine manual.
Engine will stop.
1. Let engine cool.
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2. Check fan belt tension.
3. Check engine oil level.
4. Check cooling fins for dirt and
debris.
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FX50 Operator’s Manual Controls - 27
Power Pack
Item Description Notes
5. Cold start wait indicator Indicates intake air preheater
is operating.
Wait until light goes off before
starting engine. See “Cold
Start Procedure” on page 57.
Explosion possible.
Serious injury or
equipment damage
could occur.
To help avoid injury: do not use
ether or starting fluid
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Controls - 28 FX50 Operator’s Manual
Power Pack
Miscellaneous
2
3
1
4
1. Battery disconnect
2. Flow direction control (optional)
3. Hydraulic fluid drain
Item Description Notes
1. Battery disconnect
switch
_
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+
_
+
To connect, turn clockwise.
To disconnect, turn
counterclockwise.
4. Engine oil drain
5. Auxiliary outlets
IMPORTANT: Use battery disconnect
switch when servicing, welding, and
during long-term storage.
5
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FX50 Operator’s Manual Controls - 29
Power Pack
Item Description Notes
2. Flow direction control To operate in reverse flow
mode, turn counterclockwise.
To operate in vacuum mode,
turn clockwise.
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3. Hydraulic fluid drain To drain:
• Remove plug.
• Replace plug when drain
pan is empty.
4. Engine oil drain To drain:
• Remove plug.
• Replace plug when drain
pan is empty.
5. Auxiliary outlets To operate work lights or
other 12V devices, plug into
outlet.
Use reverse flow to unload tank
contents to another tank. Operate in
reverse flow mode only when drain/
outlet valve is open.
Outlet has power only when ignition
switch is on.
Device can be turned on and
off with auxiliary power
switch.
CMW
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