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

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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

Equipment Modification

Equipment Modification

Overview - 3

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	2					3					4			5		6

7

8

9

10

11

12

132

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1.	Inlet valve	7.	Hose reel
2.	Vacuum tank	8.	Potholing tools
3.	Primary shut-off valve	9.	Tool storage
4.	Water tank	10.	Antifreeze tank
5.	Operator’s station	11.	Vacuum filter
6.	Power unit	12.	Cyclonic separator
		13.	Drain/outlet valve

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Overview - 4

FX50 Operator’s Manual

Unit Components

800-Gallon Tank

1	2										3											4						5											6

7	8	9	10												11			12		132

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1.	Inlet valve	7.	Hose reel
2.	Vacuum tank	8.	Potholing tools
3.	Primary shut-off valve	9.	Tool storage
4.	Water tank	10.	Antifreeze tank
5.	Operator’s station	11.	Vacuum filter
6.	Power unit	12.	Cyclonic separator
		13.	Drain/outlet valve

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FX50 Operator’s Manual

Unit Components

Overview - 5

1200-Gal (4542-L)Tank

1	2								3													4														5

6

7

8

9

10

13	11
	12

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1.	Inlet valve	8.	Antifreeze tank
2.	Vacuum tank	9.	Water tanks
3.	Primary shutoff valve	10.	Vacuum filter/secondary shutoff valve
4.	Operator’s station	11.	Drain/Outlet valve
5.	Power unit	12.	Hose reel
6.	Potholing tools	13.	Tool storage
7.	Water lance

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Overview - 6

FX50 Operator’s Manual

Operator Orientation

Operator Orientation					1
1.	Front of unit	3.	Rear of unit
2.	Right of unit	4.	Left of unit
Right and left sides of machine are determined by				4	2
facing towing vehicle.

3

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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

Reporting Safety Defects

Foreword - 7

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.

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Foreword - 8	FX50 Operator’s Manual

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

Works, Inc.

U.S. patents pending.

CMW

FX50 Operator’s Manual

Contents - 9

Contents

Overview

1

machine serial number, information about the type of work this machine is designed to perform, basic machine components, and how to use this manual

Foreword

7

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

Safety	11
machine safety alerts and emergency procedures
Controls	21
machine controls, gauges, and indicators and how to use them
Operation Overview	37
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	41
procedures for inspecting and classifying the jobsite, and preparing the jobsite for
work
Transport	47
procedures for lifting and hauling
Vacuum and Pothole	51
procedures for removing debris and potholing utility locations
Complete the Job	69
procedures for restoring the jobsite and rinsing and storing equipment
Service	73
service intervals and instructions for this machine including lubrication, replacement
of wear items, and basic maintenance
Specifications	115
machine specifications including weights, measurements, power ratings, and fluid
capacities
Support	127
the warranty policy for this machine, and procedures for obtaining warranty
consideration and training

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Contents - 10	FX50 Operator’s Manual
Service Record	131
a record of major service performed on the machine
Appendix	133
Information regarding tire safety

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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.

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

Crushing weight could cause death or serious injury. Use proper procedures and equipment or stay away.

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

Explosion possible. Serious injury or equipment damage could occur. Follow directions carefully.

Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly.

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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

Emergency Procedures

Emergency Procedures

Safety - 17

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

2	3
1	4
	5
	6
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1.	Hydraulic function switch	4.	Water pressure switch
2.	Auxiliary outlet switch	5.	Ignition switch
3.	Throttle	6.	Water pressure control

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FX50 Operator’s Manual

Power Pack

Controls - 23

Item					Description	Notes
1.	Hydraulic function				To direct hydraulic power to
	switch				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.
2.	Auxiliary outlet switch				To turn on, press top.	IMPORTANT: Keep switch in off
					To turn off, press bottom.	position unless in use.

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3. Throttle		To increase engine speed,
		push up.
		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	Use bypass to feed antifreeze into
				indication, press bottom.	system when freshwater tank is
				Water pump will operate for	empty. See “Add Antifreeze” on
				60 seconds.	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	IMPORTANT:
						turn clockwise.	• When engine is on, blower
						To stop engine, turn key	operates and vacuum is present
						counterclockwise.	at tank inlet.
							• All indicators should light briefly at
							startup.
6.	Water pressure control					To increase water pressure,
						turn clockwise.
						To decrease water pressure,
						turn counterclockwise.

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FX50 Operator’s Manual

Power Pack

Controls - 25

Gauges and Indicators

2

3

1

4

5

6

1.

Water pressure gauge

4.

Engine oil pressure indicator

2.

Fuel gauge

5.

Engine oil temperature indicator

3.

Hourmeter

6.

Cold start wait indicator

Item

Description

Notes

1.

Water pressure gauge

Displays water pressure

when water pressure switch

is on and water lance is in

use.

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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	Hourmeter runs when ignition switch
									time.	is on.
										Use these times to schedule service.

4.	Engine oil pressure					Indicates engine oil pressure	Engine will stop.
	indicator					is too low.	1.	Check oil level.
						Also lights briefly when
							2.	Check for leaks before starting
						engine is started.
								engine.
							3.	If pressure is still low, consult
								engine manual.
4.	Engine oil temperature					Indicates engine oil	Engine will stop.
	indicator					temperature is too high.	1.	Let engine cool.
							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

Power Pack

Controls - 27

Item			Description		Notes
5. Cold start wait indicator			Indicates intake air preheater
			is operating.
						Explosion possible.
			Wait until light goes off before			Serious injury or
						equipment damage
			starting engine. See “Cold
						could occur.
			Start Procedure” on page 57.
					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

5

1.	Battery disconnect			4.	Engine oil drain
2.	Flow direction control (optional)			5.	Auxiliary outlets
3.	Hydraulic fluid drain
Item			Description			Notes
1.	Battery disconnect		To connect, turn clockwise.			IMPORTANT: Use battery disconnect
	switch					switch when servicing, welding, and
			To disconnect, turn			during long-term storage.
			counterclockwise.

_

+

_

+

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FX50 Operator’s Manual

Power Pack

Controls - 29

Item			Description	Notes
2. Flow direction control			To operate in reverse flow	Use reverse flow to unload tank
			mode, turn counterclockwise.	contents to another tank. Operate in
				reverse flow mode only when drain/
			To operate in vacuum mode,	outlet valve is open.
			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		Outlet has power only when ignition
				other 12V devices, plug into		switch is on.
				outlet.
				Device can be turned on and
				off with auxiliary power
				switch.

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