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FM5
User Manual
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HP FM5 User Manual

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FM5
Operator’s Manual
CMW
®
Issue 1.1
054- 121
FM5 Operator’s Manual Overview - 1

Overview

Chapter Contents
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . 2
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3
• Bulleted Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
• Numbered Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Overview - 2 FM5 Operator’s Manual

Serial Number Location

Serial Number Location
Record serial numbers and date of purchase in spaces provided. Fluid unit serial number is located as shown.
Item
date of manufacture date of purchase fluid unit serial number trailer serial number engine serial number

Intended Use

The FM5 is a self-contained drilling fluid unit capable of mixing up to 300 gal (1136 L) of drilling fluid per tank and transferring fluid under pressure to the drilling unit. It 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 FM5 can be used with Ditch Witch drilling units and Ditch Witch Subsite locating equipment. It should be operated, serviced, and repair ed only by per s ons familia r with its particular ch ar ac teris tic s and acquainted with the relevant safety procedures.
FM5 Operator’s Manual Overview - 3

Unit Components

Unit Components
1. tank
2. hopper
3. engine
4. pump

About This Manual

This manual contains information for the proper use of this machine. See the beige Opera ti on Ov erv iew pages for basic operating procedures. Cross references such as “See page 50” will direct you to detailed procedures.

Bulleted Lists

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

Numbered Lists

Numbered lists contain illustration callouts or list steps that must be performed in order.
Overview - 4 FM5 Operator’s Manual
FM5 Operator’s Manual Foreword - 5

Foreword

This manual is an important part of your equipment. It provides safety information and operation instructions to help you use and maintain your Ditch Witch equipment.
Read this manual before using your equipment. Keep it with the equipment at all times for future reference. If you sell your equipment, be sure to give this manual to the new owner.
If you need a replacement copy, contact your Ditch Witch dealer. 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.
Foreword - 6 FM5 Operator’s Manual
FM5
Operator’s Manual
Issue number 1.1/OM-11/03
Part number 054-121
Copyright 2003
by The Charles Machine Works, Inc.
, Ditch Witch, CMW, AutoCrowd, Modularmatic, Jet Trac, Roto Witch, Subsite, Fluid Miser, Perma-Soil, Power Pipe, Super Witch, Super Witch II, Pierce Airrow, The Underground, and The Underground Authority Worldwide are registered trademarks of The Charles Machine Works, Inc.
FM5 Operator’s Manual Contents - 7

Contents

Overview
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, handling drilling fluid, and leaving the jobsite; with cross references to detailed procedures
Prepare
procedures for inspecting the jobsite and preparing the jobsite for work
Transport
procedures for lifting and hauling
1
5
9
17
23
27
31
Drilling Fluid Concepts
procedures for selecting fluid additives, determining fluid requirements, and measuring viscosity
Complete the Job
procedures for 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
Service Record
a record of major service performed on the machine
35
41
43
49
51
55
Contents - 8 FM5 Operator’s Manual
FM5 Operator’s Manual Safety - 9

Safety

Chapter Contents
Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Safety Alert Classifications . . . . . . . . . . . . . . . . . . 11
Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Emergency Procedures . . . . . . . . . . . . . . . . . . . . . 14
• Electric Strike Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
• If an Electric Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
• If a Gas Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
• If a Fiber Optic Cable is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
• If Machine Catches on Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Safety - 10 FM5 Operator’s Manual

Guidelines

Guidelines
Follow these guidelines before operating any jobsite equipment:
• Complete proper training and read operator’s manual before using equipment.
• Contact One-Call (888-258-0808) and any utility companies which do not subscribe to One-Call. Have
all underground pipes and cables located and marked before operating equipment. If you damage a utility, contact utility company.
• 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 is present.
• Contact your Ditch Witch dealer if you have any question about operation, maintenance, or equipment
use.
FM5 Operator’s Manual Safety - 11

Safety Alert Classifications

Safety Alert Classifications
These classifications and the icons defined on the following pages work together to alert you to situations which could be harmful to you, jobsite bystanders or your equipment. When you see these words and icons in the book or on the machine, carefully read and follow all instructions. YOUR SAFETY IS AT STAKE.
Watch for the three safety alert levels: DANGER, WARNING and CAUTION. Learn what each level means.
indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
Watch for two other words: NOTICE and IMPORTANT. NOTICE can keep you from doing something that might damage the machine or someone’s property. It
can also alert you against unsafe practices.
IMPORTANT can help you do a better job or make your job easier in some way.
Safety - 12 FM5 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.
Deadly gases. Lack of oxygen or presence of gas will cause sickness or
death. Provide ventilation.
Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment.
Crushing weight could cause death or serious injury. Use
proper procedures and equipment or stay away.
Moving parts could cut off hand or foot. Stay away.
Incorrect procedures could result in death, injury, or property damage.
Learn to use equipment correctly.
Improper control function could cause death or serious injury. If control does
not work as described in instructions, stop machine and have it serviced.
FM5 Operator’s Manual Safety - 13
Safety Alerts
Fire or explosion possible. Fumes could ignite and cause burns. No
smoking, no flame, no spark.
Moving traffic - hazardous situation. Death or serious injury could result.
Avoid moving vehicles, wear high visibility clothing, post appropriate warning signs.
Flying objects may cause injury. Wear hard hat and safety glasses.
Hot parts may cause burns. Do not touch until cool.
Exposure to high noise levels may cause hearing loss. Wear hearing
protection.
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).
Safety - 14 FM5 Operator’s Manual

Emergency Procedures

Emergency Procedures
Before operating any equipment, review emergency procedures and check that all safety precautions have been taken.
EMERGENCY SHUTDOWN - Turn ignition switch to stop position or push remote engine stop button (if equipped).

Electric Strike Description

When working near electric cables, remember the following:
• Electricity follows all paths to ground, not just path of least resistance.
• Pipes, hoses, and cables will conduct electricity back to all equipment.
• Low voltage current can injure or kill. Almost one-third of work-related electrocutions result from
contact with less than 440 volts.
Most electric strikes are not noticeable, but indications of a strike include:
• power outage
• smoke
• explosion
• popping noises
• arcing electricity
If any of these occur, assume an electric strike has occurred.
FM5 Operator’s Manual Safety - 15
Emergency Procedures

If an Electric Line is Damaged

If you suspect an electric line has been damaged and you are on truck or trailer, DO NOT MOVE. Remain on truck or trailer and take the following actions. The order and degree of action will depend on the situation.
• Warn people nearby that an electric strike has occurred. Instruct them to leave the area and contact utility.
• Contact utility company to shut off power.
• Do not return to area or allow anyone into area until given permission by utility company.
If you suspect an electric line has been damaged and you are off truck or trailer, DO NOT TOUCH EQUIPMENT. Take the following actions. The order and degree of action will depend on the situation.
• LEAVE AREA.
• Contact utility company to shut off power.
• Do not return to area or allow anyone into area until given permission by utility company.
Safety - 16 FM5 Operator’s Manual
Emergency Procedures

If a Gas Line is Damaged

If you suspect a gas line has been damaged, take the following actions. The order and degree of action will depend on the situation.
• Immediately shut off engine(s), if this can be done safely and quickly.
• Remove any ignition source(s), if this can be done safely and quickly.
• Warn others that a gas line has been cut and that they should leave the area.
• Leave jobsite as quickly as possible.
• 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 emerg enc y pers onn el and uti lity com pany.

If a Fiber Optic Cable is Damaged

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

If Machine Catches on Fire

Perform emergency shutdown procedure and then take the following actions. The order and degree of action will depend on the situation.
• Immediately move battery disconnect switch (if equipped) to disconnect position.
• If fire is small and fire extinguisher is available, attempt to extinguish fire.
• If fire cannot be extinguished, leave area as quickly as possible and contact emergency personnel.
FM5 Operator’s Manual Controls - 17

Controls

Chapter Contents
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fluid Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Controls - 18 FM5 Operator’s Manual

Engine

Engine
1. Choke
2. Fuel shutoff valve
3. Throttle
Item Description Notes
1. Choke To help start cold engine,
close valve.
2. Fuel shutoff valve When transporting unit to or from jobsite, or anytime machine is parked, close valve.
Before starting engine, open valve.
4. Tachometer/Hourmeter
5. Rope start
This valve regulates air/fuel mixture.
This valve separates the fuel tank from the engine.
FM5 Operator’s Manual Controls - 19
Engine
Item Description Notes
3. Throttle To increase engine speed,
move lever away from fuel tank.
To decrease engine speed, move lever toward fuel tank.
4. Rope start To start engine, pull rope. Fuel shut-off valve open for this
5. Tachometer/Hourmeter Displays engine rpm when
engine is running. Displays engine operatin g
time when engine is not running.
IMPORTANT: Increasing engine speed also increases pump flow.
control to function.
Use engine operating time to schedule service.
Controls - 20 FM5 Operator’s Manual

Fluid Mixing

Fluid Mixing
1. Drain plug
2. Tank discharge valve
3. Circulation valve
Item Description Notes
1. Drain plug To drain fluid from tank,
remove plug.
4. Hopper valve
5. Mixing jet valve
6. Discharge valve
IMPORTANT: Inst all plug before filling tank.
FM5 Operator’s Manual Controls - 21
Fluid Mixing
Item Description Notes
2. T ank discharge valve T o allow flow from tank to fluid
pump, open valve. To stop flow from tank to fluid
pump, turn off engine.
3. Circulation valve T o circulate fluid while mixing, open valve.
To stop circulation, close valve.
4. Hopper valve To allow flow from hopper to mixing venturi, open valve.
To stop flow from hopper to mixing venturi, close valve.
IMPORTANT: Close valve only when disconnecting hose to fluid pump.
See “Operation Overview” on page 23 for information about how to use this control.
IMPORTANT:
• Open valve only when pouring additives into hopper for mixing. Close valve when finished.
• Open circulation valve before opening hopper valve to prevent hopper filling with water.
5. Mixing jet valve To allow flow from pump to tank jets, open valve.
To stop flow from pump to tank jets, close valve.
6. Discharge valve To allow flow from pump to drilling unit, open valve.
To stop flow from pump to drilling unit, close valve.
Controls - 22 FM5 Operator’s Manual
Fluid Mixing
FM5 Operator’s Manual Operation Overview - 23

Operation Overview

Chapter Contents
Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Setting Up at Jobsite . . . . . . . . . . . . . . . . . . . . . . . 24
Mixing Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Transferring Flui d . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Operating in Cold Weather . . . . . . . . . . . . . . . . . . 26
Leaving Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Operation Overview - 24 FM5 Operator’s Manual

Planning

Planning
1. Gather information about jobsite (page 28).
2. Inspect jobsite (p age 28).
3. Check supplies and prepare equipment (page 30).

Setting Up at Jobsite

1. Prepare jobsite (page 29).
2. Position fluid unit and connect to drilling unit. See drilling unit operator’s manual.
IMPORTANT: Leave unit hitched to towing vehicle or properly stabilized.
3. Block trailer wheels.
FM5 Operator’s Manual Operation Overview - 25

Mixing Fluid

Mixing Fluid
Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and mai ntain proper safe ty equipment.
NOTICE:
• Wear personal protective equipment including hard hat, safety eye wear, and hearing protection.
• Do not wear jewelry or loose clothing.
1. Verify that hopper throat is not plugged before mixing.
2. Fill fluid tank with water. Allow room for additives.
3. Open circulation valve and tank discharge valve.
4. Start engine and run at half throttle or higher.
5. Open hopper valve.
6. Open hopper lid and pour in bentonite. See page 37.
IMPORTANT: Before adding bentonite to drilling fluid, be sure drilling unit is equipped to use a bentonite mixture.
7. Close hopper valve and close hopper lid.
8. Mix well.
9. Slowly add polymer and other liquid additives into top of tank. See page 37.
Operation Overview - 26 FM5 Operator’s Manual

Transferring Fluid

Transferring Fluid
Electric shock. Contacting electric lines will cause death or serious injury.
Know location of lines and stay away.
NOTICE: If electrical strike occurs while fluid hose is connected to drilling unit, fluid system will also become electrified.
1. Connect hose from mixing pump to drilling unit.
2. Open hopper and discharge valves.
IMPORTANT: If drilling fluid contains bentonite, leave circulation valve approximately half open to allow continuous mixing while drilling.
3. Adjust engine throttle to give desired flow rate to drilling unit.
• Half throttle is recommended for most drilling situations.
• A higher throttle setting is required when recirculating fluid to maintain the mix in the tank.

Operating in Cold Weather

For successful operation in cold weather, follow these procedures.
• Use pump to keep drilling fluid circulating at all times, even during transport to and from the jobsite.
• If possible, use all drilling fluid in tank before transporting unit.
• For cold weather storage, drain tank and ensure all fluid system valves are open. Also open drain
valve on pump.

Leaving Jobsite

1. Rinse unit and tools (page 42).
2. Disconnect hoses (page 42).
FM5 Operator’s Manual Prepare - 27

Prepare

Chapter Contents
Gather Information . . . . . . . . . . . . . . . . . . . . . . . . . 28
• Arrange for Traffic Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
• Prepare for Working Near Existing Utilities . . . . . . . . . . . . . . . . . . . . . .28
• Plan for Emergency Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Inspect Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Prepare Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Install Fluid Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
• Consider Load Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
• Installation Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Check Supplies and Prepare Equipment . . . . . . . 30
• Assemble Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
• Check Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
• Prepare Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Prepare - 28 FM5 Operator’s Manual

Gather Information

Gather Informatio n
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 ANSI Z-41, 1991, 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 D120-87.
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.

Inspect Jobsite

• Follow U.S. Department of Labor regulations on excavating and trenching (Part 1926, Subpart P) and other similar regulations.
• Contact One-Call (888-258-0808) and any utility companies which do not subscribe to One-Call.
• 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.
FM5 Operator’s Manual Prepare - 29

Prepare Jobsite

Prepare Jobsite
Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment.
NOTICE:
• If jobsite classification is in question or if the possibility of unmarked electric utilities exists, classify jobsite as electric.
• Cutting high voltage cable can cause electrocution. Expose lines by hand before digging.
• All vegetation near operator’s station must be removed. Contact with trees, shrubs, or weeds during
electrical strike could result in electrocution.

Install Fluid Unit

Consider Load Requirements

IMPORTANT: The FM5 unit must be installed on a trailer or truck that meets the following requirements.
• All trailer or truck components including axles and tires are in good condition.
• Axle loads meet US requirements. In countries other than the US, check local regulations.

Installation Tips

• Drill holes through trailer cross members to provide adequate connection to trailer structure, not just deck boards.
• Use high-quality, properly-sized mounting hardware.
Prepare - 30 FM5 Operator’s Manual

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.

Check Supplies

• water and additional hoses
• fuel
• keys
• drilling fluid additives, suc h as ben toni te and polymer
• personal protective equipment, such as hard hat and safety glasses

Prepare Equipment

Fluid Levels
• fuel
• engine oil
Condition and Function
• filters (air, oil)
• tires
• hoses and valves
• couplers and fittings
• water tank
FM5 Operator’s Manual Transport - 31

Transport

Chapter Contents
Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
• Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
• Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Haul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
• Inspect Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
• Hitch Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
• Unhitch Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Transport - 32 FM5 Operator’s Manual

Lift

Lift
Crushing weight. If load falls or moves it could kill or crush you. Use
proper procedures and equipment or stay away.

Points

Lifting points are identified by lifting decals. Lifting at other points is unsafe and can damage machinery.

Procedure

Tank
Use crane capable of supporting the equipment’s size and weight. See “Specifications” on page 49 or measure and weigh equipment before lifting. Lift mixing tank by attaching sling to lift points located on side of tank base. Attach securely to cross members.
IMPORTANT: Empty tank before lifting.
Engine Skid
Use fork lift capable of lifting the equipment’s size and weight. See “Specifications” on page 49 or measure and weigh equipment before lifting. Slide forks completely under engine skid.
FM5 Operator’s Manual Transport - 33

Haul

Haul
Crushing weight. If load falls or moves it could kill or crush you. Use
proper procedures and equipment or stay away.

Inspect Trailer

• Check hitch for wear and cracks. Lubricate if needed.
• Check battery for 12V charge.
• Inspect lights for cleanliness and correct operation. Inspect reflectors and replace if needed.
• Check tire pressure. Check lug nut torque with a torque wrench. Adjust if needed.
• Ensure trailer brakes are adjusted to come on in synchronization with tow vehicle brakes.
• Check ramps (if equipped) and trailer bed for cracks.

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 to level load.
4. Connect safety chains to tow vehicle.
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.
8. Remove wheel blocks.
Transport - 34 FM5 Operator’s Manual
Haul

Unhitch T r ailer

1. Stop tow vehicle and trailer on level ground.
2. Put manual transmission into first or reverse gear or automatic transmission into park. Turn off ignition. Set parking brake.
3. Block trailer wheels.
4. To unhitch trailer from tow vehicle, reverse “Hitch Trailer” steps.
FM5 Operator’s Manual Drilling Fluid Concepts - 35

Drilling Fluid Concepts

Chapter Contents
Recommended Products . . . . . . . . . . . . . . . . . . . . 36
Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Polymer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Bentonite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Mixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
• General mixing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
• Basic fluid recipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Drilling Fluid Requirements. . . . . . . . . . . . . . . . . . 40
Funnel Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Drilling Fluid Concepts - 36 FM5 Operator’s Manual

Recommended Products

Recommended Products
For productive drilling and equipment protection, use these recommended Baroid® products, available from your Ditch Witch dealer.
• Soda ash
• Quik-Gel™ dry powder bentonite (p/n 259-804)
• E-Z Mud™ liquid polymer (p/n 259-805)
• Liqui-Trol™ liquid polymer suspension (p/n 259-808)
• Quik-Trol™ dry powder polymer (p/n 259-809)
• Bore-Gel™ drilling fluid (p/n 259-807)
• Con-Det™ water-soluble cleaning solution (p/n 259-810)

Guidelines

Match drilling fluid to soil type. This chart is meant as a guideline only. See your local Ditch Witch dealer for soil conditions and drilling fluid recommendations for your area. Also see our interactive Drilling Fluid Formulator at www.ditchwitch.com.
Soil type Drilling fluid recommendation
smooth, flowing sand bentonite or Bore-Gel + medium chain polymer coarse sand or light soil bentonite or Bore-Gel heavy clay long chain polymer + Con-Det swelling clay long chain polymer + Con-Det rock Bore-Gel
FM5 Operator’s Manual Drilling Fluid Concepts - 37

Polymer

Polymer
This drilling fluid additive provides excellent lubrication and increases viscosity in average soils and heavy clay. In swelling clay, polymer can reduce swelling that traps pipe in the bore.
There are two types of polymer:
• long chain such as Baroid EZ- Mud
• medium chain such as Baroid Quik-Trol

Bentonite

Bentonite is a dry powder. When properly mixed with water, it forms a thin cake on bore walls, lubricating the bore, keeping it open, and holding fluid in the bore.
Some things to remember when mixing bentonite:
• Use clean water free of salt, calcium, or excessive chlorine.
• Use water with pH level between 9 and 10.
• Use water with hardness of less than 120 ppm.
• Do not use bentonite containing sand.
• Mix bentonite thoroughly or it will settle in tank.
• Do not mix bentonite to a funnel viscosity of over 50.
For information on measuring funnel viscosity, see “Funnel Viscosity” on page 40.
Drilling Fluid Concepts - 38 FM5 Operator’s Manual

Mixtures

Mixtures
Bentonite does not mix well in water containing polymer. To use both, mix bentonite first, then add polymer. When adding other products follow the order listed below.
NOTICE:
• If chemicals are added in the wrong order, they will not mix properly and will form clumps.
• If tank contains bentonite/polymer mix and more drilling fluid is needed, completely empty tank and
start with fresh water before mixing another batch.

General mixing order

1. Soda ash
2. Bentonite
3. Polymer
4. Con-Det
Bore-Gel contains premixed bentonite, polymer, and soda ash. Follow guidelines below to ensure proper drilling fluid viscosity for expected drilling conditions.
Conditions Amount to Use
normal drilling 15 lb/100 gal 7 kg/380 L sand or gravel up to 45 lb/100 gal up to 21 kg/380 L rock up to 50 lb/100 gal up to 23 kg/380
FM5 Operator’s Manual Drilling Fluid Concepts - 39
Mixtures

Basic Fluid Recipes

Soil type Mixture/100 gal (378 L) of water Notes
fine sand 35 lb (16 kg) Bore-Gel coarse sand 35 lb (16 kg) Bore-Gel
.5 lb (225 g) No-Sag
fine sand below water table
coarse sand below water table
gravel 50 lb (23 kg) Bore-Gel
cobble 50 lb (23 kg) Bore-Gel
sand, gravel, clay or shale
clay .5 lb (225 g) Poly Bore
swelling/sticky clay .75 - 1 lb (340-450 g) Poly Bore
40 lb (18 kg) Bore-Gel .75 lb (340 g) Quik-Trol
40 lb (18 kg) Bore-Gel .75 lb (340 g) Quik-Trol .75 lb (340 g) No-Sag
.75 lb (340 g) Quik-Trol .75 lb (340 g) No-Sag
.75 lb (340 g) Quik-Trol .75 lb (340 g) No-Sag
35 - 40 lb (16-18 kg) Bore-Gel .5 pt (235 mL) EZ-Mud .5 gal (2 L) Con-Det
.5 gal (2 L) Con-Det
.5 - 1 gal (2-4 L) Con-Det
Add .5 lb (225 g) of Quik-Trol for additional filtrate con trol
Add .5 - 1 gal (2-4 L) of Dinomul in high torque situations
Add .5 - 1 gal (2-4 L) of Dinomul in high torque situations
Add .5 lb (225 g) of Barolift to reduce loss of returns
Add .5 lb (225 g) of Barolift to reduce loss of returns
Vary mixture according to percentage of sand and clay
Flow rate should be 3-5 parts fluid to 1 part soil. May use .25 - .5 gal (1-2 L) of Penetrol instead of Con-Det
Flow rate should be 3-5 parts fluid to 1 part soil. May use .25 - .5 gal (1-2 L) of Penetrol instead of Con-Det
solid rock (shale) 40 lb (18 kg) Bore-Gel Use .5 pt (235 mL) of No Sag for large
diameter or longer bores
solid rock (other than shale)
rock/clay mixture 40 - 50 lb (18-23 kg) Bore-Gel
rock/sand mixture 40 - 50 lb (18-23 kg) Bore-Gel Use .5 pt (235 mL) of No Sag for large
fractured rock 50 lb (23 kg) Bore-Gel
40 - 50 lb (18-23 kg) Bore-Gel Use .5 pt (235 mL) of EZ-Mud in reactive
shales
.5 pt (235 mL) EZ-Mud
diameter or longer bores Use .5 lb (225 g) of Barolift to reduce fluid
.5 - 1lb (225-450 g) No-Sag
loss to formation
Drilling Fluid Concepts - 40 FM5 Operator’s Manual

Drilling Fluid Requirements

Drilling Fluid Requirements
1. Determine drilling conditions and choose appropriate drilling fluid mix.
2. Estimate amount of supplies needed and check availability.
• Drilling fluid
• Water supply . If more water than can be carried with the unit will be needed, arrange to transport
additional water.
• Bentonite and/or polymer
3. Check water quality.
• Use meter or pH test strips to test pH of water. If pH is below 9.0, add 1 lb (454 g) soda ash per
tank. Test and repeat until pH is between 9 and 10.
• Check water hardness using hardness test strips. Treat with soda ash if hardness exceeds 125
ppm.

Funnel Viscosity

Viscosity is the measure of internal resistance of a fluid to flow; the greater the resistance, the higher the viscosity. Viscosity of drilling fluids must be controlled.
To determine viscosity, you will need a Marsh funnel (p/n 259-267) and a measuring cup, available from your Ditch Witch dealer.
IMPORTANT: Make sure Marsh funnel is clean and free of obstruction and that you have a stopwatch available for timing the viscosity.
1. Using wash hose and a clean container, take a fresh sample of drilling fluid. The sample must be at least
1.5 qt (1.4 L).
2. With finger over bottom of funnel, fill with fluid from the container through the screen until fluid reaches the bottom of the screen.
3. Move funnel over 1 qt (.95 L) container.
4. Remove finger from bottom of funnel and use the stopwatch to count the number of seconds it takes for 1 qt (.95 L) of fluid to pass through the funnel. The number of seconds is the viscosity.
5. Thoroughly rinse measuring cup and Marsh funnel.
FM5 Operator’s Manual Complete the Job - 41

Complete the Job

Chapter Contents
Rinse Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Complete the Job - 42 FM5 Operator’s Manual

Rinse Equipment

Rinse Equipment
Spray water onto equipment to remove dirt and mud.

Disconnect

Disconnect and store hoses and cables.
FM5 Operator’s Manual Service - 43

Service

Chapter Contents
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Recommended Lubricants/ Service Key . . . . . . . . 44
10 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
20 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
100 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Service - 44 FM5 Operator ’s Manual

Precautions

Precautions
Incorrect procedures could result in death, injury, or property damage.
Learn to use equipment correctly.
NOTICES:
• Unless otherwise instructed, all service should be performed with engine off.
• Refer to engine manufacturer’s manual for engine maintenance instructions.
• Refer to trailer operator’s manual for trailer service instructions.

Recommended Lubricants/Service Key

Item Description
GEO Gasoline engine oil meeting current API service classifications and SAE viscosity
recommended by engine manufacturer (SAE 15W40)
NLGI#1 Polyurea based NLGI #1
Check level of fluid or lubricant
Check condition
Filter
Change, replace, adjust, service or test
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 49.
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 55 to record all required service to your machine.
CMW
FM5 Operator’s Manual Service - 45

10 Hour

Engine Oil Temperature Chart

Temperature range anticipated before next oil change
10 Hour
Check Engine Oil
Check engine oil at dipstick (shown) before operation and every 10 hours thereafter. Check with unit on level surface and at least 15 minutes after stopping engine. Add GEO at fill as necessary to keep oil level at highest line on dipstick.
Service - 46 FM5 Operator ’s Manual

20 Hour

20 Hour
Change Engine Oil (Initial Service)
Change oil after first 20 hours. Pull drain plug and drain crankcase while oil is still warm. Refill at fill neck with 2.3 pt (1.1 L) of GEO.

50 Hour

Grease Pump
Lube grease fitting with NLGI #1 every 50 hours. Grease cavity is full when grease escapes from grease cylinder relief valve.
FM5 Operator’s Manual Service - 47

100 Hour

100 Hour
Location T ask Notes
change engine oil regular service change air filter
Change Engine Oil
Change oil every 100 hours. Pull drain plug and drain crankcase while oil is still warm. Refill at fill neck with
2.3 pt (1.1 L) of GEO.
Change Air Filter
Change foam air filter element every 100 hours. Do not allow dirt to fall into carburetor.
Service - 48 FM5 Operator ’s Manual
100 Hour
FM5 Operator’s Manual Specifications - 49
L
W
H

Specifications

L
W
H
j11om015h.eps
Dimensions U.S. Metric
A Length 123 in 3.1 m B Height 53 in 1.3 m C Width 25.6 in 650 mm Weight, empty 660 lb 299 kg Weight, with full tank (water) 3164 lb 1435 kg
Performance U.S. Metric
Maximum flow rate at 26 viscosity 160 gpm 606 L/min Mixing hopper capacity
Suction time for 50 lb (22.7 kg) 1 min 1 min Suction time for 100 lb (45 kg) 2 min 2 min
1 ft
3
28 L
Specifications - 50 FM5 Operator’s Manual
Engine U.S. Metric
Honda GX160, gasoline
Cooling medium air Number of cylinders 1 Displacement
9.9 in
3
162 cm
3
Bore 2.7 in 69 mm Stroke 1.8 in 46 mm * Maximum tilt angle fore & aft 35° * Maximum tilt angle side 35°
Flywheel power @ 3600 rpm 5.5 hp 4.1 kW
* Exceeding these operating angles will cause engine damage. This DOES NOT IMPLY machine is stable to maximum angle of safe engine operation.
Fluid Capacities U.S. Metric
Fuel tank .95 gal 3.6 L Engine oil, including filter 0.63 qt 0.6 L Drilling fluid/mixing tank capacity 300 gal 1136 L
Noise levels
Operator 91 dBA sound pressure per ISO 6394 Exterior 105 dBA sound power per ISO 6393.
Specifications are called out according to SAE recommended practices. Specifications are general and subject to change without notice. If exact measurements are required, equipment should be weighed and measured. Due to selected options, delivered equipment may not match that shown.
FM5 Operator’s Manual Support - 51

Procedure

Support

Procedure
Notify your dealer immediately of any malfunction or failure of Ditch Witch equipment. Always give model, serial number, and approximate date of your equipment purchase. This information
should be recorded and placed on file by the owner at the time of purchase. Return damaged parts to dealer for inspection and warranty consideration if in warranty time frame. Order genuine Ditch Witch replacement or repair parts from your authorized Ditch Witch dealer. Use of
another manufacturer’s parts may void warranty consideration.

Resources

Publications

Contact your Ditch Witch dealer for publications and videos covering safety, operation, service, and repair of your equipment.

Ditch Witch Traini ng

For information about on-site, individualized training, contact your Ditch Witch dealer.
Warranty - 52 FM5 Operator’s Manual

Warranty

Ditch Witch Equipment and Parts
Limited Warranty Policy
Subject to the limitations and exclusions herein, free replacement parts will be provided at any authorized Ditch Witch dealership for any Ditch Witch equipment or parts manufactured by The Charles Machine Works, Inc. (CMW) that fail due to a defect in material or workmanship within one (1) year of first commercial use (Exception: 2 years for all SK500 attachments). Free labor will be provided at any authorized Ditch Witch dealership for installation of parts under this warranty during the first year following initial commercial use of the serial-numbered Ditch Witch equipment on which it is installed.
Exclusions from Product Warranty
• Wear-related failure of parts subject to ground contact including, but not limited to, digging teeth, digging chains, sprockets, backhoe buckets, plow blades, drill pipe, drill bits, backreamers, and swivels.
• All incidental or consequential damages.
• All defects, damages, or injuries caused by misuse, abuse, improper installation, alteration, neglect, or uses other than those for
which products were intended.
• All defects, damages, or injuries caused by improper training, operation, or servicing of products in a manner inconsistent with manufacturer’s recommendations.
• All engines and engine accessories (these are covered by original manufacturer’s warranty).
• Tires, belts, and other parts which may be subject to another manufacturer’s warranty (such warranty will be available to
purchaser).
• All implied warranties not expressly stated herein, including any warranty of fitness for a particular purpose and merchantability.
IF THE PRODUCTS ARE PURCHASED FOR COMMERCIAL PURPOSES AS DEFINED BY THE UNIFORM COMMERCIAL CODE, THEN THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE FACE HEREOF AND THERE ARE NO IMPLIED WARRANTIES OF ANY KIND WHICH EXTEND TO A COMMERCIAL BUYER. ALL OTHER PROVISIONS OF THIS LIMITED WARRANTY APPLY INCLUDING THE DUTIES IMPOSED.
Ditch Witch products have been tested to deliver acceptable performance in most conditions. This does not imply they will deliver acceptable performance in all conditions. Therefore, to assure suitability, products should be operated under anticipated working conditions prior to purchase.
Defects will be determined by an inspection within thirty (30) days of the date of failure of the product or part by CMW or its authorized dealer. CMW will provide the location of its inspection facilities or its nearest authorized dealer upon inquiry. CMW reserves the right to supply remanufactured replacements parts under this warranty as it deems appropriate.
Extended warranties are available upon request from your local Ditch Witch dealer or CMW.
Some states do not allow exclusion or limitation of incidental or consequential damages, so above limitation of exclusion may not apply. Further, some states do not allow exclusion of or limitation of how long an implied warranty lasts, so the above limitation may not apply . This limited warranty gives product owner specific legal rights and the product owner may also have other right s which vary from state to state.
For information regarding this limited warranty, contact CMW’s Product Support department, P.O. Box 66, Perry, OK 73077-0066, or contact your local Ditch Witch dealer.
First version: 1/91; Latest version: 1/03
FM5 Operator’s Manual Service Record - 55

Service Record

Service Performed Date Hours
Service Record - 56 FM5 Operator’s Manual
Service Performed Date Hours
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