HP FM5 User Manual

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

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Overview - 2 FM5 Operator’s Manual

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.

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FM5 Operator’s Manual Overview - 3

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.

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Overview - 4 FM5 Operator’s Manual

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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.

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Foreword - 6 FM5 Operator’s Manual

FM5

Operator’s Manual

Issue number 1.1/OM-11/03

Part number 054-121

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.

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FM5 Operator’s Manual Contents - 7

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

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

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Contents - 8 FM5 Operator’s Manual

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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

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Safety - 10 FM5 Operator’s Manual

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.

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FM5 Operator’s Manual Safety - 11

Safety Alert Classifications

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

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

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

serious injury.

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

serious injury.

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

moderate injury.

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

can also alert you against unsafe practices.

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

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Safety - 12 FM5 Operator’s Manual

Safety Alerts

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

Know location of lines and stay away.

Deadly gases. Lack of oxygen or presence of gas will cause sickness or

death. Provide ventilation.

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.

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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).

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Safety - 14 FM5 Operator’s Manual

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.

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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.

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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.

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FM5 Operator’s Manual Controls - 17

Controls

Chapter Contents

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Fluid Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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+ 39 hidden pages