FM5
Operator’s
Manual
CMW®
Issue 1.1
054- 121
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 repaired only by persons familiar with its particular characteristics and
acquainted with the relevant safety procedures.
CMW
FM5 Operator’s Manual
Unit Components
Overview - 3
Unit Components
1. tank
3. engine
4. pump
2. hopper
About This Manual
This manual contains information for the proper use of this machine. See the beige Operation Overview
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.
CMW
Overview - 4
FM5 Operator’s Manual
CMW
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
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.
CMW
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.
CMW
FM5 Operator’s Manual
Contents - 7
Contents
1
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
5
part number, revision level, and publication date of this manual, and factory contact
information
Safety
9
machine safety alerts and emergency procedures
Controls
17
23
27
31
35
41
43
49
51
55
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
CMW
Contents - 8
FM5 Operator’s Manual
CMW
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
CMW
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.
CMW
FM5 Operator’s Manual
Safety Alert Classifications
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.
CMW
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.
CMW
FM5 Operator’s Manual
Safety Alerts
Safety - 13
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).
CMW
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.
CMW
FM5 Operator’s Manual
Emergency Procedures
Safety - 15
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.
CMW
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 emergency personnel and utility company.
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.
CMW
FM5 Operator’s Manual
Controls - 17
Controls
Chapter Contents
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fluid Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CMW
Controls - 18
FM5 Operator’s Manual
Engine
Engine
1. Choke
4. Tachometer/Hourmeter
5. Rope start
2. Fuel shutoff valve
3. Throttle
Item
Description
Notes
1. Choke
To help start cold engine,
close valve.
This valve regulates air/fuel mixture.
2. Fuel shutoff valve
When transporting unit to or
from jobsite, or anytime
machine is parked, close
valve.
This valve separates the fuel tank
from the engine.
Before starting engine, open
valve.
CMW
FM5 Operator’s Manual
Engine
Controls - 19
Item
Description
Notes
3. Throttle
To increase engine speed,
move lever away from fuel
tank.
IMPORTANT: Increasing engine
speed also increases pump flow.
To decrease engine speed,
move lever toward fuel tank.
4. Rope start
To start engine, pull rope.
Fuel shut-off valve open for this
control to function.
5. Tachometer/Hourmeter
Displays engine rpm when
engine is running.
Displays engine operating
time when engine is not
running.
Use engine operating time to
schedule service.
CMW
Controls - 20
FM5 Operator’s Manual
Fluid Mixing
Fluid Mixing
1. Drain plug
4. Hopper valve
2. Tank discharge valve
3. Circulation valve
5. Mixing jet valve
6. Discharge valve
Item
Description
Notes
1. Drain plug
To drain fluid from tank,
remove plug.
IMPORTANT: Install plug before filling
tank.
CMW
FM5 Operator’s Manual
Fluid Mixing
Controls - 21
Item
Description
Notes
2. Tank discharge valve
To allow flow from tank to fluid IMPORTANT: Close valve only when
pump, open valve.
disconnecting hose to fluid pump.
To stop flow from tank to fluid
pump, turn off engine.
3. Circulation valve
To circulate fluid while mixing, See “Operation Overview” on page 23
open valve.
for information about how to use this
control.
To stop circulation, close
valve.
4. Hopper valve
To allow flow from hopper to
mixing venturi, open valve.
IMPORTANT:
•
Open valve only when pouring
additives into hopper for mixing.
Close valve when finished.
To stop flow from hopper to
mixing venturi, close valve.
•
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.
CMW
Controls - 22
FM5 Operator’s Manual
Fluid Mixing
CMW
FM5 Operator’s Manual
Operation Overview - 23
Operation Overview
Chapter Contents
Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Setting Up at Jobsite . . . . . . . . . . . . . . . . . . . . . . . 24
Mixing Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Transferring Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Operating in Cold Weather . . . . . . . . . . . . . . . . . . 26
Leaving Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
CMW
Operation Overview - 24
FM5 Operator’s Manual
Planning
Planning
1. Gather information about jobsite (page 28).
2. Inspect jobsite (page 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.
CMW
FM5 Operator’s Manual
Mixing Fluid
Operation Overview - 25
Mixing Fluid
Jobsite hazards could cause death or serious injury. Use
correct equipment and work methods. Use and maintain proper safety
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.
CMW
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).
CMW
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
CMW
Prepare - 28
FM5 Operator’s Manual
Gather Information
Gather Information
A successful job begins before the excavation. The first step in planning is reviewing information already
available about the job and jobsite.
Arrange for Traffic Control
If working near a road or other traffic area, contact local authorities about safety procedures and
regulations.
Prepare for Working Near Existing Utilities
If jobsite may contain electrical lines, wear protective boots and gloves meeting the following standards:
•
•
Boots must have high tops and meet the electric hazard protection requirements of 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.
CMW
FM5 Operator’s Manual
Prepare Jobsite
Prepare - 29
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.
CMW
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, such as bentonite 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
CMW
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
CMW
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.
CMW
FM5 Operator’s Manual
Haul
Transport - 33
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.
CMW
Transport - 34
FM5 Operator’s Manual
Haul
Unhitch Trailer
1. Stop tow vehicle and trailer on level ground.
2. Put manual transmission into first or reverse gear or automatic transmission into park. Turn off ignition.
Set parking brake.
3. Block trailer wheels.
4. To unhitch trailer from tow vehicle, reverse “Hitch Trailer” steps.
CMW
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
CMW
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
Soil type
Drilling fluid recommendation
bentonite or Bore-Gel + medium chain polymer
bentonite or Bore-Gel
smooth, flowing sand
coarse sand or light soil
heavy clay
long chain polymer + Con-Det
long chain polymer + Con-Det
Bore-Gel
swelling clay
rock
CMW
FM5 Operator’s Manual
Polymer
Drilling Fluid Concepts - 37
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.
CMW
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
normal drilling
sand or gravel
rock
Amount to Use
15 lb/100 gal
7 kg/380 L
up to 45 lb/100 gal
up to 50 lb/100 gal
up to 21 kg/380 L
up to 23 kg/380
CMW
FM5 Operator’s Manual
Mixtures
Drilling Fluid Concepts - 39
Basic Fluid Recipes
Soil type
fine sand
Mixture/100 gal (378 L) of water Notes
35 lb (16 kg) Bore-Gel
coarse sand
35 lb (16 kg) Bore-Gel
.5 lb (225 g) No-Sag
Add .5 lb (225 g) of Quik-Trol for
additional filtrate control
fine sand below water 40 lb (18 kg) Bore-Gel
Add .5 - 1 gal (2-4 L) of Dinomul in high
torque situations
table
.75 lb (340 g) Quik-Trol
coarse sand below
water table
40 lb (18 kg) Bore-Gel
.75 lb (340 g) Quik-Trol
.75 lb (340 g) No-Sag
Add .5 - 1 gal (2-4 L) of Dinomul in high
torque situations
gravel
cobble
50 lb (23 kg) Bore-Gel
.75 lb (340 g) Quik-Trol
.75 lb (340 g) No-Sag
Add .5 lb (225 g) of Barolift to reduce loss
of returns
50 lb (23 kg) Bore-Gel
.75 lb (340 g) Quik-Trol
.75 lb (340 g) No-Sag
Add .5 lb (225 g) of Barolift to reduce loss
of returns
sand, gravel, clay or
shale
35 - 40 lb (16-18 kg) Bore-Gel
.5 pt (235 mL) EZ-Mud
.5 gal (2 L) Con-Det
Vary mixture according to percentage of
sand and clay
clay
.5 lb (225 g) Poly Bore
.5 gal (2 L) 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
swelling/sticky clay
solid rock (shale)
.75 - 1 lb (340-450 g) Poly Bore
.5 - 1 gal (2-4 L) 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
40 lb (18 kg) Bore-Gel
Use .5 pt (235 mL) of No Sag for large
diameter or longer bores
solid rock (other than 40 - 50 lb (18-23 kg) Bore-Gel
shale)
Use .5 pt (235 mL) of EZ-Mud in reactive
shales
rock/clay mixture
rock/sand mixture
fractured rock
40 - 50 lb (18-23 kg) Bore-Gel
.5 pt (235 mL) EZ-Mud
40 - 50 lb (18-23 kg) Bore-Gel
Use .5 pt (235 mL) of No Sag for large
diameter or longer bores
50 lb (23 kg) Bore-Gel
.5 - 1lb (225-450 g) No-Sag
Use .5 lb (225 g) of Barolift to reduce fluid
loss to formation
CMW
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.
CMW
FM5 Operator’s Manual
Complete the Job - 41
Complete the Job
Chapter Contents
Rinse Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
CMW
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.
CMW
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
CMW
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
10 Hour
Service - 45
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.
CMW
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.
CMW
FM5 Operator’s Manual
100 Hour
Service - 47
100 Hour
Location
Task
Notes
change engine oil
change air filter
regular service
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.
CMW
Service - 48
FM5 Operator’s Manual
100 Hour
CMW
FM5 Operator’s Manual
Specifications - 49
Specifications
W
L
H
j11om015h.eps
Dimensions
U.S.
Metric
3.1 m
A
Length
Height
Width
123 in
53 in
B
1.3 m
C
25.6 in
660 lb
3164 lb
650 mm
299 kg
1435 kg
Weight, empty
Weight, with full tank (water)
Performance
U.S.
Metric
606 L/min
28 L
Maximum flow rate at 26 viscosity
Mixing hopper capacity
160 gpm
1 ft3
Suction time for 50 lb (22.7 kg)
Suction time for 100 lb (45 kg)
1 min
2 min
1 min
2 min
CMW
Specifications - 50
FM5 Operator’s Manual
Engine
U.S.
Metric
Honda GX160, gasoline
Cooling medium
air
1
Number of cylinders
Displacement
9.9 in3
2.7 in
1.8 in
35°
162 cm3
69 mm
46 mm
Bore
Stroke
* Maximum tilt angle fore & aft
* 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
3.6 L
Fuel tank
.95 gal
0.63 qt
300 gal
Engine oil, including filter
Drilling fluid/mixing tank capacity
0.6 L
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.
CMW
FM5 Operator’s Manual
Procedure
Support - 51
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 Training
For information about on-site, individualized training, contact your Ditch Witch dealer.
CMW
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 rights 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
CMW
FM5 Operator’s Manual
Service Record - 55
Service Record
Service Performed
Date
Hours
CMW
Service Record - 56
FM5 Operator’s Manual
Service Performed
Date
Hours
CMW
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