Ditch Witch FM25 Operator's Manual
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Ditch Witch FM25 Operator's Manual

Self-contained drilling fluid unit
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FM25/FM25X
Operator's
Manual
Issue 2.0
053-1187

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Summary of Contents for Ditch Witch FM25

  • Page 1 FM25/FM25X Operator’s Manual Issue 2.0 053-1187...

  • Page 2: Overview

    FM25/FM25X Operator’s Manual Overview - 1 Overview Chapter Contents Serial Number Location ..... . 2 Intended Use ......2 Unit Components .
  • Page 3 Intended Use The FM25/FM25X is a self-contained drilling fluid unit capable of mixing up to 950 gal (3596 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°...
  • Page 4 FM25/FM25X Operator’s Manual Overview - 3 Unit Components Unit Components 1. tank 3. pumps 2. hopper 4. power unit 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.
  • Page 5 FM25/FM25X Operator’s Manual Overview - 4...

  • Page 6: Foreword

    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.
  • Page 7 Issue number 2.0/OM-11/17 Part number 053-1187 Copyright 2007, 2017 by The Charles Machine Works, Inc. and Ditch Witch are registered trademarks of The Charles Machine Works, Inc. This product and its use may be covered by one or more patents at http://patents.charlesmachine.works.

  • Page 8: Table Of Contents

    FM25/FM25X 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...
  • Page 9 FM25/FM25X Operator’s Manual Contents - 8...

  • Page 10: Safety

    FM25/FM25X Operator’s Manual Safety - 9 Safety Chapter Contents Guidelines ....... . 10 California Proposition 65 Warning .

  • Page 11: Guidelines

    • Fully inspect equipment before operating. Repair or replace any worn or damaged parts. Replace missing or damaged safety shields and safety signs. Contact your Ditch Witch dealer for assistance. • Use equipment carefully. Stop operation and investigate anything that does not look or feel right.

  • Page 12: Emergency Procedures

    FM25/FM25X Operator’s Manual Safety - 11 Emergency Procedures Emergency Procedures Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. Before operating any equipment, review emergency procedures and check that all safety precautions have been taken.

  • Page 13: If An Electric Line Is Damaged

    FM25/FM25X Operator’s Manual Safety - 12 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.

  • Page 14: If A Gas Line Is Damaged

    FM25/FM25X Operator’s Manual Safety - 13 Emergency Procedures If a Gas Line is Damaged Fire or explosion possible. Fumes could ignite and cause burns. No smoking, no flame, no spark. 275-419 (2P) Explosion possible. Serious injury or equipment damage could occur.

  • Page 15: If A Fiber Optic Cable Is Damaged

    FM25/FM25X Operator’s Manual Safety - 14 Emergency Procedures If a Fiber Optic Cable is Damaged Do not look into cut ends of fiber optic or unidentified cable. Vision damage can occur. Contact utility company. 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.

  • Page 16: Safety Alert Classification

    FM25/FM25X Operator’s Manual Safety - 15 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.

  • Page 17: Machine Safety Alerts

    FM25/FM25X Operator’s Manual Safety - 16 Machine Safety Alerts Machine Safety Alerts Lift point. See Transport chapter for more information. Tiedown point. See Transport chapter for more information. Misuse of machine can cause death or serious injury. Read and understand operator’s manual and all other safety instructions before use.
  • Page 18 FM25/FM25X Operator’s Manual Safety - 17 Machine Safety Alerts Silica dust. Exposure can cause lung disease. Use breathing protection. Buried electric lines. Contact will cause death or serious injury. Know locations of lines. Stay away.
  • Page 19 FM25/FM25X Operator’s Manual Safety - 18 Machine Safety Alerts Tanks Buried electric lines. Contact will cause death or serious injury. Know locations of lines. Stay away. Tiedown location. See Transport chapter for more information. Lift point. See Transport chapter for more information.

  • Page 20: Controls

    FM25/FM25X Operator’s Manual Controls - 19 Controls Chapter Contents Power Unit ....... 20...
  • Page 21 FM25/FM25X Operator’s Manual Controls - 20 Power Unit Power Unit 1. Ignition 7. Glow plug button 2. Fuel gauge 8. Auxiliary outlet 3. Hourmeter 9. Throttle 4. Engine oil pressure indicator 10. Pump 2 control 5. Coolant temperature indicator 11. Pump 1 control 6.
  • Page 22 FM25/FM25X Operator’s Manual Controls - 21 Power Unit Item Description Notes 2. Fuel gauge Displays fuel level in tank. Use #2 diesel fuel. In temperatures below 40° F (4° C), use #1 diesel fuel. Tank holds 9.2 gal (35 L).
  • Page 23 FM25/FM25X Operator’s Manual Controls - 22 Power Unit Item Description Notes 6. Glow plug wait Lights when intake air pre- indicator heater is operating. Wait until light goes off before starting engine. 7. Glow plug button To activate glow plugs, press.
  • Page 24 FM25/FM25X Operator’s Manual Controls - 23 Power Unit Item Description Notes 11. Pump 1 control To turn on pump, press right side of switch. To turn off pump, press left side of switch.
  • Page 25 FM25/FM25X Operator’s Manual Controls - 24 Item Description Notes Battery disconnect switch To connect, move clockwise. To disconnect, move counterclockwise.
  • Page 26 FM25/FM25X Operator’s Manual Controls - 25 Mixing Unit Mixing Unit j69om001h.eps j69om001h.eps 1. Mixing jet valve 5. Pump drain valve 2. Circulation valve 6. Liquid additive pickup valve 3. Transfer valve 7. Hopper valve 4. Discharge valve 8. Drain plug...
  • Page 27 FM25/FM25X Operator’s Manual Controls - 26 Mixing Unit Item Description Notes 3. Transfer valve To allow flow from pump to pump, open valve. To stop flow from pump to pump, turn off engine. 4. Discharge valve To allow flow from pump to drilling unit, open valve.

  • Page 28: Operation Overview

    FM25/FM25X Operator’s Manual Operation Overview - 27 Operation Overview Chapter Contents Planning ....... . . 28 Setting Up at Jobsite .

  • Page 29: Planning

    FM25/FM25X Operator’s Manual Operation Overview - 28 Planning Planning 1. Gather information about jobsite (page 32). 2. Inspect jobsite (page 33). 3. Check supplies and prepare equipment (page 34). Setting Up at Jobsite 1. Prepare jobsite (page 33). 2. Position fluid unit and connect to drilling unit. See drilling unit operator’s manual.

  • Page 30: Mixing Fluid

    FM25/FM25X Operator’s Manual Operation Overview - 29 Mixing Fluid Mixing Fluid Silica dust. Exposure can cause lung disease. Use breathing protection. To help avoid injury: To help avoid injury: • Use water spray or other means to control dust. •...

  • Page 31: Transferring Fluid

    FM25/FM25X Operator’s Manual Operation Overview - 30 Transferring Fluid Transferring Fluid Buried electric lines. Contact will cause death or serious injury. Know locations of lines. Stay away. To help avoid injury: Remember that if electrical strike occurs while fluid hose is connected to drilling unit, fluid system will also become electrified.

  • Page 32: Prepare

    FM25/FM25X Operator’s Manual Prepare - 31 Prepare Chapter Contents Gather Information ......32 • Arrange for Traffic Control ........32 •...

  • Page 33: Gather Information

    FM25/FM25X Operator’s Manual Prepare - 32 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.

  • Page 34: Inspect Jobsite

    FM25/FM25X Operator’s Manual Prepare - 33 Inspect Jobsite Inspect Jobsite • Follow U.S. Department of Labor regulations on excavating and trenching (Part 1926, Subpart P) and other similar regulations. • Mark proposed path with white paint and have underground utilities located before working.

  • Page 35: Check Supplies And Prepare Equipment

    FM25/FM25X Operator’s Manual Prepare - 34 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.

  • Page 36: Transport

    FM25/FM25X Operator’s Manual Transport - 35 Transport Chapter Contents Lift ........36 •...
  • Page 37 FM25/FM25X Operator’s Manual Transport - 36 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.
  • Page 38 FM25/FM25X Operator’s Manual Transport - 37 Haul Haul IMPORTANT: For trailer information, see the trailer manufacturer’s manual.
  • Page 39 FM25/FM25X Operator’s Manual Transport - 38 Haul...

  • Page 40: Drilling Fluid Concepts

    FM25/FM25X Operator’s Manual Drilling Fluid Concepts - 39 Drilling Fluid Concepts Chapter Contents Recommended Products ....40 Guidelines ....... . 40 Polymer .

  • Page 41: Recommended Products

    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.

  • Page 42: Polymer

    FM25/FM25X Operator’s Manual Drilling Fluid Concepts - 41 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: •...

  • Page 43: Mixtures

    FM25/FM25X Operator’s Manual Drilling Fluid Concepts - 42 Mixtures Mixtures NOTICE: Bentonite does not mix well in water containing polymer. To use both, mix bentonite first, then add polymer. • If chemicals are added in the wrong order, they will not mix properly and will form clumps.

  • Page 44: Basic Fluid Recipes

    FM25/FM25X Operator’s Manual Drilling Fluid Concepts - 43 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 Add .5 lb (225 g) of Quik-Trol for .5 lb (225 g) No-Sag...

  • Page 45: Drilling Fluid Requirements

    FM25/FM25X Operator’s Manual Drilling Fluid Concepts - 44 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.

  • Page 46: Complete The Job

    FM25/FM25X Operator’s Manual Complete the Job - 45 Complete the Job Chapter Contents Rinse Equipment ......46...
  • Page 47 FM25/FM25X Operator’s Manual Complete the Job - 46 Rinse Equipment Rinse Equipment Spray water onto equipment to remove dirt and mud. Disconnect Disconnect and store hoses and cables.

  • Page 48: Service

    FM25/FM25X Operator’s Manual Service - 47 Service Chapter Contents Service Precautions ......48 • Welding Precaution ........48 •...

  • Page 49: Service Precautions

    FM25/FM25X Operator’s Manual Service - 48 Service Precautions Service Precautions Misuse of machine can cause death or serious injury. Read and understand operator’s manual and all other safety instructions before use. To help avoid injury: • Unless otherwise instructed, all service should be performed with engine off and engine cool.

  • Page 50: Recommended Lubricants/Service Key

    For more information on engine lubrication and maintenance, see your Kubota 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 71 to record all required service to your machine.

  • Page 51: Engine Oil Temperature Chart

    This unit was filled with Fleetguard ES Compleat™ coolant (blue in color) before shipment from factory. ® This coolant is available, pre-diluted, from your Ditch Witch dealer as part number 255-1055. Add or replace with heavy duty diesel engine coolant meeting ASTM D6210.
  • Page 52 In certain markets, higher blends may be used if certain steps are taken. Extra attention is needed when using biodiesel, especially when operating in cold weather or storing fuel. Contact your Ditch Witch dealer or the engine manufacturer for more information.

  • Page 53: 10 Hour

    FM25/FM25X Operator’s Manual Service - 52 10 Hour 10 Hour Location Task Notes Check coolant level DEAC Check engine oil level Check Coolant Level Check coolant level every 10 hours. Add coolant at cap (shown) as needed to maintain level between LOW and FULL on overflow tank.

  • Page 54: Hour

    FM25/FM25X Operator’s Manual Service - 53 50 Hour 50 Hour Location Task Notes Check air filter Change engine oil and filter Initial, DEO Lube pump Check radiator Check Air Filter Check air filter every 50 hours. Replace as needed. Change Engine Oil and Filter (Initial) Change engine oil after 50 hours while oil is warm and with unit parked on level ground.
  • Page 55 FM25/FM25X Operator’s Manual Service - 54 50 Hour Lube Pump Lube zerk (2) with MPG every 50 hours. Grease cavity is full when grease escapes from grease cylinder relief valve (1). Check Radiator Check radiator for dirt, grass, and other foreign matter every 50 hours.

  • Page 56: 100 Hour

    FM25/FM25X Operator’s Manual Service - 55 100 Hour 100 Hour Location Task Notes Change fuel filters Check fan belt tension Change Fuel Filters Change fuel filter (1) and inline fuel filter (2) every 100 hours. 1. Remove filters. 2. Fill new filter with clean fuel.

  • Page 57: 150 Hour

    FM25/FM25X Operator’s Manual Service - 56 150 Hour 150 Hour Change Engine Oil and Filter Change engine oil every 150 hours while oil is warm and with unit parked on level ground. 1. Open drain (3). 2. Drain crankcase while oil is warm.

  • Page 58: 500 Hour

    FM25/FM25X Operator’s Manual Service - 57 500 Hour 500 Hour Location Task Notes Replace fan belt Replace pump drive belt Replace Fan Belt Replace fan belt (shown) every 500 hours. To replace 1. Loosen bolts (1, 2) and remove belt.

  • Page 59: 2000 Hour

    FM25/FM25X Operator’s Manual Service - 58 2000 Hour 2000 Hour Change Engine Coolant Drain cooling system at drain (2). Add approved coolant at fill (1) every two years or 2000 hours. NOTICE: • The use of non-approved coolant may lead to engine damage or premature engine failure and will void engine warranty.

  • Page 60: As Needed

    FM25/FM25X Operator’s Manual Service - 59 As Needed As Needed Location Task Notes Adjust fan belt Adjust pump drive belt Check battery Charge battery Adjust Fan Belt Adjust fan belt as needed. 1. Turn off engine and remove key. 2. Apply moderate thumb pressure to belt between pulleys where shown.
  • Page 61 FM25/FM25X Operator’s Manual Service - 60 As Needed Check Battery Check battery as needed. Keep battery clean and terminals free of corrosion. To clean: 1. Turn battery disconnect switch, if equipped, to the off position. 2. Ensure that no ignition sources are near batteries.
  • Page 62 FM25/FM25X Operator’s Manual Service - 61 As Needed Charge Battery Explosion possible. Serious injury or equipment damage could occur. Follow directions carefully. To help avoid injury: • Use a single 12V maximum source for charging. Do not connect to rapid chargers or dual batteries.
  • Page 63 FM25/FM25X Operator’s Manual Service - 62 As Needed Charging Procedure (Engine Off) 1. Park service vehicle close to disabled equipment but do not allow vehicles to touch. Engage parking brake in both vehicles. 2. Turn the ignition switch to the OFF position in both vehicles, and turn off all electrical loads. Disconnect the machine controller.

  • Page 64: Specifications

    FM25/FM25X Operator’s Manual Specifications - 63 Specifications Component weights U.S. Metric Pumping/power unit 1150 lb 520 kg Mixing hopper (each) 100 lb 50 kg 500-gal (1890-L) tank and hoses (each) 500 lb 227 kg 500-gal (1890-L) tank and hoses (w/500 gal/1890 L water)
  • Page 65 FM25/FM25X Operator’s Manual Specifications - 64 Dimensions with two 500-gal (1892-L) tanks U.S. Metric Length (as shown; variable with layout flexibility) 175 in 4.45 m Width (as shown; variable with layout flexibility) 92 in 2.34 m Height, without fill pipe 68 in 1.73 m...
  • Page 66 FM25/FM25X Operator’s Manual Specifications - 65 Engine U.S. Metric Kubota D1105, diesel Cooling medium water Injection indirect Aspiration natural Number of cylinders Displacement 1.12 L 68.5 in Bore 3.07 in 78.0 mm Stroke 3.09 in 78.4 mm Manufacturer’s gross power (per SAE J1995) 24.8 hp...
  • Page 67 FM25/FM25X Operator’s Manual Specifications - 66 Fluid Capacities U.S. Metric Fuel tank 9.2 gal 35 L Engine oil, including filter 4.2 qt Noise levels This machine can generate sound levels exceeding 80 dBA. Always wear appropriate hearing protection when operating machine. Find sound power and pressure information at www.ditchwitch.com, or contact customersupport@ditchwitch.com.

  • Page 68: Support

    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.
  • Page 69 Defects will be determined by an inspection within thirty (30) days of the date of failure of the product or part by Ditch Witch Product Support (DWPS) or its authorized dealer. DWPS will provide the location of its inspection facilities or its nearest authorized dealer upon inquiry.

  • Page 72: Service Record

    FM25/FM25X Operator’s Manual Service Record - 71 Service Record Service Performed Date Hours...
  • Page 73 FM25/FM25X Operator’s Manual Service Record - 72 Service Performed Date Hours...

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