XT1600 Operator’s Manual Overview - 1 Overview Chapter Contents Serial Number Location ..... . 2 Intended Use ....... 3 Unit Components .
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XT1600 Operator’s Manual Overview - 2 Serial Number Location Serial Number Location Record serial numbers and date of purchase in spaces provided. XT1600 serial number is located as shown. Date of manufacture Date of purchase XT1600 serial number Engine serial number...
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The XT1600 excavator allows 260° swing and digging depths to 11’ 2” (3.4 m). The XT1600 lift arms have a quick attach mount plate which makes it easy for an operator to connect different attachments. The unit is designed for operation in temperatures typically experienced in earth moving and construction work environments.
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XT1600 Operator’s Manual Overview - 4 Operator Orientation Operator Orientation 1. Front of unit 3. Rear of unit 2. Right of unit 4. Left of unit Right and left sides of machine are determined by facing front (toward lift arms) of unit while seated in the operator’s station.
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.
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Copyright 2006, 2008, 2011 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.
XT1600 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...
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XT1600 Operator’s Manual Contents - 8 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...
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.
XT1600 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.
XT1600 Operator’s Manual Safety - 12 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.
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XT1600 Operator’s Manual Safety - 13 Safety Alerts Fall possible. Riders can fall from machine and be injured or killed. Only operator is allowed on machine. Rollover possible. If machine rolls over, you could be thrown from seat and killed or crushed. Wear seat belt.
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XT1600 Operator’s Manual Safety - 14 Safety Alerts 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.
XT1600 Operator’s Manual Safety - 15 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. Electric Strike Description When working near electric cables, remember the following: •...
XT1600 Operator’s Manual Safety - 16 Emergency Procedures If an Electric Line is Damaged If you suspect an electric line has been damaged and you are on unit, DO NOT MOVE. Remain on unit and take the following actions. The order and degree of action will depend upon the situation.
XT1600 Operator’s Manual Safety - 17 Emergency Procedures If a Fiber Optic Cable is Damaged Do not look into cut ends of fiber optic or unidentified cable. Vision damage can occur. If Machine Catches on Fire Perform emergency shutdown procedure and then take the following actions. The order and degree of action will depend on the situation.
XT1600 Operator’s Manual Controls - 20 Front Console Front Console Controls 1. 2-Speed flow switch 6. Front attachment lock switch 2. Front light switch 7. Glow plug switch 3. Rear light switch 8. Ignition switch 4. Auxiliary power outlet 9. Throttle 5.
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XT1600 Operator’s Manual Controls - 21 Front Console Item Description Notes 3. Rear light switch To turn on, press right side. To turn off, press left side. 4. Auxiliary power outlet To operate work lights or other 12V devices, plug into outlet.
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XT1600 Operator’s Manual Controls - 22 Front Console Item Description Notes 8. Ignition switch To start engine, insert key and IMPORTANT: If engine does not start turn clockwise. or stalls, turn key to STOP and then restart. To stop engine, turn key counterclockwise.
XT1600 Operator’s Manual Controls - 26 SAE/ISO Control Valve SAE/ISO Control Valve 1. SAE/ISO control Item Description Notes 1. SAE/ISO control To operate in ISO mode, turn Loosen wing bolt to unlock lever. lever to position 1. Tighten wing bolt to lock lever into To operate in SAE mode, turn place.
XT1600 Operator’s Manual Controls - 27 Joysticks Joysticks 1. Right joystick 7. Left stabilizer switch 2. Attachment drive switch 8. Right stabilizer switch 3. Attachment power switch (optional) 9. Ground drive joystick 4. Left joystick 10. Operator presence switch 5. Boom offset switch 11.
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XT1600 Operator’s Manual Controls - 28 Joysticks Item Description Notes 1. Right joystick With work mode switch in IMPORTANT: tool carrier mode: • Control can perform more than • To move lift arms down, one action at a time. Using them push.
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XT1600 Operator’s Manual Controls - 29 Joysticks Item Description Notes 3. Attachment power To activate attachment IMPORTANT: Optional auxiliary switch electric power in forward, electric kit must be installed for this push top. switch to function. To activate attachment electric power in reverse, push bottom.
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XT1600 Operator’s Manual Controls - 30 Joysticks Item Description Notes 6. 2-Speed ground drive To select high speed, press switch top. To select low speed, press bottom. 7. Left stabilizer switch While facing the excavator: IMPORTANT: If operator is facing tool carrier, control operates •...
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XT1600 Operator’s Manual Controls - 31 Joysticks Item Description Notes 10. Operator presence For use in excavator mode: IMPORTANT: The operator presence switch switch is not necessary in tool carrier • To enable ground drive, mode. press. • To disable ground drive, release.
XT1600 Operator’s Manual Controls - 32 Seat Seat 1. Seat belt 3. Operator’s station pivot control 2. Seat slide control Item Description Notes 1. Seat belt To fasten, insert latch into NOTICE: Always fasten seat belt buckle. Adjust until seat belt when operating unit.
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XT1600 Operator’s Manual Controls - 33 Seat Item Description Notes 2. Seat slide control To slide forward or backward, move left. To lock seat in position, move right. 3. Operator’s station pivot To pivot, press and swing control station to desired position.
XT1600 Operator’s Manual Controls - 34 Battery Battery 1. Battery disconnect switch Item Description Notes 1. Battery disconnect To disconnect, move switch Use when servicing unit and during switch so that indicator points left. long-term storage. To connect, move switch so...
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XT1600 Operator’s Manual Operation Overview - 36 Planning Planning 1. Gather information about jobsite. See page 38. 2. Inspect jobsite. See page 39. 3. Classify jobsite. See page 40. 4. Check supplies and prepare equipment. See page 42. 5. Load unit onto truck or trailer. See page 52.
XT1600 Operator’s Manual Prepare - 38 Gather Information Gather Information A successful job begins before you dig. The first step in planning is reviewing information already available about the job and jobsite. Review Job Plan Review blueprints or other plans. Check for information about existing or planned structures, elevations, or proposed work that may be taking place at the same time.
XT1600 Operator’s Manual Prepare - 39 Inspect Site Inspect Site Inspect jobsite before transporting equipment. Check for the following: • changes in elevation such as hills or other open trenches • obstacles such as buildings, railroad crossings, or streams •...
XT1600 Operator’s Manual Prepare - 40 Classify Jobsite Classify Jobsite Inspect Jobsite • Follow U.S. Department of Labor regulations on excavating and trenching (Part 1926, Subpart P) and other similar regulations. • Contact your local One-Call (811 in USA) or the One-Call referral number (888-258-0808 in USA and Canada) to have underground utilities located before working.
XT1600 Operator’s Manual Prepare - 41 Classify Jobsite Apply Precautions Once classified, precautions appropriate for jobsite must be taken. Electric Jobsite Precautions Use one or both of these methods. • Expose line by careful hand digging or soft excavation. •...
XT1600 Operator’s Manual Prepare - 42 Check Supplies and Prepare Equipment Check Supplies and Prepare Equipment Supplies • fuel • keys • personal protective equipment, such as hard hat and safety glasses Fluid Levels • fuel • hydraulic fluid •...
XT1600 Operator’s Manual Drive - 44 Start Unit Start Unit EMERGENCY SHUTDOWN: Turn ignition switch to STOP. 1. Fasten and adjust seat belt. 2. Ensure all controls are in neutral. 3. If necessary, use glow plug button to warm cold engine. See page 21.
XT1600 Operator’s Manual Drive - 45 Drive Drive General Operation NOTICE: When driving unit more than a few feet (meters), pivot seat so that operator is facing lift arms. If operator is facing excavator, operation of track drive controls is reversed.
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XT1600 Operator’s Manual Drive - 46 Drive Safe Slope Operation Tipover possible. Machine can tip over and crush you. • Always operate with heavy end uphill. • Always carry load low. High load can cause tipping, loss of load or loss of visibility.
XT1600 Operator’s Manual Drive - 47 Steer Steer NOTICE: When driving unit more than a few feet (meters), pivot seat so that operator is facing lift arms. If operator is facing excavator, operation of track drive controls is reversed. To steer while moving forward, push forward and then move to left or right. Unit will turn to left or right.
XT1600 Operator’s Manual Drive - 48 Shut Down Shut Down 1. Move all controls to neutral position. 2. Ensure lift arms are lowered to ground and ensure excavator boom lock is engaged. 3. Run engine at low idle for three minutes to cool.
XT1600 Operator’s Manual Transport - 50 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.
XT1600 Operator’s Manual Transport - 51 Haul Haul Inspect Trailer • Check hitch for wear and cracks. Lubricate if needed. • Check u-bolts and axles for wear. Replace if needed. • Check fasteners for wear and tightness. Replace or tighten if needed.
XT1600 Operator’s Manual Transport - 52 Haul Load Crushing weight. If load falls or moves it could kill or crush you. Use proper procedures and equipment or stay away. NOTICE: • Load and unload trailer on level ground. • Verify that trailer wheels are blocked.
XT1600 Operator’s Manual Transport - 53 Haul Tie Down Points Tiedown points are identified by tiedown decals. Securing to trailer at other points is unsafe and can damage machinery. Procedure Incorrect procedures could result in death, injury, or property damage.
XT1600 Operator’s Manual Transport - 54 Haul Unload Crushing weight. If load falls or moves it could kill or crush you. Use proper procedures and equipment or stay away. NOTICE: • Load and unload trailer on level ground. • Ensure trailer wheels are blocked.
XT1600 Operator’s Manual Transport - 55 Under normal conditions, unit should not be towed. If unit breaks down and towing is necessary: • Do not tow for more than 200 yd (180 m). • Tow at less than 1 mph (1.6 km/h).
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XT1600 Operator’s Manual Transport - 56...
IMPORTANT: This chapter covers how to use the excavator. For information on how to use front- mounted attachments, refer to controls chapter and attachment operator’s manual. The XT1600 can perform a variety of different kinds of work in excavator mode. All basic excavator work involves filling and dumping the bucket.
XT1600 Operator’s Manual Dig - 59 Overview Dumping Bucket Use right and left joysticks to control excavator dipper, boom, and bucket. 1. Position unit. Onto truck Into hole or onto ground Position unit between material to be loaded and Position unit to minimize the need for travel.
XT1600 Operator’s Manual Dig - 60 Diggin g Diggin g Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. NOTICE: Cutting, drilling, or working materials such as concrete, sand, or rock containing quartz may result in exposure to silica dust.
XT1600 Operator’s Manual Dig - 61 Diggin g Single Inline Trench 1. Position unit with tracks parallel with the intended digging path. 2. Fill and dump buckets. 3. Reposition unit as needed to continue trench. IMPORTANT: If operator is facing excavator when driving, unit movements are reversed.
XT1600 Operator’s Manual Dig - 62 Diggin g Multiple Trenches 1. Position unit in a central location to the intended digging paths. 2. Swing excavator and offset boom as needed to align with first digging path. 3. Fill and dump buckets.
XT1600 Operator’s Manual Systems and Equipment - 64 Front Attachments Front Attachments Connect Attachment Attachment IMPORTANT: Before connecting attachment to unit, ensure that mount and receiver plates are free of dirt and debris. 1. Position attachment on level surface with enough space behind it to accommodate unit.
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XT1600 Operator’s Manual Systems and Equipment - 65 Front Attachments 7. Turn ignition switch off and remove key. 8. Push lock pin handles down to secure attachment to lift plate. Note: If unit is equipped with hydraulic attachment lock option, move attachment lock switch to the lock position.
Keep bystanders clear of work area. • Do not walk or work under raised attachments unless lift arms are securely supported. See “Joysticks” on page 27 for a description of XT1600 front-attachment controls and refer to attachment operator’s manual for specific attachment operating instructions.
XT1600 Operator’s Manual Systems and Equipment - 67 Optional Equipment Optional Equipment See your Ditch Witch dealer for more information about the following optional equipment. Equipment Description Ditch Witch XT series a variety of attachments are available to expand the capabilities of the tool...
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XT1600 Operator’s Manual Systems and Equipment - 68 Optional Equipment...
XT1600 Operator’s Manual Complete the Job - 69 Complete the Job Chapter Contents Rinse Equipment ......70 Disconnect Attachment .
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XT1600 Operator’s Manual Complete the Job - 70 Rinse Equipment Rinse Equipment 1. Spray water onto equipment to remove dirt and mud. NOTICE: Do not spray water onto operator’s console. Electrical components could be damaged. Wipe down instead. 2. Open hood and remove debris from inside of unit.
XT1600 Operator’s Manual Service - 71 Service Chapter Contents Service Precautions ......72 Lubrication Overview ..... . 73 Recommended Lubricants/Service Key .
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XT1600 Operator’s Manual Service - 72 Service Precautions Service Precautions Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly. NOTICE: Unless otherwise instructed, all service should be performed with engine off. Working Under Raised Lift Arms Crushing weight could cause death or serious injury.
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XT1600 Operator’s Manual Service - 73 Lubrication Overview Lubrication Overview See next page for service key.
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For more information on engine lubrication and maintenance, see your Kubota engine manual. NOTICE: • Use only genuine Ditch Witch parts, filters, approved lubricants, and approved coolants to maintain warranty. • Use the “Service Record” on page 101 to record all required service to your machine.
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XT1600 Operator’s Manual Service - 75 Recommended Lubricants/Service Key Engine Oil Temperature Chart Temperature range anticipated before next oil change Track Planetary Gear Oil Temperature Chart Use SAE 85W-140 lubricating oil in operating temperatures up to 90°F (32°C). Synthetic oil 75W-140 is recommended in operating temperatures above 80°F (27°C).
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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. Approved Coolant Any coolant is approved for use with this unit.
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XT1600 Operator’s Manual Service - 78 10 Hour Clean Radiator Screen Clean radiator screen every 10 hours. To access radiator screen, remove bolts and lift screen up. Check Radiator Fins Check radiator fins for dirt, grass, and other foreign matter every 10 hours. Clean out with compressed air or spray wash if required.
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XT1600 Operator’s Manual Service - 79 10 Hour Lubricate Excavator Lubricate excavator every 10 hours of use. Apply MPG at each of the 13 zerks. Check Track Tension Check track tension every 10 hours. Tracks are properly tensioned when inner rod (1) is flush with end of cylinder (2).
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XT1600 Operator’s Manual Service - 81 50 Hour Change Engine Oil and Filter (Initial) Change engine oil and filter after 50 hours. 1. Remove large cover plate under unit to access drain (3, on side of pan). 2. Drain crankcase while oil is warm.
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XT1600 Operator’s Manual Service - 82 50 Hour Change Planetary Gearbox Oil (Initial) Change planetary gearbox oil after 50 hours. To change 1. Position one plug level with center of track and the other at the bottom as shown. 2. Remove plugs (1, 2) and drain oil.
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XT1600 Operator’s Manual Service - 83 100 Hour 100 Hour Location Task Notes Change fuel filter Change inline fuel filter Check track rollers Change Fuel Filter Change fuel filter every 100 hours. 1. Remove filter. 2. Fill new filter with clean fuel.
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XT1600 Operator’s Manual Service - 84 200 Hour Check Track Rollers Check track rollers for wear every 100 hours. Replace as needed. 200 Hour Change Engine Oil and Filter Change engine oil and filterevery 150 hours. 1. Remove large cover plate under unit to access drain (3, on side of pan).
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XT1600 Operator’s Manual Service - 85 250 Hour 250 Hour Location Task Notes Change air filter Check planetary gearbox oil SAE 80W140 or synthetic 75W140 Change hydraulic filter Change Air Filter Change air filter every 250 hours. Change more frequently if operating in dusty conditions.
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XT1600 Operator’s Manual Service - 86 250 Hour Check Planetary Gearbox Oil Level Check planetary gearbox oil level every 50 hours. Position one plug level with center of track and the other at the bottom as shown. Oil level should be visible at fill plug (shown).
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XT1600 Operator’s Manual Service - 87 500 Hour 500 Hour Replace Fan Belt Replace fan belt every 500 hours. Adjust properly. See page 89. 1000 Hour Location Task Notes Change hydraulic fluid and filter THf16 gal (60.5 L) Change track planetary oil...
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XT1600 Operator’s Manual Service - 88 2000 Hour Change Planetary Gearbox Oil Change planetary gearbox oil every 1000 hours. To change 1. Position one plug level with center of track and the other at the bottom as shown. 2. Remove plugs (1, 2) and drain oil.
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XT1600 Operator’s Manual Service - 89 As Needed As Needed Location Task Notes Adjust track tension Empty radiator cleanout Adjust fan belt Adjust pump drive belt Adjust Track Tension Adjust track tension as needed. To increase tension, pump MPG into cylinder at point shown.
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XT1600 Operator’s Manual Service - 90 As Needed Adjust Pump Drive Belt Adjust pump drive belt as needed. 1. Raise lift arms and engage props. See “Working Under Raised Lift Arms” on page 72. 2. Turn off engine and remove key.
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XT1600 Operator’s Manual Specifications - 91 Specifications General Dimensions U.S. Metric Wheelbase/track length 58” 1.5 m Overall height of machine 107” 2.7 m Tool Carrier Dimensions U.S. Metric Operating height with standard bucket, max 155” 3.9 m Hinge pin height, max 121”...
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XT1600 Operator’s Manual Specifications - 92 Excavator Dimensions U.S. Metric Reach from main swing joint 219” 5.6 m Max reach from swing post 177” 4.5 m Reach from swing post at grade 176” 4.5 m Vertical wall depth, max. 77”...
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XT1600 Operator’s Manual Specifications - 93 Tool Carrier Dimensions U.S. Metric Bucket width, max 73” 1.8 m Excavator Dimensions U.S. Metric Swing angle from center 130° 130° Total swing angle 260° 260° Performance U.S. Metric Ground drive speed, forward 3.5/6.8 mph 5.6/10.9 km/h...
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XT1600 Operator’s Manual Specifications - 94 Power U.S. Metric Engine: Kubota V2003-M-DI-TE2B diesel Cooling medium: liquid coolant (see “Approved Coolant” on page 76) Number of cylinders: 4 Injection: direct Displacement 112 in 1835 cm Bore 3.27” 83 mm Stroke 3.64”...
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SAE reserve capacity 80 min, SAE cold crank @ 0°F (-18°C) 800 amp, 12V electrical system Vibration Levels Under normal operation of the excavator or tool carrier of the XT1600, the vibration level to the arms does not exceed 6.18 m/sec .
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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.
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Subject to the limitation 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 SK5 attachments).
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XT1600 Operator’s Manual Service Record - 101 Service Record Service Performed Date Hours...
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XT1600 Operator’s Manual Service Record - 102 Service Performed Date Hours...
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