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CMW FM5 Operator's Manual

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FM5
Operator's
Manual
®
Issue 1.1
CMW
054- 121

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Summary of Contents for CMW FM5

  • Page 1 Operator’s Manual ® Issue 1.1 054- 121...

  • Page 2: Overview

    FM5 Operator’s Manual Chapter Contents Serial Number Location ..... . 2 Intended Use ....... 2 Unit Components .

  • Page 3: Overview

    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°...

  • Page 4: About This Manual

    FM5 Operator’s Manual Unit Components Unit Components 1. tank 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.

  • Page 5: Fm5 Operator's Manual Overview

    FM5 Operator’s Manual Overview - 4...

  • Page 6: Foreword

    FM5 Operator’s Manual 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.
  • Page 7 FM5 Operator’s Manual Foreword - 6 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...

  • Page 8: Table Of Contents

    FM5 Operator’s Manual 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: Fm5 Operator's Manual Contents

    FM5 Operator’s Manual Contents - 8...

  • Page 10: Safety

    FM5 Operator’s Manual Chapter Contents Guidelines ....... . 10 Safety Alert Classifications ....11 Safety Alerts .

  • Page 11: Guidelines

    Use equipment carefully. Stop operation and investigate anything that does not look or feel right. • Do not operate unit where flammable gas is present. • Contact your Ditch Witch dealer if you have any question about operation, maintenance, or equipment use. FM5 Operator’s Manual Guidelines...

  • Page 12: Safety Alert Classifications

    FM5 Operator’s Manual 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 13: Safety Alerts

    Improper control function could cause death or serious injury. If control does not work as described in instructions, stop machine and have it serviced. FM5 Operator’s Manual Jobsite hazards could cause death or serious injury. Use Crushing weight could cause death or serious injury. Use Moving parts could cut off hand or foot.
  • Page 14 FM5 Operator’s Manual 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.

  • Page 15: Emergency Procedures

    Most electric strikes are not noticeable, but indications of a strike include: • power outage • smoke • explosion • popping noises • arcing electricity If any of these occur, assume an electric strike has occurred. FM5 Operator’s Manual Emergency Procedures...

  • Page 16: If An Electric Line Is Damaged

    FM5 Operator’s Manual 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 17: If A Gas Line Is Damaged

    Immediately move battery disconnect switch (if equipped) to disconnect position. • If fire is small and fire extinguisher is available, attempt to extinguish fire. • If fire cannot be extinguished, leave area as quickly as possible and contact emergency personnel. FM5 Operator’s Manual Emergency Procedures...

  • Page 18: Controls

    FM5 Operator’s Manual Controls - 17 Controls Chapter Contents Engine ........18...
  • Page 19 To help start cold engine, This valve regulates air/fuel mixture. close valve. When transporting unit to or This valve separates the fuel tank from jobsite, or anytime from the engine. machine is parked, close valve. Before starting engine, open valve. FM5 Operator’s Manual Engine...
  • Page 20 FM5 Operator’s Manual Engine Item Description 3. Throttle To increase engine speed, move lever away from fuel tank. To decrease engine speed, move lever toward fuel tank. 4. Rope start To start engine, pull rope. 5. Tachometer/Hourmeter Displays engine rpm when engine is running.
  • Page 21 2. Tank discharge valve 3. Circulation valve Item 1. Drain plug 4. Hopper valve 5. Mixing jet valve 6. Discharge valve Description Notes To drain fluid from tank, IMPORTANT: Install plug before filling remove plug. tank. FM5 Operator’s Manual Fluid Mixing...
  • Page 22 FM5 Operator’s Manual Fluid Mixing Item Description 2. Tank discharge valve To allow flow from tank to fluid pump, open valve. To stop flow from tank to fluid pump, turn off engine. 3. Circulation valve To circulate fluid while mixing, open valve.
  • Page 23 FM5 Operator’s Manual Controls - 22 Fluid Mixing...

  • Page 24: Operation Overview

    FM5 Operator’s Manual Operation Overview - 23 Operation Overview Chapter Contents Planning ....... . . 24 Setting Up at Jobsite .

  • Page 25: Planning

    FM5 Operator’s Manual Operation Overview - 24 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.

  • Page 26: Mixing Fluid

    FM5 Operator’s Manual Mixing Fluid Mixing Fluid 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.

  • Page 27: Transferring Fluid

    • For cold weather storage, drain tank and ensure all fluid system valves are open. Also open drain valve on pump. Leaving Jobsite 1. Rinse unit and tools (page 42). 2. Disconnect hoses (page 42). FM5 Operator’s Manual Transferring Fluid...

  • Page 28: Prepare

    FM5 Operator’s Manual Chapter Contents Gather Information ......28 • Arrange for Traffic Control ........28 •...

  • Page 29: Gather Information

    – Utility facilities without overhead lines – Gas or water meters – Junction boxes – Drop boxes – Light poles – Manhole covers – Sunken ground • Mark location of all buried utilities and obstructions. FM5 Operator’s Manual Gather Information...

  • Page 30: Prepare Jobsite

    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.

  • Page 31: Check Supplies And Prepare Equipment

    Prepare Equipment Fluid Levels • fuel • engine oil Condition and Function • filters (air, oil) • tires • hoses and valves • couplers and fittings • water tank FM5 Operator’s Manual Check Supplies and Prepare Equipment...

  • Page 32: Transport

    FM5 Operator’s Manual Chapter Contents Lift ........32 •...

  • Page 33: Lift

    FM5 Operator’s Manual Transport - 32 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 34: Haul

    FM5 Operator’s Manual Haul Haul Crushing weight. If load falls or moves it could kill or crush you. Use proper procedures and equipment or stay away. Inspect Trailer • Check hitch for wear and cracks. Lubricate if needed. • Check battery for 12V charge.

  • Page 35: Unhitch Trailer

    FM5 Operator’s Manual Transport - 34 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.

  • Page 36: Drilling Fluid Concepts

    FM5 Operator’s Manual Chapter Contents Recommended Products ....36 Guidelines ....... . 36 Polymer .

  • Page 37: Recommended Products

    Soil type smooth, flowing sand coarse sand or light soil heavy clay swelling clay rock FM5 Operator’s Manual Recommended Products Drilling fluid recommendation bentonite or Bore-Gel + medium chain polymer bentonite or Bore-Gel long chain polymer + Con-Det long chain polymer + Con-Det Bore-Gel ®...

  • Page 38: Polymer

    FM5 Operator’s Manual 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 39: Mixtures

    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 FM5 Operator’s Manual Amount to Use 15 lb/100 gal 7 kg/380 L up to 45 lb/100 gal up to 21 kg/380 L...

  • Page 40: Basic Fluid Recipes

    FM5 Operator’s Manual Mixtures Basic Fluid Recipes Soil type Mixture/100 gal (378 L) of water fine sand 35 lb (16 kg) Bore-Gel coarse sand 35 lb (16 kg) Bore-Gel .5 lb (225 g) No-Sag fine sand below water 40 lb (18 kg) Bore-Gel table .75 lb (340 g) Quik-Trol...

  • Page 41: Drilling Fluid Requirements

    1 qt (.95 L) of fluid to pass through the funnel. The number of seconds is the viscosity. 5. Thoroughly rinse measuring cup and Marsh funnel. FM5 Operator’s Manual Drilling Fluid Requirements...

  • Page 42: Complete The Job

    FM5 Operator’s Manual Complete the Job - 41 Complete the Job Chapter Contents Rinse Equipment ......42...

  • Page 43: Complete The Job

    FM5 Operator’s Manual Complete the Job - 42 Rinse Equipment Rinse Equipment Spray water onto equipment to remove dirt and mud. Disconnect Disconnect and store hoses and cables.

  • Page 44: Service

    FM5 Operator’s Manual Service - 43 Service Chapter Contents Precautions ......44 Recommended Lubricants/Service Key .

  • Page 45: Precautions

    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. FM5 Operator’s Manual Precautions...

  • Page 46: Engine Oil Temperature Chart

    FM5 Operator’s Manual Service - 45 10 Hour Engine Oil Temperature Chart Temperature range anticipated before next oil change 10 Hour Check Engine Oil Check engine oil at dipstick (shown) before operation and every 10 hours thereafter. Check with unit on level surface and at least 15 minutes after stopping engine.

  • Page 47: Hour

    FM5 Operator’s Manual Service - 46 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.

  • Page 48: 100 Hour

    FM5 Operator’s Manual 100 Hour 100 Hour Location Task change engine oil change air filter Change Engine Oil Change oil every 100 hours. Pull drain plug and drain crankcase while oil is still warm. Refill at fill neck with 2.3 pt (1.1 L) of GEO.
  • Page 49 FM5 Operator’s Manual Service - 48 100 Hour...

  • Page 50: Specifications

    FM5 Operator’s Manual j11om015h.eps Dimensions Length Height Width Weight, empty Weight, with full tank (water) Performance Maximum flow rate at 26 viscosity Mixing hopper capacity Suction time for 50 lb (22.7 kg) Suction time for 100 lb (45 kg) Specifications U.S.

  • Page 51: Specifications

    Specifications are called out according to SAE recommended practices. Specifications are general and subject to change without notice. If exact measurements are required, equipment should be weighed and measured. Due to selected options, delivered equipment may not match that shown. FM5 Operator’s Manual U.S. Metric 9.9 in...

  • Page 52: Support

    FM5 Operator’s Manual Support - 51 Procedure Support Procedure Notify your dealer immediately of any malfunction or failure of Ditch Witch equipment. Always give model, serial number, and approximate date of your equipment purchase. This information should be recorded and placed on file by the owner at the time of purchase.

  • Page 53: Warranty

    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 Ditch Witch Equipment and Parts Limited Warranty Policy Exclusions from Product Warranty FM5 Operator’s Manual Warranty...

  • Page 56: Service Record

    FM5 Operator’s Manual Service Record - 55 Service Record Service Performed Date Hours...

  • Page 57: Service Record

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

Table of Contents