HP (Hewlett-Packard) FM5 manual

FM5 Operator ’ s Manual 054- 121 Issue 1.1 CMW ®[...]

FM5 Operator ’ s Manual Over view - 1 CMW Overview Chapter Content s Seria l Numb er Loc ation . . . . . . . . . . . . . . . . . . . . . . 2 Intend ed Us e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Unit Compo nent s . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 About This Man ua l . . . . . . . . . . . . . . . . . [...]

Overview - 2 FM5 Operator ’ s Manual Serial Number Location CMW Serial Number Location Record ser ial num bers and date of purc hase in s paces provid ed. Fluid un it se rial num ber is locate d as sho wn. Intended Use The FM5 i s a self -con tained drillin g flui d unit capabl e of mi xing up to 30 0 gal (1 136 L) of drill ing fluid per tank and[...]

FM5 Operator ’ s Manual O verv iew - 3 Unit Components CMW Unit Component s About This Manual This m anual con tains inf ormation for th e proper use of thi s machi ne. Se e the be ige O pera ti on Ov erv iew pages for ba sic opera ting proc edur es. Cross referenc es suc h as “ S ee page 50 ” will direct you to detailed procedu res. Bulleted[...]

Overview - 4 FM5 Operator ’ s Manual CMW[...]

FM5 Operator ’ s Manual Foreword - 5 CMW Foreword This m anual is an imp ortant part of y our equip ment. It provide s sa fety in formatio n and op eration instruc tions to help you use an d main tain your Ditc h Witch e quipm ent. Read this manual be fore u sing yo ur equ ipmen t. Keep it with the equip ment at all times for future refer ence. I[...]

Foreword - 6 FM5 Operator ’ s Manual CMW FM5 Operator ’ s Manual Issue nu mber 1.1 /OM-1 1 /03 Part nu mber 05 4-121 Copyright 2003 by The Charles M achine Works, Inc. , Ditch Witc h, CMW , A utoCrowd, Modula rmatic, Je t T rac, Roto W itch, Sub site, Fluid Mis er , Pe rma-So il, Power Pipe, S uper Wi tch, S uper Wit ch II, Pie rce Ai rrow , Th[...]

FM5 Operator ’ s Manual Con ten ts - 7 CMW Content s Overv iew machine seria l number , informa tion a bout th e typ e of wo rk this machi ne is desig ned to perform, basic machin e comp onents, an d how to use this manual 1 Foreword part number , revisi on level, and pub lica tion dat e of this manua l, and f actory c ontact informat ion 5 Safet[...]

Contents - 8 FM5 Operator ’ s Manual CMW[...]

FM5 Operator ’ s Manual Safe ty - 9 CMW Safety Chapter Content s Guide lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 Safety Alert Classi fica tions . . . . . . . . . . . . . . . . . . 1 1 Safet y Ale rt s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Emerg enc y P rocedur es . . . . . . . . . . . . . .[...]

Safe ty - 10 FM5 Operator ’ s Manual Guidelines CMW Guidel ines Follow these gui deline s before operatin g any jobsite equipm ent: • Complete p roper tr aining a nd re ad operat or ’ s manual befo re usin g equipme nt. • Contact One-C all (888- 258-080 8) and any uti lity com panies which do not subsc ribe to One -Call. Have all under grou[...]

FM5 Operator ’ s Manual Safety - 1 1 Safety A lert Cl assifi cations CMW Safety Alert Classifications These cl assific ations a nd the i cons def ined o n the fol lowin g pages work tog ether to alert y ou to si tuation s which co uld be har mful to you, jo bsite bystande rs or you r equipm ent. Wh en you see th ese word s and icons in th e book [...]

Safe ty - 12 FM5 Operator ’ s Manual Safety Alerts CMW Safety Alert s Electric shock . Contactin g electr ic line s will cause d eath or serio us injur y . Know loc ation o f lines a nd stay a way . Deadly ga ses. Lack of oxyge n or p resenc e of gas wi ll ca use sick ness or death. Pr ovid e ventila tion. Jobsite haza rds cou ld ca use de ath or[...]

FM5 Operator ’ s Manual Safety - 13 Safety Alerts CMW Fire or explosi on possi ble. Fu mes coul d igni te and ca use bu rns. No smokin g, no fl ame, no spark. Moving t raffic - haz ardous situa tion. De ath or se riou s injur y could resu lt. Avoid moving v ehicle s, wear hi gh vi sibili ty cloth ing, po st app ropriat e warn ing si gns. Flying o[...]

Safe ty - 14 FM5 Operator ’ s Manual Emergency Procedures CMW Emergenc y Procedures Before op erating a ny equ ipment , revi ew emerge ncy p rocedur es an d check t hat a ll safety precaut ions h ave been taken. Electri c Str ike Description When w orking nea r ele ctric cab les, rem ember the follow ing: • Electric ity fo llows al l paths to g[...]

FM5 Operator ’ s Manual Safety - 15 Emergency Procedures CMW If an Electri c Line is Damaged If you su spec t an ele ctric line ha s been da maged and yo u are on tr uck or traile r , DO NOT MOVE. Remain on truck or trai ler and take the followi ng actio ns. The orde r and de gree of action will dep end on the situa tion. • W a rn peopl e near [...]

Safe ty - 16 FM5 Operator ’ s Manual Emergency Procedures CMW If a Gas L ine is Dam aged If you s uspect a gas l ine has been d amaged , take the fol lowing actions . The o rder an d degr ee of a ction wi ll depend on the si tuation . • Immediate ly shut o ff engine(s) , if this can be done s afely an d quic kly . • Remove an y ign ition sou [...]

FM5 Operator ’ s Manual Controls - 17 CMW Controls Chapter Content s Engin e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Fluid Mixi ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20[...]

Controls - 18 FM5 Operator ’ s Manual Eng ine CMW Engine 1. Choke 2. Fuel shuto ff valve 3. Throttle 4. T achometer/Ho urmeter 5. Rope start Item Description Notes 1. Choke T o he lp start col d engine, close v alve. This val ve regu lates air/fu el mixtu re. 2. Fuel shutoff valve When tra nsporti ng unit to or from jobsite, or anytime machine is[...]

FM5 Operator ’ s Manual Controls - 19 Engine CMW 3. Thrott le T o in crease engin e spee d, move lev er aw ay from fuel tank. T o de crease engine speed , move lev er towar d fuel tank. IMPORT ANT : I ncreas ing engin e speed al so in crea ses p ump flow . 4. Rope start T o start en gine, p ull rope . Fuel shut- off valve op en for thi s control [...]

Controls - 20 FM5 Operator ’ s Manual Fluid Mixing CMW Flui d Mixing 1. Drain pl ug 2. T ank di scha rge val ve 3. Circulati on valve 4. Hopper val ve 5. Mixing jet valve 6. Discharge valv e Item Description Notes 1. Drain plug T o drain fl uid from tank, remove plug. IMPORT ANT : Install plug bef ore filli ng tank.[...]

FM5 Operator ’ s Manual Controls - 21 Fluid Mixing CMW 2. T an k discharg e val ve T o all ow flow fr om tank to fluid pump, o pen va lve. T o stop f low from tank t o fluid pump, tur n off engine. IMPORT ANT : C lose valv e only when discon necting h ose to fluid pump. 3. Circulatio n valve T o circu late flui d while mixi ng, open val ve. T o s[...]

Controls - 22 FM5 Operator ’ s Manual Fluid Mixing CMW[...]

FM5 Operator ’ s Manual Operat ion Over view - 2 3 CMW Operation Overview Chapter Content s Planni ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Settin g U p at Job sit e . . . . . . . . . . . . . . . . . . . . . . . 24 Mixi ng Flui d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 T ransferr in g Fluid [...]

Operation Overvi ew - 24 FM5 Operator ’ s Manual Planning CMW Planning 1. Gather inf ormati on abo ut jobsit e (page 28). 2. I nspec t jobsite (p ag e 28). 3. Check supp lies and prepare equipm ent (page 30). Setting Up at Jobsite 1. Prepare jobs ite (page 29). 2. Positio n flui d unit and co nnect t o drill ing unit. S ee dril ling unit op erato[...]

FM5 Operator ’ s Manual Operat ion Over view - 2 5 Mixing Fluid CMW Mixi ng Flu id 1. V erify th at hopp er throa t is not pl ugged before mi xing . 2. Fill fluid tank with water . Allow roo m for add itives. 3. Open ci rculati on va lve a nd tank di scharg e valve. 4. S tart eng ine and run at ha lf throttl e or h igher . 5. Open hop per val ve.[...]

Operation Overvi ew - 26 FM5 Operator ’ s Manual Transferring Fluid CMW T ransferring Flu id 1. Connect ho se from mixi ng pump to drillin g unit. 2. Open hop per and di schar ge valv es. 3. Adjust e ngine throttle t o give desi red flow r ate to drilli ng unit . • Half thro ttle is recomm ended for most dril ling sit uations. • A higher thro[...]

FM5 Operator ’ s Manual Prepare - 27 CMW Prep are Chapter Content s Gathe r In form ation . . . . . . . . . . . . . . . . . . . . . . . . . 28 • Arrange fo r T raffic Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 • Prepare for Worki ng Near E xisting Uti lities . . . . . . . . . . . . . . . . . . . . . .28 ?[...]

Prepar e - 28 FM5 Operator ’ s Manual Gather Information CMW Gathe r In formati on A succes sful job begins before the exc avation . The fir st step i n pla nning is reviewi ng inf ormation already availab le about th e job a nd job site. Arrange for T raffic Contro l If working n ear a road or other tr affic area, contact l ocal aut horit ies ab[...]

FM5 Operator ’ s Manual Prepare - 29 Prepar e Jobsite CMW Prep ar e Jobsite Inst all Fluid Unit Consider Load Requirements Inst allation T ip s • Drill h oles t hrough tr aile r cross member s to pr ovide adequa te connec tion to trailer struc ture, n ot just deck boa rds. • Use high-qu ality , prop erly- sized m ounting hardware. Jobsite haz[...]

Prepar e - 30 FM5 Operator ’ s Manual Check S upplies and Prepare Equipment CMW Check Supplies and Prep are Equipm ent Assemble Access ori es Fire Extinguisher If required , mount a fire ex tingui sher ne ar the power uni t but awa y from po ssible points of igni tion. Th e fire extingui sher s hould a lways be class ified for both oil and el ect[...]

FM5 Operator ’ s Manual Transport - 3 1 CMW T r ansport Chapter Content s Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 • Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 • Procedur e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

Transport - 32 FM5 Operator ’ s Manual Lift CMW Lift Point s Lifting po ints are identi fied by l iftin g deca ls. Lifti ng at ot her po ints is unsafe and can d amage m achiner y . Procedure Ta n k Use crane c apable of suppo rting the equipm ent ’ s si ze and weight . See “ Sp ecifi cations ” on page 49 or measure and weigh eq uipmen t be[...]

FM5 Operator ’ s Manual Transport - 3 3 Haul CMW Haul Insp ect T r ai ler • Check hitc h for w ear and c racks . Lubric ate if needed. • Check ba ttery for 12 V cha rge. • Inspect lig hts for cle anlines s and c orrect op erati on. Inspec t reflec tors an d replac e if neede d. • Check tire pressu re. Chec k lug nut torque with a torque w[...]

Transport - 34 FM5 Operator ’ s Manual Hau l CMW Unhitch T railer 1. S top to w vehicl e and t railer on level ground. 2. Put manu al tr ansmis sion i nto fi rst or rever se ge ar or a utomati c tr ansmis sion i nto park. T urn o ff ignition. Set parkin g brake. 3. Block trail er wheel s. 4. T o unhitc h trail er from tow v ehicle , reverse “ H[...]

FM5 Operator ’ s Manual Drilling Fluid Concepts - 35 CMW Drilling Fluid Concept s Chapter Content s Recom mend ed P roduc t s . . . . . . . . . . . . . . . . . . . . 36 Guide lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 6 Polym er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 7 Benton ite . . . .[...]

Drilling Fluid Concepts - 36 FM5 Operator ’ s Manual Recommended Products CMW Recomm en ded Pro d uct s For prod uctive d rillin g and eq uipment pr otectio n, use these re comme nded B aroid ® p roducts, avai lable from your Ditch Witch deale r . • Soda a sh • Quik-Gel ™ dry powder benton ite (p/n 2 59-80 4) • E-Z Mu d ™ liqui d poly [...]

FM5 Operator ’ s Manual Drilling Fluid Concepts - 37 Poly mer CMW Polymer This drilli ng fluid additi ve prov ides e xcellen t lubri catio n and increas es vi scosity in average soils and h eavy clay . In swe lling c lay , p olyme r can reduce sw elling th at traps p ipe in the bore. There ar e two types of pol ymer: • long chain su ch as Baro [...]

Drilling Fluid Concepts - 38 FM5 Operator ’ s Manual Mixtures CMW Mixtures Bentonite does not mi x well i n water containing polymer. T o use both , mix be ntonite first, t hen add poly mer . When a dding othe r produ cts foll ow the or der li sted be low . General m ixing order 1. Soda a sh 2. Benton ite 3. Polymer 4. Con-Det Bore-Gel contains p[...]

FM5 Operator ’ s Manual Drilling Fluid Concepts - 39 Mixtur es CMW Basic Fluid Recipes Soil type Mixture/10 0 gal (378 L) of water Notes fine sand 35 lb (1 6 kg) Bo re- Gel coarse sand 35 lb (1 6 kg) Bo re- Gel .5 lb (225 g ) No-Sag Add .5 lb (225 g) of Qu ik-Trol for addition a l filt rate con tr ol fine sand below water table 40 lb (18 kg) Bore[...]

Drilling Fluid Concepts - 40 FM5 Operator ’ s Manual Drilling Fluid Requirem ents CMW Drilling Fl uid Requiremen t s 1. Determin e drill ing condi tions an d choo se app ropriate d rillin g fluid mi x. 2. Estimate amoun t of suppl ies neede d and c heck av ailabil ity . • Drilling f luid • W a ter supp ly . If more wa ter than c an be car rie[...]

FM5 Operator ’ s Manual Complete the Job - 41 CMW Complete the Job Chapter Content s Rins e Equi pment . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Disconn ec t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42[...]

Complete the Job - 42 FM5 Oper ator ’ s Manual Rinse Equipment CMW Rinse Equ ipme nt Spray w ater o nto equipm ent to r emove di rt and mu d. Disconnect Disconn ect and s tore h oses and cable s.[...]

FM5 Operator ’ s Manual Servi ce - 43 CMW Service Chapter Content s Prec autions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4 Recommended Lubricant s/Servic e Key . . . . . . . . 44 10 Hou r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 20 Hou r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

Servi ce - 44 FM5 Operator ’ s Manual Precautions CMW Precautions Recommende d Lubrica nt s/Service Ke y Proper lu bricati on and mainte nance protects Ditch Witc h equipme nt from damag e and fail ure. Ser vice interva ls listed are fo r minimum r equire ments. In ex treme c onditions , serv ice mac hine m ore freq uently . Use only recomm ended[...]

FM5 Operator ’ s Manual Servi ce - 45 10 Hour CMW Engine Oil T emperature Chart 10 Hour Check Engine Oil Check en gine oil at dipstick (shown) before operat ion and ev ery 10 hours th ereafte r . Chec k with uni t on leve l surface a nd at l east 1 5 minut es after stoppi ng engine . Add G EO at fi ll as ne cess ary to k eep oi l level at highes [...]

Servi ce - 46 FM5 Operator ’ s Manual 20 Hour CMW 20 Hour Change Engine Oil (Initial Ser v ice) Change oil after first 20 ho urs. Pull dr ain plug a nd dr ain cra nkcase while oil is sti ll warm. Refill at f ill neck wi th 2.3 pt (1.1 L) of GEO. 50 Hour Greas e Pump Lube gre ase fi tting with N LGI #1 every 50 hour s. Greas e cavity is full when [...]

FM5 Operator ’ s Manual Servi ce - 47 100 Ho ur CMW 100 Hour Change Engine Oil Change oil ev ery 100 ho urs. Pull drain plug and drai n crankc ase whil e oil is still war m. Refill at fill neck with 2.3 pt (1. 1 L) of G EO. Change Air Filter Change foam air filter el ement eve ry 1 00 hours . Do not allow d irt to fal l into c arbureto r . Locati[...]

Servi ce - 48 FM5 Operator ’ s Manual 100 Hour CMW[...]

FM5 Operator ’ s Manual Specificat ions - 4 9 CMW Specifications Dimensions U.S. Metr ic A Length 123 in 3.1 m B Height 53 in 1.3 m C Width 25.6 in 650 mm Weight, empty 660 lb 299 kg Weight, with ful l tank (wate r) 3164 l b 1435 kg Performance U.S. Metric Maximum flow rate at 26 v iscosity 160 gpm 60 6 L/min Mixing hopp er capaci ty 1 ft 3 28 L [...]

Specifica tions - 50 FM5 Operator ’ s Manual CMW Specifi catio ns are c alled ou t acc ording to SAE reco mmende d practi ces. Specifi cation s are ge neral an d subject to cha nge wit hout not ice. If exact me asureme nts are requir ed, eq uipme nt should be weig hed and measure d. Due to selecte d opti ons, de livere d equipme nt may not match [...]

FM5 Operator ’ s Manual Support - 51 Procedure CMW Support Procedure Notify yo ur deale r imm ediately of any ma lfunc tion or fa ilure o f Dit ch Witc h equipme nt. Always gi ve mod el, se rial num ber , an d appr oximate d ate of y our equi pment purchas e. This informa tion should b e recor ded an d placed on file by the own er at the time of [...]

Wa rranty - 52 FM5 Operator ’ s Manual CMW W arranty Ditch Witch Equipment an d Part s Limited W arranty Policy Subject to the li mitations and exclusions herein, free r eplacement parts will be provided at any authorized Ditch Witch dealers hip for any Ditch Witch equipment or part s manufa ctured by The Charles Machine Works, Inc. (CMW) that fa[...]

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FM5 Operator ’ s Manual Service Re cord - 55 CMW Service Record Service P erfor med Date Hours[...]

Service Re cord - 56 F M5 Operator ’ s Manual CMW Service P erfor med Date Hours[...]