Dicth Witch FX30-Manual

7/30/2019 Dicth Witch FX30-Manual

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FX30Tier 4i

OperatorsManual

053-1274Issue 2.0CMW


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FX30 Operators Manual Overview - 1

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Overview

Chapter Contents

Serial Number Location . . . . . . . . . . . . . . . . . . . . . . 2

Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Equipment Modif ication . . . . . . . . . . . . . . . . . . . . . 3

Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Operator Orientat ion. . . . . . . . . . . . . . . . . . . . . . . . . 5

About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Bulleted Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Numbered Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5


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Overview - 2 FX30 Operators ManualSerial Number Location

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Serial Number Location

Record serial numbers and date of purchase in spaces provided. FX30 serial number is located as shown.

Intended Use

The FX30 is a self-contained vacuum excavation unit capable of vacuuming a wide variety of non-hazardous, non-flammable liquid and solid debris. It is designed to perform efficient soft excavation,including exposing utilities for visual verification and/or potholing. The optional reverse flow system allows

for spoils transfer to another tank. The FX30 is intended for operation in ambient temperatures from 0 to115F (-18 to 46C). Use in any other way is considered contrary to the intended use.

The FX30 should be operated, serviced, and repaired only by persons familiar with its particularcharacteristics and acquainted with the relevant safety procedures.

Date of manufacture

Date of purchase

FX30 serial number (shown)

Engine serial number

Blower serial number

Water pump serial number

Trailer serial number

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FX30 Operators Manual Overview - 3Equipment Modification

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Equipment Modification

This equipment was designed and built in accordance with applicable standards and regulations.Modification of equipment could mean that it will no longer meet regulations and may not function properlyor in accordance with the operating instructions. Modification of equipment should only be made by

competent personnel possessing knowledge of applicable standards, regulations, equipment designfunctionality/requirements and any required specialized testing.

Unit Components (500 gallon tank)

1. Inlet valve

2. Primary shut-off valve

3. Vacuum tank

4. Water tank

5. Operators station

6. Power pack

7. Hose reel

8. Potholing tools

9. Tool storage

10. Antifreeze tank

11. Vacuum filter

12. Drain/Outlet valve

11 22 33 44 55 66

77 88 10109 1111 1212



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Overview - 4 FX30 Operators ManualUnit Components (800 gallon tank)

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Unit Components (800 gallon tank)

1. Inlet valve

2. Vacuum tank

3. Primary shut-off valve

4. Water tank

5. Operators station

6. Power pack

7. Hose reel

8. Potholing tools

9. Tool storage

10. Antifreeze tank

11. Vacuum filter


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77 88 10109 1111 1212



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FX30 Operators Manual Overview - 5Operator Orientation

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Operator Orientation

Right and left sides of machine are determined byfacing towing vehicle.

About This Manual

This manual contains information for the proper use of this machine. SeeOperation Overview for basicoperating procedures. Cross references such as See page 50 will direct you to detailed procedures.

Bulleted Lis ts

Bulleted lists provide helpful or important information or contain procedures that do not have to beperformed in a specific order.

Numbered Lists

Numbered lists contain illustration callouts or list steps that must be performed in order.

1. Front of unit

2. Right of unit

3. Rear of unit

4. Left of unit

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Overview - 6 FX30 Operators ManualAbout This Manual

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FX30 Operators Manual Foreword - 7Reporting Safety Defects

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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 adealer, visit our website at www.ditchwitch.com or write to the following address:

The Charles Machine Works, Inc.Attn: Marketing Department

PO Box 66Perry, OK 73077-0066

USA

The descriptions and specifications in this manual are subject to change without notice. The CharlesMachine Works, Inc. reserves the right to improve equipment. Some product improvements may havetaken place after this manual was published. For the latest information on Ditch Witch equipment, see yourDitch Witch dealer.

Thank you for buying and using Ditch Witch equipment.

Reporting Safety Defects

If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you

should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition tonotifying the Product Safety Coordinator at The Charles Machine Works, Inc.

If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect existsin a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot becomeinvolved in any individual problems between you, your Ditch Witch dealer, or The Charles Machine Works,Inc.

To contact NHTSA you may either call the Auto Safety Hotline toll-free at 1-888-327-4236 (TTY: 1-800-424-9153), go to http://www.safercar.gov, or write to:

Administrator

NHTSA1200 New J ersey Avenue S.E.Washington, DC 20590

You can also obtain other information about motor vehicle safety from http://www.safercar.gov.


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Foreword - 8 FX30 Operators Manual

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FX30 with Tier 4i EngineOperators Manual

Issue number 2.0/OM-7/12

Part number 053-1274

Copyright 2009, 2012by The Charles Machine Works, Inc.

, Ditch Witch, and CMW are registered trademarks of The Charles MachineWorks, Inc.

U.S. patents pending.


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FX30 Operators Manual Contents - 9

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Contents

Overviewmachine serial number, information about the type of work this machine is designedto perform, basic machine components, and how to use this manual

1

Forewordpart number, revision level, and publication date of this manual, and factory contactinformation

7

Safetymachine safety alerts and emergency procedures

11

Controlsmachine controls, gauges, and indicators and how to use them

21

Operation Overviewan overview for completing a job with this machine: planning, setting up, vacuuming,potholing, and restoring the jobsite; with cross references to detailed procedures

39

Prepareprocedures for inspecting and classifying the jobsite, and preparing the jobsite forwork

43

Transportprocedures for lifting and hauling

49

Vacuum and Potholeprocedures for removing debris and potholing utility locations

53

Complete the Jobprocedures for restoring the jobsite and rinsing and storing equipment

69

Serviceservice intervals and instructions for this machine including lubrication, replacementof wear items, and basic maintenance

73

Specificationsmachine specifications including weights, measurements, power ratings, and fluidcapacities

111

Supportthe warranty policy for this machine, and procedures for obtaining warrantyconsideration and training

121

Service Recorda record of major service performed on the machine

125


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Contents - 10 FX30 Operators Manual

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Appendixadditional information about Ditch Witch equipment

121


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FX30 Tier 4i Operators Manual Safety - 11

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Safety

Chapter Contents

Guidel ines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Safety Alert Classifications . . . . . . . . . . . . . . . . . . 13

Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Emergency Procedures . . . . . . . . . . . . . . . . . . . . . 17

Electric Strike Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

If an Electric Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 If a Gas Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

If a Fiber Optic Cable is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

If Machine Catches on Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20


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Safety - 12 FX30 Tier 4i Operators ManualGuidelines

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Guidelines

Follow these guidelines before operating any jobsite equipment:

Complete proper training and read operators manual before using equipment.

Contact your local One-Call (811 in USA) or the One-Call referral number (888-258-0808 in USA andCanada) to have underground utilities located before digging. Also contact any utilities that do notparticipate in the One-Call service.

Classify jobsite based on its hazards and use correct tools and machinery, safety equipment, and workmethods for jobsite.

Mark jobsite clearly and keep spectators away.

Wear personal protective equipment.

Review jobsite hazards, safety and emergency procedures, and individual responsibilities with allpersonnel 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 may be present.

Contact your Ditch Witch dealer if you have any question about operation, maintenance, or equipmentuse.


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FX30 Tier 4i Operators Manual Safety - 13Safety Alert Classifications

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Safety Alert Classifications

These classifications and the icons defined on the following pages work together to alert you to situationswhich could be harmful to you, jobsite bystanders or your equipment. When you see these words andicons 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 levelmeans.

indicates a hazardous situation that, if not avoided, will result in death or serious injury.This signal word is to be limited to the most extreme situations.

indicates a hazardous situation that, if not avoided, could result in death or serious injury.

indicates a hazardous situation that, if not avoided, could result in minor or moderateinjury.

Watch for two other words: NOTICE and IMPORTANT.

NOTICE indicates information considered important, but not hazard-related (e.g., messages relating toproperty damage).

IMPORTANT can help you do a better job or make your job easier in some way.


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Safety - 14 FX30 Tier 4i Operators ManualSafety Alerts

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Safety Alerts

Electric shock. Contacting electric lines will cause death or serious injury.Know location of lines and stay away.

Confined space will cause suffocation. Use proper procedures for enteringor stay away.

Vacuum will suffocate. Maintain distance between face and vacuum inlets.

J obsite hazards could cause death or serious injury. Usecorrect equipment and work methods. Use and maintain proper safetyequipment.

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.

Explosion possible. Serious injury or equipment damage could occur.

Follow directions carefully.

Incorrect procedures could result in death, injury, or property damage.Learn to use equipment correctly.


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FX30 Tier 4i Operators Manual Safety - 15Safety Alerts

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Improper control function could cause death or serious injury. If control doesnot work as described in instructions, stop machine and have it serviced.

Fire or explosion possible. Fumes could ignite and cause burns. Nosmoking, 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.


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Safety - 16 FX30 Tier 4i Operators ManualSafety Alerts

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Hot pressurized cooling system fluid could cause serious burns. Allow tocool before servicing.

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 hearingprotection.

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, orequipment damage. Follow instructions on labels and in material safety data sheets(MSDS).

Breathing crystalline silica dust may cause lung disease. Cutting, drilling, orworking materials such as concrete, sand, or rock containing quartz may result in exposure

to silica dust. Use dust control methods or appropriate breathing protection when exposedto silica dust.


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FX30 Tier 4i Operators Manual Safety - 17Emergency Procedures

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Emergency Procedures

Before operating any equipment, review emergency procedures and check that all safety precautions havebeen taken.

Electric Strike Descript ion

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. Many work-related electrocutions result from contact with lessthan 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.

J obsite hazards could cause death or serious injury. Usecorrect equipment and work methods. Use and maintain proper safety

equipment.

EMERGENCY SHUTDOWN - Turn ignition switch to stop position or push remote engine stop button (ifequipped).



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Safety - 18 FX30 Tier 4i Operators ManualEmergency Procedures

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If an Electric L ine 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 thesituation.

Warn people nearby that an electric strike has occurred. Instruct them to leave the area and contactutility.

Do not allow anyone into area until given permission by utility company.

Do not allow anyone to touch equipment.

If you suspect an electric line has been damaged and you are off truck or trailer, DO NOT TOUCHEQUIPMENT. Take the following actions. The order and degree of action will depend on the situation.

LEAVE AREA. The ground surface may be electrified so take small shuffle steps with feet closetogether to reduce the hazard of being shocked from one foot to the other.

Contact utility company to shut off power.

Do not return to area or allow anyone into area until given permission by utility company.


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Safety - 20 FX30 Tier 4i Operators ManualEmergency Procedures

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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 ofaction will depend on the situation.

Immediately move battery disconnect switch (if equipped and accessible) 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.


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FX30 Operators Manual Controls - 21

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Controls

Chapter Contents

Power Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Controls and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Gauges and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Tethered Boom Control ler . . . . . . . . . . . . . . . . . . . 36


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Controls - 22 FX30 Operators ManualPower Pack

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Power Pack

Controls and Connectors

1. Throttle

2. Water pressure switch

3. Tethered tank control outlet

4. Water pressure control

5. Ignition switch

6. Auxiliary outlet switch

7. Hydraulic function switch

8. Tethered tank control

Item Description Notes

1. Throttle To increase engine speed,push up.

To decrease engine speed,pull down.

IMPORTANT: Run engine at fullthrottle during operation.


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FX30 Operators Manual Controls - 23Power Pack

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2. Water pressure switch To turn on water pump, presstop.

To turn off water pump, moveto center position.

To bypass low waterindication, press bottom.Water pump will operate for60 seconds.

Use bypass to feed antifreeze intosystem when freshwater tank isempty. See Add Antifreeze onpage 70.

3. Tethered tank control

outlet

Connection for tethered tanklift/lower control.

4. Water pressure control To increase water pressure,

turn clockwise.

To decrease water pressure,turn counterclockwise.

5. Igni tion swi tch To start engine, insert key andturn clockwise.

To stop engine, turn keycounterclockwise.

IMPORTANT:

When engine is on, bloweroperates and vacuum is presentat tank inlet.

All indicators should light briefly atstartup.

6. Auxil iary outlet switch To turn on, press top.

To turn off, press bottom.


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7. Hydraulic function

switch

To operate the vacuum boomoption, press top.

To operate hydraulic door lift,move to center position.

To operate hydraulic tank tilt,press bottom.

8. Tethered tank control To lift and lower tank, sethydraulic function switch tothe tank position, then

To lift tank, press UP.

To lower tank, pressDOWN.

To open and close tank door,set hydraulic function switchto the door position, then

To open door, press UP.

To close door, pressDOWN.

Note:The vacuum boom uses adifferent tethered controller. Seepage 36.


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Gauges and Indicators

1. Hourmeter

2. Engine oil pressure indicator

3. Engine coolant temperature indicator

4. Cold start wait indicator

5. Not used

6. Water pressure gauge

7. Fuel gauge


1. Hourmeter Displays engine operatingtime.

Hourmeter runs when engine isrunning.

Use these times to schedule service.

1

6

7

5

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2. Engine oi l pressure

indicator

Indicates engine oil pressureis low.

Also lights briefly whenengine is started.

Engine will stop.

1. Check oil level.

2. Check for leaks before startingengine.

3. Engine coolant

temperature ind icator

Indicates cooling system fluidis overheated.

Engine will stop.

1. Let engine cool.

2. Check cooling system fluid level.

4. Cold start wait indicator Indicates engine preheater(glow plug) is on.

Wait for engine preheater to go offbefore starting engine.

5. Not used

6. Water pressure gauge Displays water pressurewhen water pressure switchis on and spray wand is inuse.


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7. Fuel gauge Displays fuel level in tank. Use only #2 diesel fuel.

In temperatures below 40 F(4 C), use #1 diesel fuel.

Tank holds 15 gal (57 L).



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Miscellaneous

1. Flow direction control

2. Auxiliary outlet

3. Battery disconnect switch


1. Flow direction control To operate in reverse flowmode, turn counterclockwise.

To operate in vacuum mode,turn clockwise.

Use reverse flow to unload tankcontents to another tank. Operate inreverse flow mode only when drain/outlet valve is open.

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2. Auxil iary out let To operate work lights orother 12V devices, plug intooutlet.

Outlet has power only when ignitionswitch is on.

3. Battery disconnect

switch

To connect, turn clockwise.

To disconnect, turncounterclockwise.

IMPORTANT: Use battery disconnectswitch when servicing, welding, andduring long-term storage.


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Machine Controls (500 gallon tank)

1. Inlet valve

2. Water tank supply valve

3. Water tank drain


5. Reverse flow gauge

6. Antifreeze tank supply valve

7. Vacuum gauge


1. In let valve To close valve (stop suction),rotate up.

To open valve (start suction),rotate down.

NOTICE: Do not idle engine with inletvalve closed.

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2. Water tank supply valve To open valve (send waterfrom the water tank throughthe pump and water lance),rotate counterclockwise.

To close valve (stop waterflow), rotate clockwise.

IMPORTANT: Water tank supplyvalve or antifreeze supply valve mustbe open when pump is running orpump will be damaged.

3. Water tank drain To drain tank, open valve.

Close valve when tank isempty.

4. Drain/Outlet valve To drain tank, rotate down.

To close drain, rotate up.

5. Reverse f low gauge Displays reverse flowpressure.


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6. Antifreeze tank supply

valve

To open valve (sendantifreeze through pump andwater lance), rotatecounterclockwise.

To close valve (stopantifreeze flow), rotateclockwise.


7. Vacuum gauge Displays blower vacuumreading in inches of mercury.Vacuum relief valve openswhen vacuum reaches 15(381 mm).


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Machine Controls (800 gallon tank)

1. Inlet valve

2. Water tank supply valve

3. Water tank drain


5. Reverse flow gauge

6. Antifreeze tank supply valve

7. Vacuum gauge


1. In let valve To close valve (stop suction),rotate up.

To open valve (start suction),rotate down.

NOTICE: Do not idle engine with inletvalve closed.

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2. Water tank supply valve To open valve (send waterfrom the water tank throughthe pump and water lance),rotate counterclockwise.

To close valve (stop waterflow), rotate clockwise.


3. Water tank drain To drain tank, open valve.

Close valve when tank isempty.

4. Drain/Outlet valve To drain tank, rotate down.

To close drain, rotate up.

5. Reverse f low gauge Displays reverse flowpressure.


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6. Antifreeze tank supply

valve

To open valve (sendantifreeze through pump andwater lance), rotatecounterclockwise.

To close valve (stopantifreeze flow), rotateclockwise.


7. Vacuum gauge Displays blower vacuumreading in inches of mercury.Vacuum relief valve openswhen vacuum reaches 15(381 mm).


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Controls - 36 FX30 Operators ManualTethered Boom Control ler (optional)

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Tethered Boom Controller (optional)

1. Boom up

2. Boom down

3. Boom retract

4. Boom extend


1. Boom up To raise boom, press.

To stop movement, release.

NOTICE: Do not use boom to raise orlower objects.

2. Boom down To lower boom, press.


NOTICE: Do not use boom to raise orlower objects.


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FX30 Operators Manual Controls - 37Tethered Boom Control ler (optional)

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3. Boom ret ract To retract boom, press.


4. Boom extend To extend boom, press.




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Controls - 38 FX30 Operators ManualTethered Boom Control ler (optional)

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FX30 Operators Manual Operation Overview - 39

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Operation Overview

Chapter Contents

Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Setting Up at Jobsite . . . . . . . . . . . . . . . . . . . . . . . 40

Vacuuming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Potholing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Leaving Jobsi te . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Stor ing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 41


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Operation Overview - 40 FX30 Operators ManualPlanning

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Planning

1. Gather information about jobsite (page 44).

2. Inspect jobsite (page 45).

3. Check supplies and prepare equipment (page 47).

Setting Up at Jobsite

1. Prepare jobsite (page 46 ).

2. Position vacuum excavation unit (page 49).

3. Leave unit hitched to towing vehicle or properly stabilized (page 52).

4. Block trailer wheels (page 52).

Vacuuming

1. Connect hoses (page 54).

2. Start unit (page 58).

3. Position optional vacuum boom (page 59).

4. Remove debris (page 60).

5. Disconnect hoses (page 71).

6. Drain tank (page 63) or unload to another tank (page 65).


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FX30 Operators Manual Operation Overview - 41Potholing

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Potholing

1. Connect hoses (page 54).

2. Start unit (page 58).

3. Pothole (page 61).

4. Disconnect hoses (page 71).

5. Drain tank (page 63).

Leaving Jobsite

1. Rinse unit and tools (page 71).

2. Stow tools (page 72).

Storing Equipment

1. For cold weather storage, antifreeze vacuum excavation unit (page 70).

2. For long-term storage, disconnect battery disconnect switch (page 29).


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Operation Overview - 42 FX30 Operators ManualStoring Equipment

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FX30 Operators Manual Prepare - 43

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Prepare

Chapter Contents

Gather Information . . . . . . . . . . . . . . . . . . . . . . . . . 44

Arrange for Traffic Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Prepare for Working Near Existing Utilities . . . . . . . . . . . . . . . . . . . . . 44

Plan for Emergency Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Inspect Jobsi te . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Prepare Jobsi te . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Prepare Excavation Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Check Supplies and Prepare Equipment . . . . . . . 47

Assemble Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Check Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Prepare Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48


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Prepare - 44 FX30 Operators ManualGather Information

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Gather Information

A successful job begins before the excavation. The first step in planning is reviewing information alreadyavailable about the job and jobsite.

Arrange for Traff ic Control

If working near a road or other traffic area, contact local authorities about safety procedures andregulations.

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 ASTM F2413 orASTM F1117, 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.

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 haveaccess to a telephone.


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FX30 Operators Manual Prepare - 45Inspect Jobsite

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Inspect Jobsite

Follow U.S. Department of Labor regulations on excavating and trenching (Part 1926, Subpart P) andother similar regulations.

Contact your local One-Call (811 in USA) or the One-Call referral number (888-258-0808 in USA andCanada) to have underground utilities located before digging. Also contact any utilities that do notparticipate in the One-Call service.

Inspect jobsite and perimeter for evidence of underground hazards, such as:

Buried utility notices

Utility facilities without overhead lines

Gas or water meters

J unction boxes

Drop boxes

Light poles

Manhole covers

Sunken ground

Mark location of all buried utilities and obstructions.


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Prepare - 46 FX30 Operators ManualPrepare Jobsite

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Prepare Jobsite

Prepare Excavation Point

Clear the area to be excavated. Remove rocks or branches too large for vacuum hose.

If excavating fluids while drill string is moving, clear area of trees, shrubs, and weeds.

Select a solid area to stand on while excavating.

J obsite hazards could cause death or serious injury. Usecorrect equipment and work methods. Use and maintain proper safety

equipment.

To help avoid injury :

Classify jobsite as electric if jobsite classification is in question or if the possibility of unmarkedelectric utilities exists.

Expose lines by hand before digging.Cutting high voltage cable can cause electrocution.

All vegetation near operators station must be removed. Contact with trees, shrubs, or weeds duringelectrical strike could result in electrocution.


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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 fireextinguisher should always be classified for both oil and electric fires. It should meet legal and regulatoryrequirements.

Lighting Kit

If you will need additional light, plug lighting kit into provided outlet. Contact your Ditch Witch dealer forfurther information.

Check Supplies

water and additional hoses

fuel

keys

spray lubricant

personal protective equipment, such as hard hat and safety glasses


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Prepare - 48 FX30 Operators ManualCheck Supplies and Prepare Equipment

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Prepare Equipment

Fluid Levels

fuel

hydraulic fluid

engine coolant

battery charge

engine oil

blower oil

Condition and Function

filters (air, oil, hydraulic)

belts hydraulic pump

blower

tires

hoses and valves

couplers and fittings

water tanks


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FX30 Operators Manual Transport - 49

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Transport

Chapter Contents

Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Haul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Inspect Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Hitch Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Unhitch Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52


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Transport - 50 FX30 Operators ManualLift

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Lift

Points

Lifting points are identified by lifting decals. Lifting at other points is unsafeand can damage machinery.

Procedure

Power Pack

Use a crane capable of supporting 2000 lb (907 kg).Remove bolts on each upper corner and install lift eyes(p/n 105-1391). Lift as shown.

Tank

Use crane capable of supporting the weight shown below.Use top lift point (1) as shown. Use end lift point (2) todrain tank if machine is disabled.

Crushing weight. If load falls or moves it could kill or crush you. Useproper procedures and equipment or stay away.

500 gallon 2000 lb (907 kg)

800 gallon 2500 lb ( kg) kg

NOTICE:

Relieve pressure in tank before storing ortransporting.

Only lift empty water or spoils tanks.

Do not lift tank by vacuum boom, if installed.


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FX30 Operators Manual Transport - 51Haul

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Haul

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.

Ensure trailer brakes are adjusted to come on in synchronization with tow vehicle brakes.

Check ramps (if equipped) and trailer bed for cracks.

Crushing weight. If load falls or moves it could kill or crush you. Useproper procedures and equipment or stay away.


Do not haul or move trailer unless tank is fully lowered and horizontal. Damage to machine or injuryto personnel could occur.

Do not haul or move trailer unless optional vacuum boom is secured by boom latch. Damage tomachine or injury to personnel could occur.

Do not travel on roads with reducer or any other fitting installed on tank outlet valve. Fitting willextend beyond the rear impact guard and will not be legal for operation on roadways.


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Transport - 52 FX30 Operators ManualHaul

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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 totow vehicle hitch and lock in place with lockpin. If needed, adjust drawbar, lunette orcoupler height (shown) to level load.

4. Connect safety chains to tow vehicle chainkeepers (cross-shaped slots on bumper oftow vehicle). Attach left chain to right side oftow vehicle and vice versa to cradle hitch. Donot connect to pintle hook or hitch ball.

5. Connect breakaway switch cable to towvehicle. Do not connect to pintle hook or hitch

ball.

6. Plug trailer electrical connector into towvehicle connector.

7. Use jack crank to raise jack base and stow.

8. Remove wheel blocks.

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.

TrailerHitchAdjust_T18.epsTrailerHitchAdjust_T18.eps


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FX30 Operators Manual Vacuum and Pothole - 53

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Vacuum and Pothole

Chapter Contents

Connect Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Determine Tank Fil l Level . . . . . . . . . . . . . . . . . . . 55

500-gal Vacuum Tank on T9S Trailer . . . . . . . . . . . . . . . . . . . . . . . . . 55

500-gal Vacuum Tank on T12S Trailer . . . . . . . . . . . . . . . . . . . . . . . . 56

800-gal Vacuum Tank on T18S Trailer . . . . . . . . . . . . . . . . . . . . . . . . 57

Start Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Standard Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Cold Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Posi tion Vacuum Boom . . . . . . . . . . . . . . . . . . . . . 59

Remove Debris . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Pothole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Drain Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Unload to Another Tank . . . . . . . . . . . . . . . . . . . . 65

Open/Close Tank Door . . . . . . . . . . . . . . . . . . . . . 67


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Vacuum and Pothole - 54 FX30 Operators ManualConnect Hoses

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Connect Hoses

1. Remove vacuum hoses from storage.

2. If potholing, remove 2-in-1 potholing tool or basic potholing tool from storage.

3. Connect hoses. Secure all locking clamps.

4. Ensure drain/outlet valve is closed.

5. If potholing, connect water pressure hose.

2-in-1 Tool Basic Tool


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FX30 Operators Manual Vacuum and Pothole - 55Determine Tank Fil l Level

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Determine Tank Fill Level

Use these reference charts to help determine how full of various materials the vacuum tank can be withoutoverloading trailer. Exceeding the maximum fill level will overload the trailer.

Neverexceed the trailer capacity. You can exceed the vacuum tank lifting capacity if you drain the tankdown to the lifting capacity before lifting tank.

To use these charts, first select the appropriate table based on trailer and vacuum tank size. Next find thematerial being excavated. If the material being excavated is not listed, find a material with similar density.

Then, determine the maximum fill level based on the amount of water in the water tank.

500-gal Vacuum Tank on T9S Trailer

IMPORTANT: For all materials, the vacuum tank should be no more than half full when lifting the tank.

Material Maximum Vacuum TankFill Level

Water tank fill level full (80 gal) empty (0 gal)

wood chips (dry) 100% 100%

snow (dry) 100% 100%

water 81% 96%

light weight mud (8-10 lb/gal) 75% 88%

earth (dry, loose) 70% 83%

caliche 65% 76%

earth, loam 65% 76%

medium weight mud (10-12 lb/gal) 61% 72%

limestone (crushed) 53% 62%

asphalt 51% 59%

sand (dry) 51% 59%

earth (wet, excavated) 51% 59%

heavy weight mud (12-15 lb/gal) 50% 59%

gravel (dry) 49% 58%

shale, riprap 48% 57%

sand (wet) 39% 46%


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Vacuum and Pothole - 56 FX30 Operators ManualDetermine Tank Fil l Level

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Material Maximum Vacuum Tank

Fill Level

Water tank fill level full (200 gal) empty (0 gal)

wood chips (dry) 100% 100%

snow (dry) 100% 100%

water 100% 100%

light weight mud (8-10 lb/gal) 96% 100%

earth (dry, loose) 90% 100%

caliche 83% 100%

earth, loam 83% 100%

medium weight mud (10-12 lb/gal) 78% 100%

limestone (crushed) 67% 90%

asphalt 65% 87%

sand (dry) 64% 86%

earth (wet, excavated) 64% 86%

heavy weight mud (12-15 lb/gal) 64% 86%

gravel (dry) 63% 84%

shale, riprap 61% 82%

sand (wet) 50% 67%


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FX30 Operators Manual Vacuum and Pothole - 57Determine Tank Fil l Level

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Material Maximum Vacuum Tank Fill Level

Water tank fill level full (200 gal) full (300 gal) empty (0 gal)

wood chips (dry) 100% 100% 100%

snow (dry) 100% 100% 100%

water 100% 97% 100%

light weight mud (8-10 lb/gal) 100% 90% 100%

earth (dry, loose) 94% 84% 100%

caliche 87% 78% 100%

earth, loam 87% 78% 100%

medium weight mud (10-12 lb/gal) 82% 74% 99%

limestone (crushed) 71% 63% 85%

asphalt 67% 61% 81%

sand (dry) 67% 61% 81%

earth (wet, excavated) 67% 61% 81%

heavy weight mud (12-15 lb/gal) 67% 60% 80%

gravel (dry) 65% 59% 79%

shale, riprap 64% 58% 77%

sand (wet) 52% 47% 63%


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Vacuum and Pothole - 58 FX30 Operators ManualStart Unit

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Start Unit

Standard Procedure

1. Open tank inlet valve.

2. If equipped with reverse flow, ensure vacuum is in vacuum mode before starting.

3. Insert key.

4. Turn key clockwise. See page 23 for more information.

5. Run engine at low throttle for 5 minutes.

Cold Start Procedure


2. If equipped with reverse flow, ensure vacuum is in vacuum mode before starting.

3. Insert key.

4. Turn key to on position. Cold start timer (glow plug) timer indicator will light.

5. Wait for cold start timer indicator to go off.

6. Turn key clockwise to start engine.

7. Run engine at low throttle for 5 minutes.

EMERGENCY SHUTDOWN: Turn ignition switch to STOP.

IMPORTANT: If power pack is not connected toexternal tank control valves, connect a -08 hose with aminimum working pressure rating of 3000 psi (207 bar)from pressure (1) to power beyond (2) connections onpower pack.

NOTICE: Avoid idling engine with inlet valve closed.


2

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FX30 Operators Manual Vacuum and Pothole - 59Position Vacuum Boom

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Position Vacuum Boom

The vacuum boom is optional equipment. Contact your Ditch Witch dealer to add this option.

Procedure

See Controls on page 21 to become familiar with the power pack controls and the tethered boomcontroller.

1. Start engine.

2. Set hydraulic function switch to boom position.

3. Remove vacuum hoses from storage.

4. Pull boom latch cable to release boom.

5. Use tethered boom controller to:

raise boom until it clears saddle.

extend/retract boom to desired length.

raise/lower boom to desired height.

6. Rotate boom by manually swinging it left or right.




Latch boom before tilting tank.

Do not unlatch boom when tank is tilted up.

If unit is parked on a slope, control boom so it does not swing freely when released.

Do not use boom to lift or move objects. Using boom in an inappropriate way may damageequipment or injure personnel.


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Vacuum and Pothole - 60 FX30 Operators ManualRemove Debris

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Remove Debris

Procedure

1. Position vacuum hose in area to be excavated.

2. Start engine.

3. Open inlet valve.

4. Use sight glasses to monitor debris level in tank. Vacuum will shut off when tank is full but always heedtrailer and tank lifting capacities as indicated on page 55. Engine will remain running.


Vacuum will suffocate. Maintain distance between face andvacuum inlets.

Fire or explosion possible. Do not vacuum flammable orcombustible substances.

Incorrect procedures could result in death, injury, or propertydamage. Learn to use equipment correctly.

To help avoid injury: Do not excavate hazardous or toxic materials. Unit is designed to excavateonly soil cuttings, drilling fluids, and other non-toxic waste.



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FX30 Operators Manual Vacuum and Pothole - 61Pothole

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Pothole

1. Start engine.

2. Open inlet valve.

3. Open water tank valve.

4. Move water pump switch to on.

5. Position tool over area to be excavated and begin pothole.


Vacuum will suffocate. Maintain distance between face andvacuum inlets.

Fire or explosion possible. Do not vacuum flammable orcombustible substances.


Electric shock. Contacting electric lines will cause death or seriousinjury. Know location of lines and stay away.

To help avoid injury: Do not direct water lance at overhead lines. Water conducts electricity.

2-in-1 Tool Basic Tool

Squeeze water pressure lever to startwater pressure.

Work pressurized water in a rocking orcircular motion to loosen and excavate soiluntil hole is at the desired diameter anddepth.

First use water lance to loosen soil.

Work tool in a rocking or circular motion to

excavate soil. Use water lance and tool alternately until

hole is at the desired diameter and depth.


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Vacuum and Pothole - 62 FX30 Operators ManualPothole

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6. Adjust water pressure as needed to match soil conditions and/or material of utility being exposed.

7. Ensure that water sprays from nozzle in a fan pattern. If it does not, nozzle may be clogged and pumpwill not function properly. Clean or replace nozzle as necessary.

8. When freshwater tank is empty, stop operation and turn water pump switch to off.

J obsite hazards could cause death or serious injury. Use correctequipment and work methods. Use and maintain proper safety equipment.

To help avoid injury: Test water pressure on a sample of the utility line material to be exposed.Adjust pressure until no damage occurs to the material. High pressure water can cut utility lines.

NOTICE: Do not continue to operate with freshwater tank empty. Running water pump with nowater will damage pump.


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FX30 Operators Manual Vacuum and Pothole - 63Drain Tank

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Drain Tank

1. Ensure that unit is hitched to vehicle. See Hitch Trailer on page 52.

2. Haul unit to approved dumping area.

3. Open drain/outlet valve and inlet valve.

4. Allow tank to drain in the horizontal position untiltank is approximately half drained. Monitor sightglasses.

5. When tank is half drained, start engine and run atlow idle.

6. Tilt tank up to help flush solids from tank.

7. Lower tank to the full horizontal position.

8. Close drain/outlet valve and inlet valve.


Incorrect procedures could result in death, injury, or propertydamage. Learn to use equipment correctly.

To help avoid injury:

Do not unhitch unit from tow vehicle before or during dumping. A freestanding unit can

become unstable when tilting tank. Do not unlatch door with tank tilted up.

Do not unlatch vacuum boom (optional) with tank tilted up.

Breathing crystalline silica dust may cause lung disease. Cutting,drilling, or working materials such as concrete, sand, or rock containing quartz mayresult in exposure to silica dust. Use dust control methods or appropriate breathingprotection when exposed to silica dust.

NOTICE: Do not drive with tank or door raised.


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Vacuum and Pothole - 64 FX30 Operators ManualDrain Tank

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9. If further draining is necessary, open tank door.See Open/Close Tank Door on page 67.

10. Tilt tank up fully. Allow tank to drain completely.

11. Connect water pressure hose to water lance.

12. Turn water pump switch on. Adjust water pressure.

13. Use water lance to thoroughly rinse inside of tankand around door seal.

14. Return tank to the fully lowered horizontal position.

Crushing weight could cause death or serious injury. Use properprocedures and equipment or stay away.

To help avoid injury : Use tools (provided with unit) if unit must be serviced withtank door up.

Confined spacewill cause suffocation. Useproper procedures for enteringor stay away.

To help avoid injury : Enter tank only ifnecessary. Follow U.S. Department of Laborguidelines for entering confined spaces.


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FX30 Operators Manual Vacuum and Pothole - 65Unload to Another Tank

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Unload to Another Tank

Optional reverse flow mode can be used to transfer vacuumed material to another tank or disposal site.

1. Throttle down completely and turn off engine. Securely connect transfer hose to FX tank. Ensure drain/outlet valve on FX tank is closed.

2. Securely connect other end of transfer hose to offboard tank. Ensure inlet valve on offboard tank isclosed and tank is vented.

3. Open FX tank drain/outlet valve. Material will flow into transfer hose.

4. Open offboard tank inlet valve.


To help avoid inju ry:

Keep unit in vacuum mode unless pressure is needed.

Restrain hose prior to pressurization. Unrestrained hose may cause property damage, injury ordeath.

Do not open fitting cams or valves when tank is pressurized. Flying debris, plugs and doors cancause injury or death.

Do not open tank door while tank is pressurized.

Do not use pressure to clear clogs in vacuum hose.

IMPORTANT: Check relief valve as shownbefore each use.

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Vacuum and Pothole - 66 FX30 Operators ManualUnload to Another Tank

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5. Move valve handle counterclockwise to engage reverse flow mode and start engine. Material will flowinto offboard tank.

6. Increase throttle as desired to transfer material.

7. When transfer is complete, throttle down completely and turn off engine. Close FX tank drain/outletvalve.

8. Close offboard tank inlet valve and disconnect hose from offboard tank inlet valve.

9. Move handle clockwise to vacuum mode and turn on engine.

10. Open FX tank drain/outlet valve. Material will empty from transfer hose.

11. Close FX tank drain/outlet valve, throttle down and turn off engine.

12. Disconnect transfer hose from FX tank.


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FX30 Operators Manual Vacuum and Pothole - 67Open/Close Tank Door

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Open/Close Tank Door

Open

1. If using optional reverse flow mode, turn off engine and ensure handle is down (in vacuum mode).

2. If tank is tilted, lower tank fully before opening door.


4. Set hydraulic function switch to door position.

5. Press OPEN on tethered control.

Close

1. Press CLOSE on tethered control until the linkage on both sides of the tank is fully collapsed.

2. Close tank inlet valve.


To help avoid injury: Use tools (provided with unit) if unit must be serviced with tankdoor up.

To help avoid injury : Do not raise tank with door held closed only by vacuum. Door may suddenlyopen and possibly injure someone.

NOTICE: Do not drive with tank or door raised.

IMPORTANT: Depressurize tank before emptying cyclonic canister, cleaning filter, clearing hoses oropening any doors.



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Vacuum and Pothole - 68 FX30 Operators ManualOpen/Close Tank Door

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FX30 Operators Manual Complete the Job - 69

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Complete the Job

Chapter Contents

Anti freeze Fluid Excavation Unit . . . . . . . . . . . . . 70

Add Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Reclaim Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Rinse Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Stow Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72


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Complete the Job - 70 FX30 Operators ManualAnti freeze Fluid Excavation Unit

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Antifreeze Fluid Excavation Unit

Add Anti freeze

Follow these steps for overnight or long-term storage of unit during cold weather.

1. Fill antifreeze tank with a propylene-glycol based antifreeze.

2. Ensure that water tank valve is closed.

3. Open antifreeze tank valve.

4. Connect water pressure hose to water lance.

5. Start engine.

6. Move water pump switch to on. If freshwater tank is empty, move to bypass.

7. Squeeze water lance handle and run until antifreeze runs through the water lance.

8. Move water pump switch to off.

9. Close antifreeze tank supply valve.

10. Turn ignition switch to off.

11. Drain water tank completely.

Reclaim Anti freeze

1. Turn water pressure down.

2. Move water pump switch to on.

3. Put end of water lance in antifreeze tank.

4. Squeeze water lance handle and run until water comes out of lance.

5. Move water pump switch to off.


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FX30 Operators Manual Complete the Job - 71Rinse Equipment

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Rinse Equipment

Spray water onto equipment to remove dirt and mud. Use water lance. Thoroughly rinse inside of tank andaround door seal.

Disconnect

Disconnect and store the following hoses and cables (if used):

vacuum hoses

water pressure hose

Confined space will cause suffocation. Use proper procedures forentering or stay away.


Enter tank only if necessary. Follow U.S. Department of Labor guidelines for entering confinedspaces.

Do not spray water onto operators console. Electrical components could be damaged. Wipe down

instead.


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Complete the Job - 72 FX30 Operators ManualStow Tools

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Stow Tools

Make sure optional vacuum boom, potholing tools, water lance, and other tools are properly stowed.


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FX30 OperatorsManual Service - 73

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Service

Chapter Contents

Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . 74

Recommended Lubricants/Service Key . . . . . . . 76

10 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

25 Hour. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

100 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

1000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

2000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

As Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

200 Mile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

3,000 Mile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

12,000 Mile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108


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Service - 74 FX30 Operators ManualService Precautions

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Service Precautions

Working Under Raised Debris Tank

1. Raise vacuum tank.

2. Remove cylinder lockout tool and place over extendedcylinder rod.

3. Lower vacuum tank until load is supported by cylinderlockout tool.



Unless otherwise instructed, all service should be performed with engine off.

Refer to engine manufacturers manual for engine maintenance instructions.


To help avoid injury: Use tools (provided with unit) if hydraulic system must be servicedwith tank tilted up.


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FX30 OperatorsManual Service - 75Service Precautions

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Working Under Raised Tank Door

1. Locate door lock tools in tool storage area and bring to rear

of tank.

2. Raise tank door completely.

3. Place door lock tools over extended cylinder rods and pininto place.

4. Lower tank lid until load is supported by door locktools.

Welding Precaution

Washing Precaution


To help avoid injury: Use tools (provided with unit) if unit must be serviced with tankdoor up.

NOTICE: Welding can damage electronics.

Disconnect battery to prevent damage to battery. Do not turn off battery disconnect switch withengine running, or alternator and other electronic devices may be damaged.

Connect welder ground clamp close to welding point and make sure no electronic components arein the ground path.

Always disconnect the Engine Control Unit ground connection from the frame, harness connectionsto the ECU, and other electronic components prior to welding on machine or attachments.

NOTICE: Water can damage electronics. When cleaning equipment, do not spray electrical componentswith water.



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Service - 76 FX30 Operators ManualRecommended Lubricants/Service Key

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Recommended Lubricants/Service Key

Proper lubrication and maintenance protects Ditch Witch equipment from damage and failure. Serviceintervals listed are for minimum requirements. In extreme conditions, service machine more frequently.Use only recommended lubricants. Fill to capacities listed in Fluid capacities on page 113.

For more information on engine lubrication and maintenance, see your Kubotaengine manual.

Item Description

DEO Diesel engine oil meeting API service classification CF-4 or E1-96 and SAE viscosity

recommended by engine manufacturer (SAE 15W40)

SGL Synthetic gear oil (ISO 100), cmw p/n 256-044

MPG Multipurpose grease meeting ASTM D217 and NLGI 5

HTG High temperature, NLGI #2 premium grade, petroleum-based grease with hightemperature resistance and good mechanical stability

NDO 30W non-detergent oil

DEAC Diesel engine antifreeze/coolant meeting ASTM D5345 (prediluted) or D4985

(concentrate)

THF Tractor hydraulic fluid, similar to Phillips 66 HG, Mobilfluid 423, Chevron TractorHydraulic Fluid, Texaco TDH Oil, or equivalent

DOT DOT 3 or 4 brake fluid

Check level of fluid or lubricant

Check condition

Filter

Change, replace, adjust, service or test

NOTICE:

Use only genuine Ditch Witch parts, filters, approved lubricants, TJ C, and approved coolants tomaintain warranty.

Use the Service Record on page 125 to record all required service to your machine.


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FX30 OperatorsManual Service - 77Recommended Lubricants/Service Key

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Engine Oil Temperature Chart

Approved Coolant

Any coolant is approved for use with this unit. However, it was filled with J ohn Deere Cool-Gard coolantbefore shipment from factory. Add only Cool-Gard (p/n 255-006) or any fully-formulated, ethylene glycolbased, low-silicate, heavy-duty diesel engine coolant meeting ASTM specification D5345 (prediluted) orD4985 (concentrate). Before using any other kind of coolant, completely flush radiator.

Approved Fuel

The engine is this unit is designed to run on diesel fuel. Use only high-quality fuel meeting ASTM D975 No.2D, EN590, or equivalent. At temperatures below 32F (0C), winter fuel blends are acceptable. Seeengine operation manual for more information.

Biodiesel blends up to 5% (B5) are approved for use in this unit. The fuel used must meet thespecifications for diesel fuel shown above. Extra attention is needed when using biodiesel, especially whenoperating in cold weather or storing fuel. Contact your Ditch Witch dealer or the engine manufacturer formore information.

NOTICE: Do not mix heavy-duty diesel engine coolant and automotive-type coolant. This will leadcoolant breakdown and engine damage.

IMPORTANT: Fuel sulfur content should be less than 5000 ppm (0.5%). Worldwide, fuel sulfurregulations vary widely. Fuel used should always comply with local regulations. Do not use lube oilmeeting API CJ -4 (or other low SAPS equivalent) if fuel sulfur content is above 5000 ppm (0.05%, lowsulfur diesel in the U.S.).

Temperature range anticipated before next oil change


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Service - 78 FX30 Operators Manual10 Hour

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10 Hour

Location Task Notes

TRAILER Check tightness of trailer hitch bolts Torque varies with trailer model. Refer

to Specifications beginning onpage 111

Check hydraulic brake actuator bolts If equipped

Check hydraulic brake fluid level If equipped

Check trailer battery

Check tire pressure and lug nut torque

Check lights and reflectors

VACUUM

SYSTEM

Check engine air filter service indicator

Check engine oil level DEO

Check coolant level DEAC

Check hydraulic hoses

Check hydraulic fluid level THF

Check blower oil SGL

Check blower belt tension

Check water pump oil level NDO

Clean water pump filter

Check tension of water pump belts

Clean vacuum air filter

Check spray nozzle

Drain cyclonic separator canister

DEBRIS

TANK

Check strobe light

Check vacuum tank door seals/fittings


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CMW

Trailer

Check Hitch Bol ts

Check that trailer hitch bolts are properly

tightened. Torque varies by trailer model. Referto Specifications beginning on page 111.

Check Hydraulic Brake Actuator Bolts

Check that hydraulic brake actuator bolts areproperly tightened.

Check Hydraulic Brake Fluid Level

Check hydraulic brake fluid level at mastercylinder cap (shown) each use. Fluid should bevisible at top of master cylinder. Add DOT 3 orDOT 4 brake fluid and bleed brakes as needed.See page 103.



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Check Trailer Battery

Check battery connections for wear or corrosion.Keep connections clean and tight. Batteriessupplied by factory are maintenance-free. Service

replacement batteries according tomanufacturers instructions.

Check Trailer Tire Pressure and

Lug Nut Torque

Check tire pressure (2) and lug nut (1) torque.See below for correct pressure and torque. Toverify trailer model, see the certification platelocated on the trailer tongue.

Check Trailer Lights and Reflectors

Check lights and reflectors for correct operationand cleanliness.

Trailer Pressure Torque

T9S,T9SH,T12S

80 psi(5.5 bar)

95 ftlb(129 Nm)

T18S 125 psi(8.6 bar)

300 ftlb(407 Nm)


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Vacuum System

Check Engine Air Filter ServiceIndicator

Check air filter restriction indicator every 10 hours.Press dust ejector valve to release dust. Change airfilter elements when air filter restriction indicator (1)reaches the red zone.

To change:

1. Remove air filter cover (2) and removeelement.

2. Wipe inside of housing and wash cover.

3. Insert new element.

4. Replace cover.

5. Reset air filter restriction indicator (1).

Check Engine Oil Level

While engine oil is warm, check oil level at dipstick(2) every 10 hours. Add DEO at fill (1) as necessaryto keep oil level at highest line on dipstick.

NOTICE: Only open the air filter canister whenair restriction is indicated. Change the elements,do not attempt to clean them.

Compressed air or water may damage filterelement.

Tapping filter elements to loosen dirt may

damage the element.


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Check Coolant Level

Check coolant level every 10 hours. Add coolant attop of cooler as needed to maintain level betweenLOW and FULL marks on overflow bottle.

Use only Ditch Witch approved coolant. ApprovedCoolant on page 77.

Check Hydraulic Hoses

Check hydraulic hoses for leaks every 10 hours.

Fluid or air pressure could pierce skin and cause injury or death. Stayaway.

To help avoid injury : Escaping pressurized fluid can cause injury or pierce skin and poison.

Before disconnecting a hydraulic line, turn engine off and operate all controls to relieve pressure.Lower, block, or support any raised component with a hoist. Cover connection with heavy cloth andloosen connector nut slightly to relieve residual pressure. Catch all fluid in a container.

Before using system, check that all connections are tight and all lines are undamaged.

Use a piece of cardboard or wood, rather than hands, to search for leaks. Wear protective clothing, including gloves and eye protection.

If you are injured, seek immediate medical attention from a doctor familiar with this type of injury.



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Check Hydraulic Fluid Level

Check hydraulic fluid level every 10 hours. Maintainfluid level at 3/4 tank when engine is off and fluid iscool. Add THF at hydraulic fluid fill (1) as

necessary.

Check Blower Oil

With frame level, check blower oil at sight glass(3) every 10 hours. Add SGL at fill (2) asnecessary to maintain oil level at halfway point onsight glass. Do not overfill.

Check Blower Belt Tension

Check belt every 10 hours for correct tension,damage or wear. Idler pulley tensioner should beset to 70 lb of force. Verify that the indicationmarks on tensioner are in the same position asinitially set, or apply 10 lb of force to the belt andcheck that deflection is .25-.375 (6-10 mm).

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Check Water Pump Oil

With frame level, check water pump oil at sightglass (2) every 10 hours. Add NDO at fill (1) asnecessary to keep oil at halfway mark on sight

glass.

Clean Water Pump Fil ter

Clean water pump filter every 10 hours andreplace as needed.

1. Open filter housing.

2. Remove element and rinse housingthoroughly with water.

3. Inspect element for signs of collapse and forbrittle or broken rubber seals on the ends ofthe element. Replace as needed. Seepage 100.

4. Replace element and close filter housing.

Check Water Pump Belt Tension

Check belt every 10 hours for correct tension,damage or wear. Contact your Ditch Witch dealerfor adjustment or belt replacement.

To check:

1. Turn ignition to STOP and remove key.

2. Apply moderate thumb pressure to belt

between pulleys.

3. Belt is properly tensioned when deflection is.125-.25 (3-6 mm).

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Clean Vacuum Air Filter

Clean filter every 10 hours or as needed.

To clean filter:

1. Remove filter from canister.

2. Run low pressure water into inside of filter.

3. Allow filter to dry completely before returningto canister.

Check Spray Nozzle

Check spray nozzle every 10 hours. Ensure thatwater sprays from nozzle in a fan pattern. Cleanor replace nozzle as necessary.

Breathing crystalline silica dust may cause lung disease. Cutting, drilling,or working materials such as concrete, sand, or rock containing quartz may result inexposure to silica dust. Use dust control methods or appropriate breathing protection

when exposed to silica dust.

NOTICE: Do not use high pressure waterto clean filter. Filter will be damaged.




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Drain Cyclonic Separator Canister

Drain canister at drain (2) every 10 hours or whenwater is visible in sight glass (1).

Debris Tank

Check Strobe Light

Check strobe light for proper function every 10hours. When ignition is on, strobe light should beflashing. Repair if necessary.

Check Vacuum Tank Door Seals andFittings

Check door seal every 10 hours for wear ordamage. Repair if necessary. Check for leaks andloose fittings every 10 hours. Repair or replace ifnecessary.

IMPORTANT: Depressurize tank beforeemptying cyclonic canister, cleaning filter,clearing hoses or opening any doors.

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25 Hour

Vacuum System

Change Water Pump Oil

Change oil after the first 25 hours of operationand every 100 hours thereafter. Change oil morefrequently if working in dusty conditions.

Drain at drain plug (3) while oil is warm.

Add NDO at fill (1) until oil is at halfway markon sight glass (2).

Location Task Notes

VACUUM

SYSTEM

Change water pump oil Initial service, NDO

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CMW

50 Hour

Location Task Notes

VACUUM

SYSTEM

Change engine oil and filter Initial service, DEO

Change fuel filters Initial service

Check and adjust fan belt tension

Check radiator

Check battery

Check water pressure hoses

Lube blower bearings

DEBRIS

TANK

Lube tank pivot pins

VACUUM

BOOM

Lube boom pivot Boom is optional equipment


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CMW

Vacuum System

Change Engine Oil and Filter(Initial Service)

Change engine oil and filter after 50 hours, andevery 100 hours thereafter. Drain oil (4), changefilter (3), and add 4.2 qt (4 L) of DEO at fill (2).

Change Fuel Filters (Initial)

Replace filters (2, 3) after the first 50 hours ofoperation, and every 100 hours thereafter.

1. Remove filter.

2. Install new filter. Apply fuel oil thinly over thegasket and hand-tighten.

3. Bleed air from the injection pump. (See enginemanufacturers manual for instructions.)

IMPORTANT: Use oil specified in temperaturechart found in Recommended Lubricants/Service Key on page 76.

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3

4


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Check and Adjust Fan Belt Tension

Check belt tension every 50 hours. Belt is properlytensioned when it moves about 1/4-3/8 (7-9 mm)when pushed at the long span (shown).

To adjust:

1. Loosen two alternator bolts (1).

2. Adjust position to allow belt to slip off.

3. Install new belt.

4. Adjust position to tighten belt.

5. Tighten bolts.

6. Check tension.

Check Radiator

Check radiator for dirt, grass, and other foreignmatter every 50 hours. Check more often ifoperating in dusty or grassy conditions. Clean finswith compressed air or spray wash.

Check Battery

Keep battery clean and free of corrosion. Applycoat of grease to cable clamps after cleaning.

In cold weather, battery loses some starting ability.Closely watch voltmeter for signs of batterydischarge.

If battery will not hold charge, see your Ditch Witchdealer for replacement battery.

IMPORTANT: Be careful not to damage finswith high pressure air or water.

IMPORTANT: Use battery disconnect switch(shown) when servicing, welding, and duringlong-term storage.

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Check Water Pressure Hoses

Check hoses every 50 hours for wear or damage.Replace as necessary.

Lube Blower Bearings

Wipe two zerks clean and lube every 500 hourswith HTG. Inject grease into zerk until cleangrease comes out of relief fittings.

Debris Tank

Lube Tank Pivot Pins

Lube two pins every 50 hours with MPG.

NOTICE: Do not inject grease too quickly.Drive shaft seal damage could occur.





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Vacuum Boom

Lube Boom Pivot

Lube six zerks every 50 hours with MPG.



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CMW

100 Hour

Vacuum System

Change Engine Oil and Filter(Regular Service)

Change engine oil and filter every 100 hours. Drainoil (4), change filter (3), and add 4.2 qt (4 L) of DEOat fill (2).

Location Task Notes

VACUUM

SYSTEM

Change engine oil and filter DEO

Change fuel filters

Change blower oil initial service, SGL

Change hydraulic fluid initial service, THF

Change water pump oil NDO

DEBRIS

TANK

Check tank deflector

Check tank mounting bolts

VACUUM

BOOM

Check structure Boom is optional equipment

Check boom deflector and plate seal

IMPORTANT: Use oil specified in temperaturechart found in Recommended Lubricants/Service Key on page 76.

2

3

4


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Change Fuel Filters

Replace filters (2,3) every 100 hours.

1. Remove filter.

2. Install new filter. Apply fuel oil thinly over thegasket and hand-tighten.

3. Bleed air from the injection pump. (See enginemanufacturers manual for instructions.)

Change Blower Oil

Change oil after the first 100 hours of operation,and every 1000 hours thereafter. Change oil morefrequently if working in dusty conditions.


Add with SGL at fill (2) until oil is at halfwaypoint on sight glass (3).

Change Hydraulic Fluid

Change hydraulic fluid after the first 100 hours, andevery 1000 hours thereafter. Drain hydraulic fluid(2), add THF at hydraulic fluid fill (1) until level is a3/4 full.

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4


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Change Water Pump Oil

Change oil after the first 25 hours of operationand every 100 hours thereafter. Change oil morefrequently if working in dusty conditions.


Add with NDO at fill (1) until oil is at halfwaymark on sight glass.

Debris Tank

Check Tank Deflector

Check tank deflector every 100 hours for wear ordamage. Replace as needed.

Check Tank Mounting Bol ts

Check vacuum tank mounting bolts (shown, bothsides) every 100 hours for looseness and damage.

Tighten or replace as needed.

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Vacuum Boom

Check Structure

Check vacuum boom and structure every 100 hours. Check welds. Replace or repair if there are any signs

of damage.

Check Boom Deflector and Plate Seal

Check boom deflector (1) and plate seal (2) every

100 hours. Replace as needed. Use Loctitetoinstall new seal.



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1000 Hour

Vacuum System

Change Blower Oil

Change oil every 1000 hours. Change oil morefrequently if working in dusty conditions.


Add with SGL at fill (2) until oil is at halfwaypoint on sight glass (3).

Change Hydraulic Fluid

Change hydraulic fluid every 1000 hours. Drain

hydraulic fluid (2), add THF at hydraulic fluid fill (1)and check level.

Location Task Notes

VACUUM

SYSTEM

Change blower oil SGL

Change hydraulic fluid THF

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3

4


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2000 Hour

Change Coolant

Drain coolant and add DEAC at radiator fill every2000 hours. To drain, open shut-off valve (top).Catch fluid at drain (bottom).

Location Task Notes

VACUUM

SYSTEM

Change coolant DEAC

Replace water pump belts

Replace blower belt




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Replace Water Pump Belts

Replace belt every 2000 hours.

Replace Blower Belt

Replace belt every 2000 hours.




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Service - 100 FX30 Operators ManualAs Needed

CMW

As Needed

Change Water Pump Filter

1. Open filter housing.

2. Remove element and rinse housingthoroughly with water.

3. Replace element and close filter housing.

Lube Blower for Long-term Storage

Lubricate blower before long-term storage to helpprevent rust and siezing.

1. Remove plug from fitting at filter.

2. Start engine.

3. Spray light oil into port and run unit for 1-2minutes.

4. Turn off engine.

Location Task Notes

VACUUM

SYSTEM

Change water pump filter

Lube blower for long-term storage

Change blower relief air filter

Empty cyclonic separator canister

DEBRIS

TANK

Clean primary shutoff valve

TRAILER Add surge brake fluid DOT 3 or 4




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Service - 102 FX30 Operators ManualAs Needed

CMW

Debris Tank

Clean Primary Shut-off Valve

Clean primary shut-off valve as needed. Replace

primary shut-off valve as needed.

To clean:

1. Open tank door.See Open/Close Tank Dooron page 67.

2. Spray valve housing inside vacuum tank withhigh-pressure water.

3. Store water pressure hose.

4. Close tank door.See Open/Close Tank Dooron page 67.

To remove:

1. Loosen three wingnuts (1) and pull out valve housing (2).

2. Remove ball (3).

3. Clean ball and housing with high-pressure water.

4. Replace ball and housing.

5. Tighten wingnuts.

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FX30 OperatorsManual Service - 103As Needed

CMW

Trailer

Add Surge Brake Fluid

Add surge brake fluid at cap (1) as needed and

bleed brakes.

1. Remove lever guide and flat emergency leverspring by removing two 5/16 hex head boltsand lock washers.

2. Using short strokes, pull forward onemergency lever (2) until brake fluid in mastercylinder stops bubbling.

3. Attach bleeder hose to bleeder valve on onewheel and submerge other end of hose into atransparent container partially filled with

Dicth Witch FX30-Manual

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Transcript of Dicth Witch FX30-Manual