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Foreword - 6

SK500 Operator’s Manual

CMW

SK500

Operator’s Manual

Issue number 2.0/OM-1/05

Part number 054-091

by The Charles Machine Works, Inc.

, Ditch Witch, CMW, AutoCrowd, Modularmatic, Jet Trac, Roto Witch, Subsite,

Fluid Miser, Perma-Soil, Power Pipe, Super Witch, Super Witch II, Pierce Airrow, The Underground, and
The Underground Authority Worldwide are registered trademarks of The Charles Machine Works, Inc.

Summary of Contents for SK500

Page 1: ...SK500 Operator s Manual 054 091 Issue 2 0 CMW...

Page 2: ...SK500 Operator s Manual Overview 1 CMW Overview Chapter Contents Serial Number Location 2 Intended Use 3 Unit Components 3 Operator Orientation 4 About This Manual 4 Bulleted Lists 4 Numbered Lists 4...

Page 3: ...Number Location CMW Serial Number Location Record serial numbers and date of purchase in spaces provided Unit serial number is located as shown Item date of manufacture date of purchase unit serial n...

Page 4: ...n temperatures typically experienced in earth moving and construction work environments Provisions may be required to operate in extreme temperatures Contact your Ditch Witch dealer Use in any other w...

Page 5: ...s machine See the beige Operation Overview pages for basic operating procedures Cross references such as See page 50 will direct you to detailed procedures Bulleted Lists Bulleted lists provide helpfu...

Page 6: ...copy contact your Ditch Witch dealer If you need assistance in locating a dealer visit our website at www ditchwitch com or write to the following address The Charles Machine Works Inc Attn Marketing...

Page 7: ...yright 2003 2004 2005 by The Charles Machine Works Inc Ditch Witch CMW AutoCrowd Modularmatic Jet Trac Roto Witch Subsite Fluid Miser Perma Soil Power Pipe Super Witch Super Witch II Pierce Airrow The...

Page 8: ...allation path if needed preparing the jobsite for work and connecting attachments 21 Drive procedures for startup cold start driving and shutdown 29 Transport procedures for lifting hauling and towing...

Page 9: ...Contents 8 SK500 Operator s Manual CMW...

Page 10: ...ntents Guidelines 10 Safety Alert Classifications 11 Safety Alerts 12 Emergency Procedures 15 Electric Strike Description 15 If an Electric Line is Damaged 16 If a Gas Line is Damaged 16 If a Fiber Op...

Page 11: ...ds and use correct tools and machinery safety equipment and work methods for jobsite Mark jobsite clearly and keep spectators away Wear personal protective equipment Review jobsite hazards safety and...

Page 12: ...levels DANGER WARNING and CAUTION Learn what each level means indicates an imminently hazardous situation which if not avoided will result in death or serious injury indicates a potentially hazardous...

Page 13: ...e death or serious injury Know location of lines and stay away Deadly gases Lack of oxygen or presence of gas will cause sickness or death Provide ventilation Jobsite hazards could cause death or seri...

Page 14: ...control does not work as described in instructions stop machine and have it serviced Looking into fiber optic cable could result in permanent vision damage Do not look into ends of fiber optic or unid...

Page 15: ...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 hearing protection Fall possible Slips or trips may...

Page 16: ...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 Almost one third of work related electro...

Page 17: ...rce s if this can be done safely and quickly Warn others that a gas line has been cut and that they should leave the area Leave jobsite as quickly as possible Immediately call your local emergency pho...

Page 18: ...ature indicator 8 Attachment drive control 9 Lift arm control 10 Throttle 11 Right track drive control 12 Left track drive control Item Description Notes 1 Choke To help start cold engine pull knob Wh...

Page 19: ...TOP and then restart 4 Fuel gauge Displays fuel level in tank Use only unleaded gasoline Tank holds 6 gal 23 L 5 Hourmeter Displays engine operating time Use these times to schedule service 6 Engine o...

Page 20: ...forward pull down 9 Lift arm control To move lift arms down push To float push forward to end To move lift arms up pull To curl attachment up move to left To curl attachment down move to right IMPORT...

Page 21: ...To counter rotate in either direction move controls fully to ends in the directions indicated above 12 Left track drive control To move forward push To move backward pull To go faster in either direct...

Page 22: ...ound Penetrating Jobs 22 Above Ground Jobs 22 Inspect Site 23 Identify Hazards 23 Classify Jobsite 24 Inspect Jobsite 24 Select a Classification 24 Apply Precautions 25 Check Supplies and Prepare Equi...

Page 23: ...ol If working near a road or other traffic area contact local authorities about safety procedures and regulations Plan for Emergency Services Have the telephone numbers for local emergency and medical...

Page 24: ...ground See Classify Jobsite on page 24 Jobsite hazards could cause death or serious injury Use correct equipment and work methods Use and maintain proper safety equipment NOTICE Wear personal protecti...

Page 25: ...ent operator sweep area within 20 feet 6 m to each side of work path Verify previously marked line and cable locations Mark location of all buried utilities and obstructions Classify jobsite Select a...

Page 26: ...use one or both of these methods Expose lines by careful hand digging or soft excavation Have gas shut off while work is in progress Have gas company test lines before returning them to service Crysta...

Page 27: ...ic fluid battery charge engine oil Condition and Function digging chain and teeth filters air oil hydraulic tracks pumps and motors hoses and valves signs guards and shields Accessories Fire Extinguis...

Page 28: ...Turn ignition switch off and remove key 8 Rotate lock pin handles toward center of mount plate to secure attachment to lift plate IMPORTANT Use only Ditch Witch approved attachments Attachments can ch...

Page 29: ...c 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 and loosen connector nut slightly to reli...

Page 30: ...SK500 Operator s Manual Drive 29 CMW Drive Chapter Contents Start Unit 30 Drive 30 Shut Down 31...

Page 31: ...nes Operate up and down slopes with heavy end of unit uphill Weight distribution changes based on attachments and load For example an empty bucket makes the rear of the unit the heavy end while a full...

Page 32: ...ve track drive controls to neutral position 2 Run engine at low idle for three minutes to cool 3 Turn ignition switch to STOP 4 Remove key NOTICE Unit should not be parked on a slope unless chocked or...

Page 33: ...Drive 32 SK500 Operator s Manual Shut Down CMW...

Page 34: ...SK500 Operator s Manual Transport 33 CMW Transport Chapter Contents Lift 34 Points 34 Procedure 34 Haul 35 Inspect Trailer 35 Hitch Trailer 35 Load 36 Tie Down 37 Unload 38 Unhitch Trailer 38 Tow 39...

Page 35: ...nd can damage machinery Procedure Use a hoist capable of supporting the equipment s size and weight See page 65 or measure and weigh equipment before lifting Use four lift points Attach securely to cr...

Page 36: ...Turn off ignition Set parking brake 3 Connect trailer drawbar lunette or coupler to tow vehicle hitch and lock in place with lock pin If needed adjust drawbar lunette or coupler height to level load...

Page 37: ...mount plate and attachment to trailer bed 7 Turn ignition switch off 8 Close fuel shutoff valve shown 9 Tie down unit Crushing weight If load falls or moves it could kill or crush you Use proper proc...

Page 38: ...n Points Tiedown points are identified by tiedown decals Securing to truck or trailer at other points is unsafe and can damage machinery Procedure Loop tiedowns around unit at tiedown points Make sure...

Page 39: ...er 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 Reverse Hitch Trailer steps on...

Page 40: ...n 100 ft 30 m use no more than 1 300 lb 5800 N of towing force disengage brakes and open bypass valve Prepare Unit for Towing 1 Block tracks 2 Insert pry bar between end of spring 1 and frame 3 Rotate...

Page 41: ...tach end of both springs 1 through hole in each side of frame 6 Stretch springs and install brake pin bolts in the same holes they were removed from 7 Install rear access panel IMPORTANT Close bypass...

Page 42: ...SK500 Operator s Manual Complete the Job 41 CMW Complete the Job Chapter Contents Rinse Equipment 42 Disconnect Attachment 42 Stow Tools 42...

Page 43: ...er attachment to the ground 2 Turn off engine 3 Disengage lock pins by turning handles away from center of attachment 4 Cycle attachment drive control and disconnect hydraulic hoses if used 5 Start en...

Page 44: ...Service 43 CMW Service Chapter Contents Precautions 44 Overview 45 Recommended Lubricants Service Key 46 Oil Temperature Chart 46 10 Hour 47 20 Hour 52 50 Hour 54 100 Hour 55 200 Hour 57 250 Hour 59...

Page 45: ...rn to use equipment correctly NOTICES Unless otherwise instructed all service should be performed with engine off Refer to engine manufacturer s manual for engine maintenance instructions Before servi...

Page 46: ...SK500 Operator s Manual Service 45 Overview CMW Overview t05om006c eps 500 h 250 h 100 h 50 h 20h 10h...

Page 47: ...ended by engine manufacturer SAE 10W30 DEO IMPORTANT DEO can be used in Honda engines to lessen foaming Diesel engine oil meeting API service classification CF 4 or E1 96 and SAE viscosity recommended...

Page 48: ...0 hours If low add GEO at fill 1 Check with unit on level surface and at least 15 minutes after stopping engine Location Task Notes Traction Unit Check engine oil level GEO Check hydraulic fluid level...

Page 49: ...low add GEO at fill 2 Check with unit on level surface and at least 15 minutes after stopping engine Check Hydraulic Fluid Level Check hydraulic fluid level every 10 hours Maintain fluid level at hal...

Page 50: ...pressure Lower block or support any raised component with a hoist Cover connection with heavy cloth and loosen connector nut slightly to relieve residual pressure Catch all fluid in a container Before...

Page 51: ...am 2 and paper 3 filter elements 3 Clean or replace elements if they are dirty or damaged See Clean Air Filter on page 54 4 Wipe dirt from insides of air cleaner cover and body with a moist rag 5 Inst...

Page 52: ...pect primary 2 and secondary 3 elements 3 Wipe inside of housing and wash end cup 4 Insert primary and secondary elements 5 Close air filter case Check Track Tension Check track tension every 10 hours...

Page 53: ...ge engine oil after 20 hours Drain oil 1 and add 1 2 qt 1 1 L of GEO at fill 2 Location Task Notes Traction Unit Change engine oil Initial service GEO IMPORTANT Use oil specified in Engine Oil Tempera...

Page 54: ...00 Operator s Manual Service 53 20 Hour CMW Kohler Change engine oil after 20 hours Drain oil 2 and add 2 1 qt 2 L of GEO at fill 1 IMPORTANT Use oil specified in Engine Oil Temperature Chart on page...

Page 55: ...apping several times on hard surface or blowing compressed air through element from the bottom Clean foam element in warm soapy water and allow to dry thoroughly 2 Clean air cleaner cover and body and...

Page 56: ...Change engine oil every 100 hours Drain oil 1 and add 1 2 qt 1 1 L of GEO at fill 2 Location Task Notes Traction Unit Change engine oil GEO IMPORTANT Use oil specified in Engine Oil Temperature Chart...

Page 57: ...ice 56 SK500 Operator s Manual 100 Hour CMW Kohler Change engine oil every 100 hours Drain oil 2 and add 2 1 qt 2 L of GEO at fill 1 IMPORTANT Use oil specified in Engine Oil Temperature Chart on page...

Page 58: ...engine oil filter every 200 hours Drain oil change filter shown and add 1 5 qt 1 4 L of GEO at fill See page 52 Location Task Notes Traction Unit Change engine oil filter IMPORTANT Use oil specified...

Page 59: ...ator s Manual 200 Hour CMW Kohler Change engine oil filter every 200 hours Drain oil change filter shown and add 2 1 qt 2 L of GEO at fill See page 52 IMPORTANT Use oil specified in Engine Oil Tempera...

Page 60: ...or s Manual Service 59 250 Hour CMW 250 Hour Traction Unit Change Hydraulic Fluid Filter Change hydraulic fluid filter every 250 hours Location Task Notes Traction Unit Change hydraulic fluid filter t...

Page 61: ...ace filter more often See parts manual or contact your Ditch Witch dealer for correct replacement filter Kohler Change inline fuel filter every 300 hours See parts manual or contact your Ditch Witch d...

Page 62: ...nditions 1 Remove air cleaner cover 1 2 Remove foam 2 and paper 3 filter elements 3 Replace both elements 4 Wipe dirt from insides of air cleaner cover and body with a moist rag 5 Install both element...

Page 63: ...ur CMW Kohler Change air filter every 300 hours 1 Open air filter housing at latches 1 2 Remove primary 2 and secondary 3 elements 3 Wipe inside of housing and wash end cup 4 Insert new primary and se...

Page 64: ...Traction Unit Change Hydraulic Fluid Change hydraulic fluid every 500 hours Drain fluid at plug 2 and add THF at fill 1 until fluid level is at halfway point on sight glass 3 Location Task Notes Trac...

Page 65: ...Service 64 SK500 Operator s Manual 500 Hour CMW...

Page 66: ...g H2 Hinge pin height max 81 1 in 2 1 m L2 Wheelbase track length 40 in 1 m W Track width min 36 in 914 mm Track width max 42 in 1 1 m Ground clearance 6 5 in 165 mm Tipping capacity 1450 lb 658 kg Ra...

Page 67: ...ary double gear pump Flow rate pump 1 4 gpm 15 L min Flow rate pump 2 8 gpm 30 L min Pressure 2500 psi 172 bar Ground drive dual hydrostat Flow rate 12 5 gpm 47 L min Pressure 2500 psi 172 bar Power H...

Page 68: ...nders 2 Displacement 44 in3 625 cm3 Bore 3 3 in 88 mm Stroke 2 6 in 67 mm Installed net power per SAE J1349 3600 rpm 27 hp 20 1 kW Maximum governed speed no load 3750 rpm 3750 rpm Idle speed 1200 rpm...

Page 69: ...lected options delivered equipment may not necessarily match that shown Battery SAE reserve capacity 180 min SAE cold crank 0 F 18 C 675 amp 12V electrical system Noise Levels Honda Engine Operator 86...

Page 70: ...chase Return damaged parts to dealer for inspection and warranty consideration if in warranty time frame Order genuine Ditch Witch replacement or repair parts from your authorized Ditch Witch dealer U...

Page 71: ...including any warranty of fitness for a particular purpose and merchantability IF THE PRODUCTS ARE PURCHASED FOR COMMERCIAL PURPOSES AS DEFINED BY THE UNIFORM COMMERCIAL CODE THEN THERE ARE NO WARRANT...

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Page 74: ...SK500 Operator s Manual Service Record 73 CMW Service Record Service Performed Date Hours...

Page 75: ...Service Record 74 SK500 Operator s Manual CMW Service Performed Date Hours...

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