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Service - 80

XT855 Operator’s Manual

Recommended Lubricants/Service Key

CMW

Engine Oil Temperature Chart

Approved Coolant

Any ethylene glycol based coolant is approved for use with this unit. However, it was filled with John Deere
Cool-Gard coolant before shipment from factory. Add only Cool-Gard or any fully-formulated, ethylene
glycol based, low-silicate, heavy-duty diesel engine coolant meeting ASTM specification D6210 (fully
formulated) or D4985 (low silicate). 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 32°F (0°C), winter fuel blends are acceptable. See
engine operation manual for more information.

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

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

NOTICE:

Do not mix heavy-duty diesel engine coolant and automotive-type coolant. This will lead to

coolant breakdown and engine damage.

Temperature range anticipated before next oil change

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Содержание XT855

Страница 1: ...XT855 Operator s Manual 053 1985 Issue 1 0 CMW...

Страница 2: ...XT855 Operator s Manual Overview 1 CMW Overview Chapter Contents Serial Number Location 2 Intended Use 3 Unit Components 4 Operator Orientation 4 About This Manual 4 Bulleted Lists 5 Numbered Lists 5...

Страница 3: ...ion CMW Serial Number Location Record serial numbers and date of purchase in spaces provided XT855 Tier 4i serial number is located as shown Date of manufacture Date of purchase XT855 Tier 4i serial n...

Страница 4: ...eratures Contact your Ditch Witch dealer Use in any other way is considered contrary to the intended use The XT855 should be operated serviced and repaired only by persons familiar with its particular...

Страница 5: ...des of machine are determined by facing front toward lift arms of unit while seated in the operator s station 1 attachment receiver plate 2 lift arms 3 engine compartment 4 tracks 5 operator s station...

Страница 6: ...iew for basic operating procedures Cross references such as See page 50 will direct you to detailed procedures Bulleted Lists Bulleted lists provide helpful or important information or contain procedu...

Страница 7: ...Overview 6 XT855 Operator s Manual CMW...

Страница 8: ...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...

Страница 9: ...wd 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...

Страница 10: ...nd restoring the jobsite with cross references to detailed procedures 37 Prepare procedures for inspecting and classifying the jobsite planning the installation path and preparing the jobsite for work...

Страница 11: ...ecifications including weights measurements power ratings and fluid capacities 95 Support the warranty policy for this machine and procedures for obtaining warranty consideration and training 243 Serv...

Страница 12: ...ontents Guidelines 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 18 If a Fiber O...

Страница 13: ...zards 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 a...

Страница 14: ...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...

Страница 15: ...bsite hazards could cause death or serious injury Use correct equipment and work methods Use and maintain proper safety equipment Crushing weight could cause death or serious injury Use proper procedu...

Страница 16: ...ury If 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...

Страница 17: ...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...

Страница 18: ...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 co...

Страница 19: ...A The ground surface may be electrified so take small steps with feet close together to reduce the hazard of being shocked from one foot to the other For more information contact your Ditch Witch deal...

Страница 20: ...sion damage can occur If Machine Catches on Fire Perform emergency shutdown procedure and then take the following actions The order and degree of action will depend on the situation If fire is small a...

Страница 21: ...Safety 20 XT855 Operator s Manual Emergency Procedures CMW...

Страница 22: ...XT855 Operator s Manual Controls 21 CMW Controls Chapter Contents Front Console 22 Left Console 26 Joysticks 28 Upper Console 31 Seat 32 Battery 34 Tool Carrier Indicator 35...

Страница 23: ...tor 6 Operator presence indicator 7 Auxiliary hydraulic fluid flow pressure indicator 8 Horn 9 Hourmeter 10 Hydraulic fluid temperature alarm 11 Fuel gauge 12 Throttle 13 Auxiliary power outlet Item D...

Страница 24: ...press and hold button for 5 seconds If ambient temperature is below 23 F 5 C press and hold button for 10 seconds 3 Work mode switch To select tool carrier mode and control lift arms and ground drive...

Страница 25: ...ow and pressure to the auxiliary attachment drive system IMPORTANT Operator must be in seat for attachment drive switch to operate correctly If operator has left seat or if unit was shut down with swi...

Страница 26: ...Fuel gauge Displays fuel level in tank Use no 2 diesel fuel See page 80 for specific fuel recommendations Tank holds 10 gal 38 L 12 Throttle To increase engine speed push To decrease engine speed pul...

Страница 27: ...W Left Console IMPORTANT Controls are shown with seat facing excavator 1 Left extension leg control 2 Right extension leg control 3 Hydraulic fluid bypass control Optional Item Description Notes 1 Lef...

Страница 28: ...raise pull 3 Hydraulic fluid bypass control Lift knob and start engine Run engine five minutes to warm hydraulic fluid Push knob down IMPORTANT Use the hydraulic fluid bypass to assist starting a cold...

Страница 29: ...Controls 28 XT855 Operator s Manual Joysticks CMW Joysticks 1 Engine stop button 2 Right joystick 3 Attachment drive switch 4 Left joystick 5 Boom offset switch...

Страница 30: ...one action at a time Using them together operator can feather or combine operations Do not exceed rated operating capacity when lifting loads See page 98 With work mode switch in excavator mode To ope...

Страница 31: ...ether operator can feather or combine operations For steering instructions see page 48 With work mode switch in excavator mode To swing excavator to right move right To swing excavator to left move le...

Страница 32: ...pper Console 1 Front light switch 2 Rear light switch Item Description Notes 1 Front light switch To turn on press top To turn off press bottom 2 Rear light switch To turn on press top To turn off pre...

Страница 33: ...4 Operator s station pivot control Item Description Notes 1 Seat belt To fasten insert latch into buckle Adjust until seat belt is low and tight NOTICE Always fasten seat belt when operating unit 2 A...

Страница 34: ...n pivot control To pivot press and swing station to desired position To lock into position release Seat can lock in 5 different positions between 0 and 180 IMPORTANT Drive tractor with seat facing att...

Страница 35: ...connect switch Item Description Notes 1 Battery disconnect switch To disconnect battery power turn counterclockwise To connect battery power turn clockwise Green switch is located under the hood on th...

Страница 36: ...5 Tool Carrier Bucket CMW Tool Carrier Bucket 1 Level bucket indicator Item Description Notes 1 Level bucket indicator To level bucket adjust bucket position until indicator is at top of sleeve Indica...

Страница 37: ...Controls 36 XT855 Operator s Manual CMW...

Страница 38: ...XT855 Operator s Manual Operation Overview 37 CMW Operation Overview Chapter Contents Planning 38 Using Tool Carrier Mode 38 Using Excavator Mode 38 Leaving Jobsite 38...

Страница 39: ...See page 52 Using Tool Carrier Mode 1 Unload from trailer See page 57 2 Drive to job See page 47 3 Connect front attachment See page 70 4 Operate attachment See page 72 and attachment operator s manua...

Страница 40: ...ne Call Services 40 Arrange for Traffic Control 40 Plan for Emergency Services 40 Inspect Site 41 Identify Hazards 41 Classify Jobsite 42 Inspect Jobsite 42 Select a Classification 42 Apply Precaution...

Страница 41: ...lace at the same time Notify One Call Services Contact your local One Call 811 in USA or the One Call referral number 888 258 0808 in USA and Canada to have underground utilities located before diggin...

Страница 42: ...y Jobsite on page 42 Jobsite hazards could cause death or serious injury Use correct equipment and work methods Use and maintain proper safety equipment NOTICE Wear personal protective equipment inclu...

Страница 43: ...poles manhole covers sunken ground Have an experienced locating equipment operator sweep area within 20 6 m to each side of trench path Verify previously marked line and cable locations Mark location...

Страница 44: ...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...

Страница 45: ...s fuel hydraulic fluid engine oil Condition and Function filters air oil hydraulic tracks pumps and motors hoses and valves signs guards and shields Accessories Fire Extinguisher If required mount a f...

Страница 46: ...XT855 Operator s Manual Drive 45 CMW Drive Chapter Contents Start Unit 46 Drive 47 Steer 48 Shut Down 48...

Страница 47: ...fluid bypass control to warm engine See page 23 and page 27 5 Turn ignition switch to start position and release when engine starts EMERGENCY SHUTDOWN Turn ignition switch to STOP IMPORTANT After star...

Страница 48: ...avy 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 bucket makes the front of the unit th...

Страница 49: ...t or right side Tracks will counter rotate and turn unit in a tight circle Shut Down 1 Move all controls to neutral position 2 Ensure lift arms are lowered to ground and ensure excavator is in the sto...

Страница 50: ...XT855 Operator s Manual Transport 49 CMW Transport Chapter Contents Lift 50 Points 50 Procedure 50 Haul 51 Inspect Trailer 51 Hitch Trailer 51 Load 52 Tie Down 54 Unload 57 Unhitch Trailer 57 Tow 58...

Страница 51: ...ze and weight See Specifications on page 95 or measure and weigh equipment before lifting 1 Attach chains to four lift points two on each side of unit 2 Attach each chain securely to cross members 3 B...

Страница 52: ...and trailer bed for cracks 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 C...

Страница 53: ...late slightly to seat in rest 9 Lower excavator bucket to trailer deck and or attach tiedown 10 Stop engine 11 Attach tiedown where indicated on page 54 Crushing weight If load falls or moves it could...

Страница 54: ...ount plate off ground 5 Move unit to rear of trailer and align with ramps 6 Slow engine speed and slowly drive unit onto trailer 7 Once unit is correctly positioned on trailer lower mount plate to tra...

Страница 55: ...Tie Down Points Tiedown points are identified by tiedown decals Securing to trailer at other points is unsafe and can damage machinery Procedure Incorrect procedures could result in death injury or pr...

Страница 56: ...XT855 Operator s Manual Transport 55 Haul CMW With Tiedown Kit Install tiedown through rear tiedown point Make sure unit is secure before transporting...

Страница 57: ...5 Operator s Manual Haul CMW Without Tiedown Kit Loop tiedowns around unit at tiedown points Make sure tiedowns are tight before transporting IMPORTANT Do not use any point on excavator and swing arm...

Страница 58: ...rier 5 Ensure work mode switch is in tool carrier mode 6 Raise mount plate 7 Slow engine speed and slowly back unit down ramps Unhitch Trailer 1 Stop tow vehicle and trailer on level ground 2 Put manu...

Страница 59: ...nts facing towing vehicle 3 Open hood 4 Open 4 tow valves on hydrostatic pumps shown 2 on each side Loosen jam nut Turn set screw in until it stops Tighten jam nut Incorrect procedures could result in...

Страница 60: ...ow CMW Prepare Unit for Normal Operation 1 Close 4 tow valves on pumps Loosen jam nut Turn set screw out 6 turns Tighten jam nut 2 Close hood 3 Disconnect tow line IMPORTANT Use 4 mm Allen wrench and...

Страница 61: ...Transport 60 XT855 Operator s Manual Tow CMW...

Страница 62: ...XT855 Operator s Manual Dig 61 CMW Dig Chapter Contents Overview 62 Filling Bucket 63 Dumping Bucket 64 Digging 65 Single Inline Trench 65 Single Offset Trench 65 Multiple Trenches 66...

Страница 63: ...ust engine speed to 1 2 to 3 4 for digging IMPORTANT This chapter covers how to use the excavator For information on how to use front mounted attachments refer to controls chapter and attachment opera...

Страница 64: ...rease excavator speed but not excavator force 5 When job is finished stow excavator pivot seat to face tool carrier end switch unit into tool carrier mode and drive away from area Jobsite hazards coul...

Страница 65: ...e and drive away from area Onto truck Into hole or onto ground Position unit between material to be loaded and back end of truck if possible Position unit to minimize the need for travel Onto truck In...

Страница 66: ...away from trench Single Offset Trench 1 Position unit near the intended digging path 2 Swing excavator and offset boom as needed to align with digging path 3 Fill and dump buckets 4 Reposition unit a...

Страница 67: ...ng paths 2 Swing excavator and offset boom as needed to align with first digging path 3 Fill and dump buckets 4 Reposition excavator and boom as need to dig additional trenches 5 When all trenches are...

Страница 68: ...anual Systems and Equipment 67 Systems and Equipment Chapter Contents Excavator Control Pattern 68 Change Pattern 68 Operate Controls 69 Front Attachments 70 Connect Attachment Operate Attachment Opti...

Страница 69: ...und 3 Change hose positions as shown below Be careful not to cross hoses near the ends 4 Verify controls work properly See Operate Controls on page 69 for ISO pattern operation and Joysticks on page 2...

Страница 70: ...e Joysticks on page 28 Item Description Notes Right joystick With work mode switch in excavator mode To open bucket move right To close bucket move left To raise boom pull To lower boom push Left joys...

Страница 71: ...ent 6 Raise lift arms while tilting back mount plate 7 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 o...

Страница 72: ...isconnecting 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 and loosen connect...

Страница 73: ...Equipment Description Ditch Witch XT series buckets and SK series attachments a variety of attachments are available to expand the capabilities of the tool carrier end of the unit Bobcat adapter plat...

Страница 74: ...XT855 Operator s Manual Complete the Job 73 CMW Complete the Job Chapter Contents Rinse Equipment 74 Disconnect Attachment 74 Stow Tools 74...

Страница 75: ...t Attachment 1 Lower attachment to the ground 2 Turn off engine 3 Disengage lock pins by turning handles away from center of attachment 4 Disconnect hydraulic hoses if used 5 Start engine 6 Tilt mount...

Страница 76: ...ce 75 CMW Service Chapter Contents Service Precautions 76 Lubrication Overview 78 Recommended Lubricants Service Key 79 10 Hour 81 50 Hour 85 100 Hour 88 150 Hour 89 250 Hour 89 400 Hour 90 1000 Hour...

Страница 77: ...props support lift arms To return to normal operation start engine raise lift arms slightly stop engine and rotate props into stowed position Incorrect procedures could result in death injury or prope...

Страница 78: ...XT855 Operator s Manual Service 77 Service Precautions CMW Opening Hood 1 Unlatch hood at points shown 2 Raise hood fully 3 Position rod in slot as shown...

Страница 79: ...Service 78 XT855 Operator s Manual Lubrication Overview CMW Lubrication Overview See next page for service key...

Страница 80: ...or the European Automobile Manufacturers Association API CI 4 or ACEA E4 E7 See Engine Oil Temperature Chart on page 80 for recommended viscosity grade NOTICE Do not use oils meeting API CJ 4 ACEA E6...

Страница 81: ...2 F 0 C winter fuel blends are acceptable See engine operation manual for more information Biodiesel blends up to 5 B5 are approved for use in this unit The fuel used must meet the specifications for...

Страница 82: ...hown on overflow bottle Check Engine Oil Level Check engine oil level at dipstick 2 every 10 hours Add DEO at fill 1 as needed to maintain oil level at highest line on dipstick Task Notes Check coolan...

Страница 83: ...elements 2 Wipe inside of housing and wash cover 3 Insert new elements 4 Replace cover 5 Reset air filter restriction indicator Clean Radiator Screen Clean radiator screen every 10 hours NOTICE Only o...

Страница 84: ...10 hours Measure length of spring as shown When tracks are properly tensioned spring length A should be 9 1 2 241 mm Adjust as needed see page 92 For more information on rubber tracks see the publica...

Страница 85: ...luid level every 10 hours Maintain level at halfway point on sight glass 2 Add THF as needed at fill 1 Lubricate Excavator Lubricate excavator every 10 hours of use Apply MPG at each of the 8 zerks IM...

Страница 86: ...2 2 lb at 1 4 5 mm maximum deflection A To adjust see page 94 Check Radiator Check radiator for dirt grass and other foreign matter every 50 hours Clean out with compressed air or spray wash if requir...

Страница 87: ...e free Service replacement batteries according to manufacturer s instructions Change Engine Oil and Filter Initial Change engine oil after 50 hours and every 150 hours thereafter 1 Remove large cover...

Страница 88: ...Hour CMW Change Hydraulic Filter Initial Change hydraulic filter after 50 hours Wash Drive Belt Area Wash drive belt area every 50 hours Spray low pressure water in belt area to remove dust and dirt R...

Страница 89: ...ressure to belt between pulleys where shown 3 Belt is properly tensioned when deflection is about 1 4 3 8 7 9 mm 4 If needed loosen alternator bolts shown and pull alternator out until correct tension...

Страница 90: ...every 150 hours thereafter 1 Remove large cover plate under unit to access drain 3 on side of pan 2 Drain crankcase while oil is warm 3 Replace filter 4 4 Close drain and install cover 5 Add DEO at f...

Страница 91: ...thin layer of fuel over the gasket and hand tighten 4 Air bleed the injection pump See engine operator s manual 1000 Hour Change Hydraulic Fluid and Filter Drain 3 hydraulic fluid and change filter 4...

Страница 92: ...t Drain cooling system at drain 2 Refill 1 with approved coolant every two years or 2000 hours NOTICE The use of non approved coolant may lead to engine damage or premature engine failure and will voi...

Страница 93: ...on turn screw 1 clockwise To reduce tension turn screw counterclockwise When tracks are properly tensioned spring length A should be 9 1 2 241 mm Location Task Notes TRACKS Adjust track tension OPERAT...

Страница 94: ...unit 3 Clean out all debris from cleanout area 4 Replace plate radiator cover and radiator screen Adjust Fan Belt Adjust fan belt as needed 1 Turn off engine and remove key 2 Apply moderate thumb pre...

Страница 95: ...and engage props See Working Under Raised Lift Arms on page 76 4 Use a belt tension meter to measure tension New belt 13 8 lb at 1 4 5 mm maximum deflection A Existing belt 12 2 lb at 1 4 5 mm maximu...

Страница 96: ...XT855 Operator s Manual Specifications 95 CMW Specifications General Dimensions U S Metric I Wheelbase track length 46 in 1 2 m J Overall height of machine 89 in 2 3 m...

Страница 97: ...ach with standard bucket fully raised 21 in 533 mm G Bucket rollback angle ground level 16 16 H Reach at grade 34 in 864 mm Excavator Dimensions U S Metric K Loading height max 72 in 1 8 m L Dig depth...

Страница 98: ...etric O Machine width 50 in 1 3 m R Overall machine length excavator stowed 120 in 3 m Weight 4440 lb 2014 kg Tool Carrier Dimensions U S Metric N Bucket width max 52 in 1 3 m Excavator Dimensions U S...

Страница 99: ...pping capacity Rated operating capacity was determined using a standard bucket in the drive position with a center of gravity ____ in mm from the face plate Depending on the attachment the actual oper...

Страница 100: ...in 78 5 mm Maximum continuous tilt angle fore and aft 20 20 Maximum continuous tilt angle side 20 20 Rated speed 3000 rpm 3000 rpm Estimated net power per SAE J1349 3000 rpm 29 5 hp 22 kW Gross power...

Страница 101: ...ay not necessarily match that shown Battery SAE reserve capacity 110 min SAE cold crank 0 F 18 C 800 amp 12V electrical system Vibration Levels Under normal operation of the excavator or tool carrier...

Страница 102: ...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...

Страница 103: ...S 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 WARRANTIES WHICH EXTEND BEYOND THE FACE...

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Страница 106: ...XT855 Operator s Manual Service Record 105 CMW Service Record Service Performed Date Hours...

Страница 107: ...CMW Service Record 106 XT855 Operator s Manual Service Performed Date Hours...

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