Ditch Witch MV800 User Manual

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MV800

Operator’s Manual

CMW

Issue 1.0

053-2767

MV800 Operator’s Manual Overview - 1

Overview

Chapter Contents

Serial Number Location . . . . . . . . . . . . . . . . . . . . . . 2 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Equipment Modification . . . . . . . . . . . . . . . . . . . . . 3 Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Operator Orientation. . . . . . . . . . . . . . . . . . . . . . . . . 4 About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 4

• Bulleted Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

• Numbered Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

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Overview - 2 MV800 Operator’s Manual

Serial Number Location

Record serial numbers and date of purchase in spaces provided. MV800 serial number is located as shown.

Date of manufacture Date of purchase MV800 serial number (shown) Engine serial number Blower serial number Water pump serial number Trailer serial number

Intended Use

The MV800 is a self-contained vacuum excavation unit designed to remove used drilling fluid from the jobsite and to expose existing buried utilities. The optional reverse flow system allows for spoils transfer to another tank. The MV800 is intended for operation in ambient temperatures from 0° to 115°F (-18° to 46°C). Use in any other way is considered contrary to the intended use.

The MV800 should be operated, serviced, and repaired only by persons familiar with its particular characteristics and acquainted with the relevant safety procedures.

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MV800 Operator’s Manual Overview - 3

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 properly or in accordance with the operating instructions. Modification of equipment should only be made by competent personnel possessing knowledge of applicable standards, regulations, equipment design functionality/requirements and any required specialized testing.

Unit Components

1. Water tank

2. Inlet valve

3. Drain/Outlet valve

4. Reverse flow valve

5. Antifreeze tank

6. Power pack

7. Operator’s station

8. Hose reel

9. Vacuum filter

10. Blower relief air filter

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Overview - 4 MV800 Operator’s Manual

Operator Orientation

1. Front of unit

2. Right of unit

Right and left sides of machine are determined by facing towing vehicle.

3. Rear of unit

4. Left of unit

About This Manual

This manual contains information for the proper use of this machine. See Operation Overview 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 procedures that do not have to be performed in a specific order.

Numbered Lists

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

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MV800 Operator’s Manual Foreword - 5

Reporting Safety Defects

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 Read this manual before using your equipment. Keep it with the equipmen t 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 a

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

The Charles Machine Works, Inc. Attn: Marketing Department PO Box 66 Perry, OK 73077-0066 USA

The descriptions and specifications in this manual are subject to change without notice. The Charles Machine Works, Inc. reserves the right to improve equipment. Some product improvements may have taken place after this manual was publishe d. For the latest information on Ditch Witch equipment, see your Ditch Witch dealer.

equipment.

Thank you for buying and using Ditch Witch equipment.

Reporting Safety Defects

If you believe that your vehicle has a defect which could cau se a cr ash o r co uld ca use injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying 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 exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved 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: 1-800424-9153), go to http://www.safercar.gov, or write to:

Administrator NHTSA 1200 New Jersey Avenue S.E. Washington, DC 20590

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

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Foreword - 6 MV800 Operator’s Manual

Works, Inc.

MV800

Operator’s Manual

Issue number 1.0/OM-9/14

Part number 053-2767

by The Charles Machine Works, Inc.

, Ditch Witch, and CMW are registered trademarks of The Charles Machine

U.S. patents pending.

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MV800 Operator’s Manual Contents - 7

Content s

Overview

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

Foreword

part number, revision level, and publication date of this manual, and factory contact information

Safety

machine safety alerts and emergency procedures

Controls

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

Operation Overview

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

Prepare

procedures for inspecting and classifying the jobsite, and preparing the jobsite for work

Transport

procedures for lifting and hauling

Vacuum and Pothole

procedures for removing debris and potholing utility locations

Complete the Job

procedures for restoring the jobsite and rinsing and storing equipment

Service

service intervals and instructions for this machine including lubrication, replacement of wear items, and basic maintenance

Specifications

machine specifications including weights, measurements, power ratings, and fluid capacities

Support

the warranty policy for this machine, and procedures for obtaining warranty consideration and training

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Contents - 8 MV800 Operator’s Manual

Service Record

a record of major service performed on the machine

Appendix

additional information about Ditch Witch® equipment

101

103

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MV800 Operator’s Manual Safety - 9

Safety

Chapter Contents

Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Emergency Procedures . . . . . . . . . . . . . . . . . . . . . 11

• Electric Strike Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

• If an Electric Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

• If a Gas Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

• If a Fiber Optic Cable is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

• If Machine Catches on Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Safety Alert Classifications . . . . . . . . . . . . . . . . . . 15 Machine Safety Alerts . . . . . . . . . . . . . . . . . . . . . . 16

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Safety - 10 MV800 Operator’s Manual

Guidelines

Follow these guidelines before operating any jobsite equipment:

• Complete proper training and read operator’s manual before using equipment.

• 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 digging. Also contact any utilities that do not participate in the One-Call service. Mark proposed p ath with white paint prior to cont acting One- Call or utilities.

• Classify jobsite based on its hazards and use cor rect tools and machin ery, safety equipment, and work methods for jobsite.

• Mark jobsite clearly and keep spectators away.

• Wear personal protective equipment.

• Review jobsite hazards, safety and emergency procedures, and individual responsibilities with all personnel before work begins. Safety videos are available from your Ditch Witch

ditchwitch.com/resources/safety .

• Replace missing or damaged safety shields and safety signs.

dealer or at

• 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, ma intenance, or equipment use.

• Complete the equipment checklist located at www.ditchwitch.com/resources/safety.

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MV800 Operator’s Manual Safety - 11

Emergency Procedures

Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment.

Before operating any equipment, review emergency proc edures and check that all safety precau tions have been taken.

EMERGENCY SHUTDOWN - Turn ignition switch to stop position or push remote e ngine stop button ( if equipped).

Electric Strike Description

or serious injury. Know location of lines and stay away.

274-050

Electric shock. Contacting electric lines will cause death

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 less than 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.

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Safety - 12 MV800 Operator’s Manual

Emergency Procedures

If an Electric Line is Damaged

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

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

• 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 TOUCH EQUIPMENT. 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 close together 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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MV800 Operator’s Manual Safety - 13

Emergency Procedures

If a Gas Line is Damaged

Fire or explosion possible. Fumes could ignite and cause

burns. No smoking, no flame, no spark.

Explosion possible. Serious injury or equipment damage could occur.

Follow directions carefully.

If you suspect a gas line has been damaged, take the following actions. The order and degree of action will depend on the situation.

• Immediately shut off engine(s), if this can be done safely and quickly.

• Remove any ignition source(s), if this can be done safely and quickly.

275-419 (2P)

• 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 phone number and utility company.

• If jobsite is along street, stop traffic from driving near jobsite.

• Do not return to jobsite until given permission by emergency personnel and utility company.

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Safety - 14 MV800 Operator’s Manual

Emergency Procedures

If a Fiber Optic Cable is Damaged

Do not look into cut ends of fiber optic or unidentified cable. Vision damage can occur. Contact utility company.

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.

• 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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MV800 Operator’s Manual Safety - 15

Safety Alert Classifications

These classifications and the icons defined on the following pages work together to alert you to situations which could be harmful to you, jobsite bystanders or your equipment. When you see these words and icons in the book or on the machine, carefully read and follow all instructions. YOUR SAFETY IS AT STAKE.

Watch for the three safety alert levels: DANGER, WARNING and CAUTION. Learn what each level means.

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 moderate injury.

Watch for two other words: NOTICE and IMPORTANT. NOTICE indicates information considered important, but not hazard-related (e.g., messages relating to

property damage).

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

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Safety - 16 MV800 Operator’s Manual

Machine Safety Alerts

275-146

• Secure equipment and accessories with chain and binder.

• Check brakes and lights prior to use.

• Use proper size coupler.

• Maintain adequate distan ce for stopping and passing vehicles.

• Block wheels when parked.

• Check tire condition and inflation frequently.

• Failure to follow these rules may result in personal injury. Lift point. See Tra nsport chapter for more information.

274-442

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MV800 Operator’s Manual Safety - 17

Machine Safety Alerts

Contents under pressure. Relieve pressure b efore

opening. Death or injury could occur.

Use breathing protection when exposed to silica

dust.

270-4952

Exposure to high noise levels may cause hearing

loss. Wear hearing protection.

Jobsite hazards could cause death or serious

injury. Use correct equipment and work methods. Use and maintain proper safety equipment.

274-050; 274-724 (2P)

270-2732

700-009 (2-P)

Read operator’s manual. Know how to use all controls. Your safety is at stake.

273-475

Hot parts may cause burns. Do not touch until cool

or wear gloves.

275-355 (2-P), 273-423 (2-P)

Confined space will cause suffocation. Use proper

procedures for entering or stay away.

273-200

Fire or explosion possible. Do not vacuum

flammable or combustible substances.

273-483

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Safety - 18 MV800 Operator’s Manual

Machine Safety Alerts

Vacuum can suffocate. Keep hose end away from

face.

273-205

Pressurized fluid or air could pierce skin and cause

severe injury. Refer to operator’s manual for proper use.

Crushing weight could cause

death or serious injury. Stay away.

275-326

Moving parts could cut off hand or foot. Stay away.

275-184

270-6035

Crushing weight. Place cylinder lock on extended

cylinder and secure.

273-231, 273-413

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MV800 Operator’s Manual Controls - 19

Controls

Chapter Contents

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Operator’s Station . . . . . . . . . . . . . . . . . . . . . . . . . 21 Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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Controls - 20 MV800 Operator’s Manual

Engine

1. Throttle

2. Choke

Item Description Notes

1. Throttle To increase engine speed,

move to right. To decrease engine speed,

move to left.

2. Choke To help start cold engine, pull knob.

When engine has warmed, push in completely.

3. Ignition switch T o star t engine, insert key and turn clockwise.

To stop engine, turn key counterclockwise.

3. Ignition switch

IMPORTANT: Run engine at full throttle during operation.

IMPORTANT:

• When engine is on, blower operates and vacuum is present at tank inlet.

• All indicators should light briefly at startup.

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MV800 Operator’s Manual Controls - 21

c00ic114t.eps

Operator Station

1. Water pressure switch

2. Water pressure control

3. Water pressure gauge

4. Auxiliary outlet

Item Description Notes

1. Water pressure switch To turn on water pump, press

top. To turn off water pump, move

to center position. To bypass low water

indication, press bottom. Water pump will operate for 60 seconds.

5. Hourmeter

6. Flow direction control (optional)

7. Battery disconnect switch

8. Tethered tank control outlet

Use bypass to feed antifreeze into system when freshwater tank is empty. See “Add Antifreeze” on page 56.

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Controls - 22 MV800 Operator’s Manual

c00ic113t.eps

c00ic112t.eps

Operator Station

Item Description Notes

2. Water pressure control To increase water pressure,

turn clockwise. To decrease water pressure,

turn counterclockwise.

3. Water pressure gauge Displays water pressure when water pressure switch is on and spray wand is in use.

4. Auxiliary outlet To operate work lights or other 12V devices, plug into outlet.

5. Hourmeter Displays engine operating time.

6. Flow direction control To operate in reverse flow mode, turn counterclockwise.

To operate in vacuum mode, turn clockwise.

Outlet has power only when ignition switch is on.

Hourmeter runs when engine is running.

Use these times to schedule service.

Use optional reverse flow to unload tank contents to another tank. Operate in reverse flow mode only when drain/outlet valve is open.

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MV800 Operator’s Manual Controls - 23

c00ic063t.eps

c00ic065t.eps

DOWN

c00ic064t.eps

U P

Operator Station

Item Description Notes

7. Battery disconnect

switch

8. Tethered tank control

outlet

Tethered tank control To lift and lower tank, set

To connect, turn clockwise. To disconnect, turn

counterclockwise.

Connection for tethered tank control.

hydraulic function switch to the tank position, then

• To lift tank, press UP.

• To lower tank, press

DOWN.

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

IMPORTANT: Use battery disconnect switch when servicing, welding, and during long-term storage.

NOTICE: When opening and closing door, stand in a position with a full view of the door.

• To open door, press UP.

• To close door, press

DOWN.

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Controls - 24 MV800 Operator’s Manual

Machine

1. Inlet valve

2. Drain/Outlet valve

3. Vacuum filter drain

4. Vacuum gauge

5. Reverse flow gauge (optional)

Item Description Notes

1. Inlet valve To close valve (stop suction),

rotate up. To open valve (start suction),

rotate down.

2. Drain/Outlet valve To drain tank, rotate down. To close drain, rotate up.

6. Antifreeze tank supply valve (optional)

7. Water tank drain (optional)

8. Water tank supply valve (optional)

9. Hydraulic function switch (optional)

NOTICE: Do not idle engine with inlet valve closed.

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MV800 Operator’s Manual Controls - 25

c00ic602h.eps

c00ic604h.eps

Machine

Item Description Notes

3. Vacuum filter drain To drain vacuum filter

canister, rotate up. To close drain, rotate down.

4. Vacuum gauge Displays blower vacuum reading in inches of mercury. Vacuum relief valve opens when vacuum reaches 15” (381 mm).

5. Reverse flow gauge Displays reverse flow pressure.

6. Antifreeze tank supply

valve

To open valve (send antifreeze through pump and water lance), rotate counterclockwise.

To close valve (stop antifreeze flow), rotate clockwise.

7. Water tank drain To drain tank, open valve. Close valve when tank is

empty.

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

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Controls - 26 MV800 Operator’s Manual

c00ic603h.eps

Machine

Item Description Notes

8. Water t ank supply valve To open valve (send water

from the water tank through the pump and water lance), rotate counterclockwise.

To close valve (stop water flow), rotate clockwise.

9. Hydraulic function

switch

To lift and lower tank, push down.

To open and close door, pull up.

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

Only with hydraulic door option.

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MV800 Operator’s Manual Operation Overview - 27

Operation Overview

Chapter Contents

Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Setting Up at Jobsite . . . . . . . . . . . . . . . . . . . . . . . 28 Vacuuming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Potholing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Leaving Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Storing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 29

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Operation Overview - 28 MV800 Operator’s Manual

Planning

1. Gather information about jobsite (page 32).

2. Inspect jobsite (page 33).

3. Check supplies and prepare equipment (page 35).

Setting Up at Jobsite

1. Prepare jobsite (page 34).

2. Leave unit hitched to towing vehicle or properly stabilized if trailer-mounted unit.

3. Block trailer wheels if trailer-mounted unit.

Vacuuming

1. Connect hoses (page 42).

2. Start unit (page 44).

3. Remove debris (page 45).

4. Disconnect hoses.

5. Drain tank (page 48) or unload to another tank (page 50).

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MV800 Operator’s Manual Operation Overview - 29

Potholing

1. Connect hoses (page 42).

2. Start unit (page 42).

3. Pothole (page 46).

4. Disconnect hoses.

5. Drain tank (page 48).

Leaving Jobsite

1. Rinse unit and tools (page 57).

2. Stow tools (page 57).

Storing Equipment

1. For cold weather storage, antifreeze vacuum excavation unit (page 56).

2. For long-term storage, disconnect battery disconnect switch (page 22).

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+ 81 hidden pages