Ditch Witch Zahn User Manual

R150/R230/R300

Operator’s Manual

CMW

Issue 1.6

053- 1173

R150/R230/R300 Operator’s Manual Overview - 1

Overview

Chapter Contents

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

Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Equipment Modification . . . . . . . . . . . . . . . . . . . . . 3

Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Operator Orientation. . . . . . . . . . . . . . . . . . . . . . . . . 4

About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

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

• “Continued” Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

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Overview - 2 R150/R230/R300 Operator’s Manual

Serial Number Location

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

Date of manufacture Date of purchase Power unit serial number Front end serial numbers

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R150/R230/R300 Operator’s Manual Overview - 3

Intended Use

The Zahn line consists of three versatile performers. The R150 is configured as a dedicated trencher. The R230 and R300 units can be configured as dedicated trenchers or they can be configured with an InterChange connection to allow them to accept a variety of front ends. Available interchangeable front ends include a trencher, vibratory plow, dumper, tool carrier, backhoe, stump grinder and tiller. Contact your Ditch Witch dealer for a complete list of available front ends.

The unit is designed for operation in temperatures typically experienced in earth moving and construction work environments. Provisions may be required to operate in extreme temperatures. Contact your Ditch

Witch dealer.

Zahn R150, R230 and R300 units should be used with genuine Ditch Witch front ends, attachments and components. They should be operated, serviced, and repaired only by persons familiar with their particular characteristics and acquainted with the relevant safety procedures.

Use in any other way is considered contrary to the intended use.

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.

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Overview - 4 R150/R230/R300 Operator’s Manual

Unit Components

1. operator platform

2. engine compartment

3. control console

Operator Orientation

1. Front of unit

2. Right of unit

Right and left sides of machine are determined by facing front of unit while standing on platform.

NOTICE: Operate unit only while standing on platform.

3. Rear of unit

4. Left of unit

4. front end manifold

5. articulation joint

6. InterChange connection (R230 and R300)

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R150/R230/R300 Operator’s Manual Overview - 5

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 procedure s 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.

“Continued” Indicators

indicates that a procedure is continued on the next page.

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Overview - 6 R150/R230/R300 Operator’s Manual

About This Manual

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R150/R230/R300 Operator’s Manual Foreword - 7

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 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 or download it at www.ditchwitch.com. If you need assistance in locating a dealer, visit our website 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.

Thank you for buying and using Ditch Witch equipment.

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Foreword - 8 R150/R230/R300 Operator’s Manual

R150/R230/R300

Operator’s Manual

Issue number 1.6/OM-9/09

Part number 053-1173

by The Charles Machine Works, Inc.

, Ditch Witch, CMW, AutoCrowd, Jet Trac, Roto Witch, Subsite, Fluid Miser, Power Pipe, Super Witch, Pierce Airrow, The Underground, The Underground Authority Worldwide, and Zahn are registered trademarks of The Ch ar les Mac hin e Works, Inc.

This product is covered by the following patent: U.S. 7,621,366; other U.S. and foreign patents pending.

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R150/R230/R300 Operator’s Manual Contents - 9

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

Prepare

procedures for inspecting and classifying the jobsite, plan ning the installation p ath (if needed), preparing the jobsite for work, and connecting front ends

Drive

procedures for startup, cold start, driving, and shutdown

Transport

procedures for lifting, hauling, and towing

Trench

procedures for trenching

Systems and Equipment

chain, teeth, sprockets, and optional equipment

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

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Contents - 10 R150/R230/R300 Operator’s Manual

Support

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

Service Record

a record of major service performed on the machine

103

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R150/R230/R300 Operator’s Manual Safety - 11

Safety

Chapter Contents

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 Optic Cable is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

• If Machine Catches on Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

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Safety - 12 R150/R230/R300 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.

• 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 at www.ditchwitch.com and from Ditch Witch dealers.

• 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 is present.

• Contact your Ditch Witch dealer if you have any question about operation, ma intenance, or equipment

use.

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R150/R230/R300 Operator’s Manual Safety - 13

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 an imminently hazardous situation which, if not avoided, will result in death or

serious injury.

indicates a potentially hazardous situation which, if not avoided, could result in death or

serious injury.

indicates a potentially hazardous situation which, if not avoided, may result in minor or

moderate injury.

Watch for two other words: NOTICE and IMPORTANT. NOTICE can keep you from doing something that might damage the machine or someone's property. It

can also alert you against unsafe practices.

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

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Safety - 14 R150/R230/R300 Operator’s Manual

Safety Alerts

Moving digging teeth will kill you or cut off arm or leg. Stay away.

Turning shaft will kill you or crush arm or leg. Stay away.

Electric shock. Contacting electric lines will cause 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.

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

proper procedures and equipment or stay away.

Jobsite hazards could cause death or serious injury. Use

Crushing weight could cause death or seriou s injur y. Use

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

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R150/R230/R300 Operator’s Manual Safety - 15

Safety Alerts

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.

Improper control function could cause death or serious injury. 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 or unidentified cable.

Pressurized fluid or air could pierce skin a nd cause injur y or

death. St ay away.

Runaway possible. Machine could run over you or others. Learn how to use

all controls. Start and operate only from operator’s position.

Fire or explosion possible. Fumes could ignite and cause burns. No

smoking, 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 R150/R230/R300 Operator’s Manual

Safety Alerts

Tipover possible. Machine can tip over and crush you.

• Always operate with load end uphill.

• Always carry load low. High load can cause tipping, loss of load or loss of visibility.

• Never jerk control levers. Use a steady even motion.

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 hearing

protection.

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

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R150/R230/R300 Operator’s Manual Safety - 17

Emergency Procedures

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

EMERGENCY SHUTDOWN: Release all controls (including cruise control pedal) and turn ignition switch to OFF

Electric Strike Description

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. Almost one-third of 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 - 18 R150/R230/R300 Operator’s Manual

Emergency Procedures

If an Electric Line is Damaged

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

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

• Raise front end and attachments and drive from immediate area.

• Contact utility company to shut off power.

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

If you suspect an electric line has been damaged and you are off platform, DO NOT TOUCH UNIT. Take the following actions. The order and degree of action will depend upon the situation.

• LEAVE AREA. 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 dealer.

• Contact utility company to shut off power.

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

If a Gas Line is Damaged

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.

• 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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R150/R230/R300 Operator’s Manual Safety - 19

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.

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) 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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Safety - 20 R150/R230/R300 Operator’s Manual

Emergency Procedures

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R150/R230/R300 Operator’s Manual Controls - 21

Controls

Chapter Contents

Gauges and Indicators . . . . . . . . . . . . . . . . . . . . . 22

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

• R150/R150E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

• R230/R300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

• R150/R230/R300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

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Controls - 22 R150/R230/R300 Operator’s Manual

Gauges and Indicators

1. Auxiliary power outlet (R150E/R230/R300 only)

2. Fuel sight glass

Item Description Notes

1. Auxiliary power outlet To operate work lights or

other 12V devices, plug into outlet.

2. Fuel tank sight window Shows level of fuel in tank.

3. Hydraulic fluid sight glass

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Shows level of hydraulic fluid in tank. Maintain fluid at halfway point on glass.

3. Hydraulic fluid sight glass

4. Hourmeter (optional)

Not available on R150 with rope start.

R150/R230/R300 Operator’s Manual Controls - 23

Gauges and Indicators

Item Description Notes

4. Hourmeter (optional) Displays engine operating

time.

Use these times to schedule service.

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Controls - 24 R150/R230/R300 Operator’s Manual

Controls

R150/R150E

1. Ground drive control

2. Traction assist switch

3. Throttle switch

4. Front end lift control

5. Front end drive control

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6. Choke (R150)/manual start switch (R150E)

7. Rope start

8. Ignition switch

9. Parking brake

10. Cruise control pedal

R150/R230/R300 Operator’s Manual Controls - 25

Controls

Item Description Notes

1. Ground drive control To move forward, push.

To move backward, pull. To turn right, move to right. To turn left, move to left. To go faster in any direction,

move control farther from neutral position.

To stop, release.

2. Traction assist switch To allow maximum power to

tires, press top. To return to normal operation,

press bottom.

3. Throttle switch To set engine speed for

operation, press top.

To make a gradual turn, move control halfway between desired directions and return to center. Unit will remain articulated until it is returned to center.

IMPORTANT: As long as control is moved to right or left, unit is articulating and turning is tightened.

Use when working on a slope to lessen undesired movement.

To set speed to middle range for transport, move to center position

To decrease speed to idle, press bottom.

4. Front end lift control To lower trencher, push.

To raise trencher, pull.

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Controls - 26 R150/R230/R300 Operator’s Manual

Controls

Item Description Notes

5. Front end drive control To engage front end drive in

reverse, lift lever release and move to right.

To engage front end drive in forward, lift lever release and move to left.

6. Choke/manual start switch

7. Rope start To start engine, pull rope. Ignition switch must be on for this

8. Ignition switch R150

Choke (R150)

To help start cold engine, close valve.

Manual start switch (R150E)

To manually start engine when electric starter doesn’t work, move switch to right, turn on power switch and pull rope start.

T o star t engine, insert key and turn clockwise. Pull rope start.

This valve regulates air/fuel mixture.

IMPORTANT: R150E units have automatic choke feature.

control to function. If engine does not start after three

pulls, turn power switch off and check for fuel blockage or electrical system problems.

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To stop engine, turn key counterclockwise.

R150E

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

To stop engine, turn key counterclockwise.

IMPORTANT:

• If engine does not start, turn key to OFF and then restart.

• Do not allow starter motor to run continuously for more than 20 seconds.

R150/R230/R300 Operator’s Manual Controls - 27

Controls

Item Description Notes

9. Parking brake lever To engage, move handle to

left. To disengage, move handle

to right.

10. Cruise control pedal To maintain ground drive and front end drive settings, press pedal and release handles.

To adjust settings, grab drive handles, step off pedal, adjust drive settings, press pedal and release handles.

IMPORTANT:

• Move unit slightly to ensure parking brake pins are engaged.

• It might be necessary to move unit slightly to disengage parking brake.

NOTICE: Pedal must return to neutral when released. Never tie down or use anything other than foot to hold pedal down.

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Controls - 28 R150/R230/R300 Operator’s Manual

Controls

R230/R300

1. Ground drive control

2. Traction assist switch

3. Front end lift control

4. Front end drive control

5. Remote throttle control (optional)

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6. Choke

7. Throttle

8. Ignition switch

9. Parking brake

10. Cruise control pedal

R150/R230/R300 Operator’s Manual Controls - 29

Controls

Item Description Notes

1. Ground drive control To move forward, push.

To move backward, pull. To turn right, move to right. To turn left, move to left. To go faster in any direction,

move control farther from neutral position.

To stop, release.

2. Traction assist switch To allow maximum power to tires, press top.

To return to normal operation, press bottom.

3. Front end lift control To retract primary cylinder or lower trencher, push.

To make a gradual turn, move control halfway between desired directions and return to center. Unit will remain articulated until it is returned to center.

IMPORTANT: As long as control is moved to right or left, unit is articulating and turning is tightened.

Use when working on a slope to lessen undesired track movement.

To float, push forward to detent.

To extend primary cylinder or raise trencher, pull.

To retract secondary cylinder, move to left.

T o extend secondary cylinde r, move to right.

4. Front end drive control To engage front end drive in reverse, lift lever release and move to right.

To engage front end drive in forward, lift lever release and move to left.

IMPORTANT: Front end will drop when unit is put in float position.

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