Ditch Witch Zahn User Manual

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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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Controls - 30 R150/R230/R300 Operator’s Manual

Controls

Item Description Notes

5. Remote throttle control

(optional)

6. Choke To help start cold engine,

7. Throttle To increase engine speed,

To increase engine speed, push.

To decrease engine speed, pull.

move to left. Move to right after engine has

warmed.

move to left. To decrease engine speed,

move to right.

NOTICE: R300 unit s must be stopped at full throttle to prevent backfiring.

This valve regulates air/fuel mixture.

This throttle is disengaged if remote throttle is installed.

NOTICE: R300 unit s must be stopped at full throttle to prevent backfiring.

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

To stop engine, turn key counterclockwise.

9. Parking brake lever To engage, move handle to left.

To disengage, move handle to right.

NOTICE: R300 unit s must be stopped at full throttle to prevent backfiring.

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.

IMPORTANT:

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

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

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R150/R230/R300 Operator’s Manual Controls - 31

Controls

Item Description Notes

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.

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 - 32 R150/R230/R300 Operator’s Manual

Controls

R150/R230/R300

1. Articulation lock To lock articulation joint, align

top and bottom holes and put pin in hole (shown).

To unlock articulation joint, return pin to storage hole.

Lock for transporting and lifting.

Unlock to maneuver unit.

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R150/R230/R300 Operator’s Manual Prepare - 33

Prep are

Chapter Contents

Gather Information . . . . . . . . . . . . . . . . . . . . . . . . . 34

Inspect Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

• Identify Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Classify Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

• Inspect Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

• Select a Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

• Apply Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Check Supplies and Prepare Equipment . . . . . . . 38

• Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

• Fluid Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

• Condition and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

• Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Attach Front End to InterChange Connection . . . 38

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Prepare - 34 R150/R230/R300 Operator’s Manual

Gather Information

A successful job begins before you start working. The fi rst step in planning is reviewing information already available about the job and jobsite.

Review Job Plan

Review blueprints or other plans. Check for information about exi sting or planned structur es, elevations, or proposed work that may be taking place at the same time.

Arrange for Traffic Control

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 facilities on hand. Check that you will have access to a telephone.

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 digging. Also contact any utilities that do not participate in the One-Call service.

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R150/R230/R300 Operator’s Manual Prepare - 35

Inspect Site

Inspect jobsite before transporting equipment. Check for the following:

• changes in elevation such as hills or other open trenches

• obstacles such as buildings, railroad crossings, or streams

• signs of utilities (See “Inspect Jobsite” on page 36.)

•traffic

•access

• soil type and condition

Identify Hazards

Identify safety hazards and classify jobsite if front end or attachment will penetrate ground. See “Classify Jobsite” on page 36.

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 including hard hat, safety eye wear, and hearing protection.

• Do not wear jewelry or loose clothing.

• Notify One-Call and companies which do not subscribe to One-Call.

• Comply with all utility notification regulations before digging or drilling.

• Verify location of previously marked underground hazards.

• Mark jobsite clearly and keep spectators away.

Remember, jobsite is classified by hazards in place -- not by line being installed.

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Prepare - 36 R150/R230/R300 Operator’s Manual

Classify Jobsite

Inspect Jobsite

• Inspect jobsite and perimeter for evidence of underground hazards, such as: – “buried utility” notices

– utility facilities without overhead lines – gas or water meters – junction boxes – drop boxes – light poles – manhole covers – sunken ground

• Follow U.S. Department of Labor regulations on excavating and trenching (Part 1926, Subpar t P) and other similar regulations.

• 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.

• Have an experienced locating equipment operator sweep area within 20’ (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 Classification

Jobsites are classified according to underground hazards present.

If working . . . then classify jobsite as . . .

within 10’ (3 m) of a buried electric line electric within 10’ (3 m) of a natural gas line natural gas in sand or granite which is capable of producing crystalline silica

(quartz) dust within 10’ (3 m) of any other hazard other

NOTICE: If you have any doubt about jobsite classification, or if jobsite might contain unmarked hazards, take steps outlined previously to identify hazards and classify jobs ite be fo re wor kin g.

crystalline silica (quartz) dust

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R150/R230/R300 Operator’s Manual Prepare - 37

Classify Jobsite

Apply Precautions

Once classified, precautions appropriate for jobsite must be taken.

Electric Jobsite Precautions

Use one or both of these methods.

• Expose line by careful hand digging or soft excavation.

• Have service shut down while work is in progress. Have electric company test lines before returning them to service.

Natural Gas Jobsite Precautions

In addition to positioning equipment upwind from gas lines, 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.

Crystalline Silica (Quartz) Dust Precautions

Follow OSHA or other guidelines for exposure to crystalline silica when trenching, sawing or drilling through material that might produce dust containing crystalline silica (quartz).

Other Jobsite Precautions

You may need to use different methods to safely avoid other underground hazards. Talk with those knowledgeable about hazards present at each site to determine which precautions should be taken or if job should be attempted.

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Prepare - 38 R150/R230/R300 Operator’s Manual

Check Supplies and Prepare Equipment

Supplies

•fuel

•lubricants

Fluid Levels

•fuel

• hydraulic fluid

• battery charge

• engine oil

Condition and Function

• parking brake pins (see “Check Parking Brake Operatio n” on page 65)

• filters (air, oil, hydraulic)

• pumps and motors

• hoses and valves

• signs, guards, and shields

Accessories

Fire Extinguisher

Mount a fire extinguisher near the power unit but away from possible points of ignition. The fire extinguisher should always be classified for both oil and electric fires. It should meet legal and regulatory requirements.

Attach Front End to InterChange Connection

Precautions

IMPORTANT: Use only Ditch Witch-approved front ends and attachments. Other front ends and

attachments will change the stability and operating characteristics of the unit.

See front end operation sheet for instructions for connecting/disconnecting front ends.

CMW

R150/R230/R300 Operator’s Manual Drive - 39

Drive

Chapter Contents

Start Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

CMW

Drive - 40 R150/R230/R300 Operator’s Manual

Start Unit

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

switch to OFF

R150

1. Ensure all controls are in neutral and parking brake is engaged.

2. Turn key to on position.

3. Move throttle switch to center position.

4. Choke engine, if necessary.

5. Pull rope or turn ignition switch to start position and release when engine starts.

R230/R300

1. Ensure all controls are in neutral and parking brake is engaged.

2. Move throttle to half open.

3. Choke engine, if necessary.

4. Turn ignition switch to start position and release when engine starts. See “Ignitio n switch” on page 30.

CMW

R150/R230/R300 Operator’s Manual Drive - 41

Drive

Incorrect procedures could result in death, injury, or property damage.

Learn to use equipment correctly.

NOTICE: Operate unit only while standing on platform.

General Operation

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.

1. Disengage parking brake.

2. Pull front end lift control to raise front end off ground.

3. Move ground drive control to forward or reverse.

4. Adjust throttle as needed.

5. Move ground drive control to side to steer in that direction. IMPORTANT: For continuous ground drive and front end drive opera tion, use cruise control ped al.

See “Cruise control pedal” on page 27.

Slope Operation Guidelines

• Engage traction control when working on a slope to lessen undesired movement.

• Keep heavy end of unit uphill on slopes.

• Avoid starting, stopping, or turning on slopes. If you must turn, keep the heavy end of the unit uphill.

• Avoid parking unit on a slope. If parking on a slope cannot be avoided, lower fro nt end, engage p arking brake and turn ignition switch to OFF.

CMW

Drive - 42 R150/R230/R300 Operator’s Manual

Shut Down

1. Lower front end to ground.

2. Move all controls to neutral position.

3. Engage parking brake.

4. Move throttle to center position (R150) or to full open (R230/R300).

5. Turn ignition switch to OFF.

6. Remove key.

CMW

R150/R230/R300 Operator’s Manual Transport - 43

Transport

Chapter Contents

Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

• Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

• Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Haul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

• Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

• Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

• Unload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Tow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

CMW

Transport - 44 R150/R230/R300 Operator’s Manual

Lift

Crushing weight. If load falls or moves it could kill or crush you. Use

proper procedures and equipment or st ay away.

Points

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

CMW

R150/R230/R300 Operator’s Manual Transport - 45

Lift

Procedure

Use a hoist capable of supporting the equipment's size and weight. See “Specifications” on page 81 or measure and weigh equipment before lifting.

Configured trencher Configured 4-wheel drive unit only

Lock articulation joint and use three lift points as shown.

Lock articulation joint and use four lift points as shown.

To lift configured 4-wheel drive unit with front end, see appropriate front end operation sheet.

CMW

Transport - 46 R150/R230/R300 Operator’s Manual

Haul

IMPORTANT: For trailer information, see the trailer manufacturer’s manual.

Load

Crushing weight. If load falls or moves it could kill or crush you. Use

proper procedures and equipment or st ay away.

Tipover possible. Machine can tip over and crush you.

• Always operate with heavy end uphill.

• Lock articulation joint when transporting.

IMPORTANT: Do not remove front end from InterChange connection before loading or unloading power unit.

1. Disengage parking brake.

2. Start engine and slow to low throttle.

3. Pull front end lift control to raise front end clear of trailer, but keep it low.

4. Move unit to rear of trailer and align with ramps.

5. Move ground drive control forward and slowly move unit onto trailer until tiedown position is

reached.

NOTICE:

• If loading onto tilt-bed trailer, be prepared for trailer bed to tilt.

• Move all controls to neutral position when stopped.

6. Push front end lift control to lower front end to trailer bed.

7. Engage parking brake and turn ignition switch to OFF.

8. Lock articulation joint.

9. Close fuel tank shutoff valve (shown).

10. Tie down unit.

CMW

R150/R230/R300 Operator’s Manual Transport - 47

Haul

Tie Down

Points

Tiedown points are identified by tiedown decals. Securing to truck or trailer at other points is unsafe and can damage machinery.

Procedure

Configured Trencher

Loop tiedowns around unit at tiedown points. Make sure tiedowns are tight before transporting.

Other Front Ends

To tie down unit with any other front end, see appropriate front end operation sheet.

IMPORTANT:

• Do not remove front end from InterChange connection before loading or unloading unit.

• Use a crane or hoist if loading additional front ends onto trailer.

CMW

Transport - 48 R150/R230/R300 Operator’s Manual

Haul

Unload

Crushing weight. If load falls or moves it could kill or crush you. Use

proper procedures and equipment or st ay away.

Tipover possible. Machine can tip over and crush you. Always operate

with heavy end uphill.

IMPORTANT: Do not remove front end from InterChange connection before loading or unloading power unit.

1. Lower trailer or ramps and remove tiedowns .

2. Unlock articulation joint.

3. Open fuel tank shutoff valve.

4. Start engine and disengage parking brake.

5. Pull front end lift control to raise front end, but keep it low.

6. Slow engine to low throttle and slowly back unit down trailer or ramps.

NOTICE: If unloading from tilt-bed trailer, be prepared for trailer bed to tilt.

CMW

R150/R230/R300 Operator’s Manual Transport - 49

Tow

Under normal conditions, unit should not be towed. If unit breaks down and towing is necessary:

• attach chains to tow point (shown) facing

towing vehicle

• tow for short distances at less than 1 mph

(1.6 km/h)

• do not tow for more than 100’ (30 m)

• use no more than 1,300 lb (5800 N) of

towing force

• disengage parking brake as shown

CMW

Transport - 50 R150/R230/R300 Operator’s Manual

Tow

Prepare Unit for Towing

1. Ensure parking brake is engaged.

2. Block wheels.

3. Connect to tow point.

4. Turn tow valve (shown).

• R150 (top illustration): Turn

counterclockwise two turns.

• R230/R300 (bottom illustration): Turn

counterclockwise 1/4 turn.

5. Disengage parking brake. See “Parking brake lever” on page 27.

6. Unblock wheels.

Return Unit to Normal Operation

1. Engage parking brake.

2. Block wheels.

3. Disconnect from tow point.

4. Turn tow valve.

• R150 (top illustration): Turn clockwise

two turns.

• R230/R300 (bottom illustration): Turn

clockwise 1/4 turn.

5. Unblock wheels.

6. Disengage parking brake. See “Parking brake lever” on page 27.

CMW

R150/R230/R300 Operator’s Manual Trench - 51

Trench

Chapter Contents

Trench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Trench - 52 R150/R230/R300 Operator’s Manual

Electrical shock. Contacting electrical lines will cause death or serious

injury. Know location of lines and stay away. NOTICE: Cutting high voltage cable can cause electrocuti on. Expose lines by hand befo re

digging.

Incorrect procedures could result in death, injury, or property damage.

Learn to use equipment correctly.

NOTICE:

• Comply with all utility notification regulations before digging or drilling.

• Notify companies that do not subscribe to One-Call.

safety glasses.

Flying objects thrown by machine may strike people. Wear hard hat and

R150/R230/R300 Operator’s Manual Trench - 53

Trench

Moving digging teeth will cause death or serious injury. Stay away.

NOTICE:

• Keep everyone at lease 6’ (2 m) from machine, digging boom, and its range of movement.

• Machine may move when chain starts to dig. Allow 3’ (1 m) between end of chain and obstacle.

• Operate unit only while standing on platform.

1. Move unit to starting point of trench.

IMPORTANT:

• When beginning trench near a wall or fence, allow enough distance between boom and footings, drains, and cables.

• When cutting across asphalt roads , start trenc h in soil at edg e of roa d an d dig with bo o m at full digging depth.

• When straight trenching across a slope, it can be helpful to stake a wooden beam parallel to intended course and just far enough from trench to guide downslope wheels.

2. Engage parking brake and move throttle to half open.

3. Use front end lift control to lower trencher to 1" (25 mm) above ground surface.

4. Use front end drive control to start forward digg ing chain rotation. DIGGING CHAIN WILL MOVE.

5. Increase engine speed to full throttle.

6. Use front end lift control to slowly lower digging boom to digging depth.

Trench - 54 R150/R230/R300 Operator’s Manual

Trench

7. Disengage parking brake and pull ground drive control to begin trenching. UNIT WILL MOVE.

IMPORTANT:

• Trenching movement is toward you.

• For easier turning, lower boom to full depth.

• If an object becomes lodged in chain, move digging chain control to neutral and raise boom slightly. Reverse chain direction. If object must be removed manually, stop engine.

8. For continuous ground drive and front end drive operation, use cruise control pedal. See “Cruise control pedal” on page 27.

9. When trench is complete, move ground drive control to neutral.

10. Move throttle to half open.

11. Use front end lift control to raise boom to top of trench.

12. Use front end drive control to stop digging chain rotation.

13. Use front end lift control to raise trencher.

14. Use ground drive control to drive unit away from trench.

15. Lower trencher to ground surface.

16. Stop engine.

R150/R230/R300 Operator’s Manual Systems and Equipment - 55

Systems and Equipment

Chapter Contents

Chain, Teeth, and Sprockets . . . . . . . . . . . . . . . . . 56

• Chain and Tooth Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

• Chain Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

• Chain Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . 58

Systems and Equipment - 56 R150/R230/R300 Operator’s Manual

Chain, Teeth, and Sprockets

Chain and Tooth Maintenance

• Always replace sprockets at the same time you replace the digging chain. Sprockets and chain are designed to work together. Replacing one without the other will cause premature wear of the new part.

• Keep digging teeth sharp. Using dull, worn teeth will decrease production and increase shock load to other trencher components. It can also cause chain stretch, which leads to premature chain wear and failure.

• Maintain the proper amount of tension on the digging chain. Overtightening will cause chain stretch and loss of machine performance. For correct tightening procedure, see pag e 67.

• Use the tooth pattern most appropriate for your digging conditions. If you move to a different soil type, contact your Ditch Witch dealer for information about the most effective chain type and tooth pattern.

Chain Types

Chain type Features

4-pitch standard chain 2-pitch more teeth for smoother cuttin g alternating side bar prevents spoil compaction on chain bolt-on adapters allow easy configuration changes Shark Chain II versatile, virtually maintenance- fr ee combination provides pick and shovel effect

R150/R230/R300 Operator’s Manual Systems and Equipment - 57

Chain, Teeth, and Sprockets

Chain Selection

These charts are meant as a guideline only. No one chain type works well in all conditions. See your Ditch Witch dealer for soil conditions and chain recommendations for your area. Ask for the latest Chain, Teeth, and Sprockets Parts Catalog.

• 1 = best

• 2 = better

• 3 = good

• 4 = not recommended

Chain Sandy

Soil

4-pitch cup tooth 3 1 2 3 4 1 2-pitch cup tooth 2 3 1 1 3 4 bolt-on adaptor, 2-pitch 4 4 3 2 1 4 bolt-on adaptor/cup tooth

combo Shark Chain II 432114 alternating side bar 4 4 4 4 4 1

Soil Description

sandy soil sugar sand, blow sand, or other soils where sand is the predominant component soft soil sandy loam medium soil loams, loamy clays hard soil packed clays, gumbo, all compacted soils

432124

Soft Soil Medium

Soil

Hard Soil Rocky

Soil

Sticky

Soil

rocky soil chunk rock, glacial till, cobble, rip rap, gravel sticky soil gumbo, sticky clays

Systems and Equipment - 58 R150/R230/R300 Operator’s Manual

Optional Equipment

See your Ditch Witch dealer for information about available optional equipment.

R150/R230/R300 Operator’s Manual Complete the Job - 59

Complete the Job

Chapter Contents

Restore Jobsite. . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

• Backfilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Rinse Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Stow Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

CMW

Complete the Job - 60 R150/R230/R300 Operator’s Manual

Restore Jobsite

After product is installed, return spoils to the trench with optional backfill blade.

Backfilling

1. Turn off engine.

2. Install backfill blade and secure with pull pins, as shown.

3. Start unit.

4. Position unit at end of trench, several feet from spoils. Aim unit at outer edge of spoils.

5. Adjust backfill blade to fit land contour.

6. Move outer edge of spoils toward trench. Take two or more passes at spoils rather than moving all spoils at once.

7. Repeat on other side of trench, if necessary.

Rinse Equipment

Spray water onto equipment to remove dirt and mud.

NOTICE: Do not spray water onto operator’s console. Electrical components could be damaged. Wipe down instead.

Stow Tools

Make sure all tools and accessories are loaded and secured on trailer.

CMW

R150/R230/R300 Operator’s Manual Service - 61

Service

Chapter Contents

Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . 62

Recommended Lubricants/Service Key . . . . . . . . 62

Oil Temperature Chart . . . . . . . . . . . . . . . . . . . . . . 63

Each Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

10 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

20 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

100 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

250 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

500 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

As Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

CMW

Service - 62 R150/R230/R300 Operator’s Manual

Service Precautions

Incorrect procedures could result in death, injury, or property damage.

Learn 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 servicing equipment, lower unstowed front ends to ground .

Recommended Lubricants/Service Key

Item Description

GEO Gasoline engine oil meeting current API service classifications and SAE viscosity

recommended by engine manufacturer (SAE 10W30)

MPG Multipurpose grease meeting ASTM D217 and NLGI 3

THF Tractor hydraulic fluid, similar to Phillips 66 HG, Mobilfluid 423, Chevron Tractor

Hydraulic Fluid, Texaco TDH Oil, or equivalent Check level of fluid or lubricant

Check condition

Filter

Change, replace, adjust, service or test

Proper lubrication and maintenance protects Ditch Witch equipment from damage and failure. Service intervals listed are for minimum requirements. In ex treme conditions, service machine more frequently. Use only recommended lubricants. Fill to capacities listed in “Specifications” on page 81.

NOTICE:

• Use only genuine Ditch Witch parts, filters, and approved lubricants to maintain warranty.

• Use the “Service Record” on page 103 to record all required service to your machine.

CMW

R150/R230/R300 Operator’s Manual Service - 63

Engine Oil Temperature Chart

R150

Temperature range anticipated before next oil change

R230/R300

Temperature range anticipated before next oil change

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

CMW

Service - 64 R150/R230/R300 Operator’s Manual

Each Use

Location Task Notes Power Unit Check engine oil level GEO

Check hydraulic fluid level THF Check parking brake operation Check tires Bar lug tire: 12 psi (82.7 kPa)

Turf tire: 22 psi (151 kPa) Lug nut torque: 65-70 ft•lb (88-95 N•m)

Power Unit

Check Engine Oil Level - R150

Check engine oil at dipstick (1) before each use. If low, add GEO until oil level is at highest line on dipstick.

IMPORTANT: For more info rm a tio n on eng in e oil, see “Recommended Lubricants/Service Key” on page 62 or see engine manual.

Check Engine Oil Level - R230/R300

Check engine oil at dipstick (1) before each use. If low, add GEO until oil level is at highest line on dipstick.

IMPORTANT: For more info rm a tio n on eng in e oil, see “Recommended Lubricants/Service Key” on page 62 or see engine manual.

CMW

R150/R230/R300 Operator’s Manual Service - 65

Each Use

Check Hydraulic Fluid Level

With digging boom fully raised, check hydraulic fluid level at sight glass (2) before each use. If low, add THF until level is at halfway point on sight glass. Clean dust from cap (1) by blowing with low pressure air.

Check Parking Brake Operation

Verify that parking brake pins engage as shown before each use.

Check Tires

Check power unit tire pressure (2, if necessary) before each use. Maintain pressure as indicated below.

• Bar lug tire: 12 psi (82.7 kPa).

• Turf tire: 22 psi (151 kPa).

Check lug nut (1) tightness before each use. Tighten to 65-70 ft•lb (88-95 N•m).

CMW

Service - 66 R150/R230/R300 Operator’s Manual

10 Hour

Location Task Notes Power Unit Check hydraulic hoses

Inspect insulation R150 only

Trencher Lube trencher pivot MPG

Lube trencher headshaft bearing MPG Check digging chain tension MPG

Power Unit

Check Hydraulic Hoses

Check hydraulic hoses for leaks every 10 hours.

Fluid or air pressure could pierce skin and cause injury or

death. Stay away.

NOTICE: Escaping pressurized fluid can cause injury or pierce skin and poison.

• Before disconnecting a hydraulic line, turn engine off and ope rate all controls to relieve pressure. Lower, blo ck, or support any raised component with a hoist. Cover connectio n with heavy cloth and loosen 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.

• Fluid leaks can be hard to detect. 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.

CMW

R150/R230/R300 Operator’s Manual Service - 67

10 Hour

Inspect Insulation (R150 units only)

Inspect heat insulation on R150 fuel tank (1) and fuel line (2) for damage every 10 hours. Replace if damaged.

Trencher

Lube Trencher Pivot

Lube two pivot zerks with MPG every 10 hours.

Lube Headshaft Bearings

Lube headshaft bearing with MPG every 10 hours.

t22om001t.eps

CMW

Service - 68 R150/R230/R300 Operator’s Manual

10 Hour

Check Digging Chain Tension

NOTICE: Do not overtighten chain.

Overtightening will cause chain stretch, loss of machine performance, and possible premature chain failure.

Check digging chain tension every 10 hours and adjust as needed. With boom horizont al, measure distance from bottom of boom to chain. When properly tensioned, distance (A) should be 1.5” (38 mm).

Adjustment Screw:

1. Loosen four clamp bolts (2) so that boom slides freely .

2. Loosen jam nut on adjustment screw (1).

3. To tighten digging chain, turn adjustment screw clockwise. To loosen digging chain, turn counterclockwise.

4. When proper tension is reached, tighten jam nut.

5. Tighten clamp bolts to 75 ft•lb (102 N•m).

Grease Cylinder:

To tighten digging chain, pump MPG into cylinder at check valve zerk.

T o loosen digging chain , stand on opposite side of boom and unscrew check valve zerk to release grease.

Fluid pressure could pierce skin and cause injury or death. Stay away.

NOTICE: Service digging boom grease cylinder only while standing on opposite side of boom. Wear gloves and safety glasses and cover fitting with cloth when relieving pressure in cylinder.

CMW

R150/R230/R300 Operator’s Manual Service - 69

20 Hour

Location Task Notes Power Unit Change engine oil - R150 Initial service, GEO

Change engine oil and filter - R230/R300 Initial service, GEO

Trencher Lube trail wheel MPG

Lube headshaft bearing MPG, headshaft auger

trencher only

Power Unit

Change Engine Oil (Initial) - R150

Change engine oil after the first 20 hours of operation.

1. Move drain hose (1) to front of unit and drain while oil is still warm.

2. Replace plug.

3. Add 1.6 qt (1.1 L) of GEO at fill neck (2).

IMPORTANT: If operating in extremely dusty conditions, change oil more frequently. Use oil specified in temperature chart found in “Recommended Lubricants/Service Key” on page 62.

CMW

Service - 70 R150/R230/R300 Operator’s Manual

20 Hour

Change Engine Oil and Filter (Initial) R230/R300

Change engine oil and filter after the first 20 hours of operation.

1. Move drain hose (1) to front of unit and drain while oil is still warm.

2. Replace plug.

3. Install new filter (3).

4. Add 2 qt (1.9 L) of GEO at fill neck (2).

IMPORTANT: If operating in extremely dusty conditions, change oil more frequently. Use oil specified in temperature chart found in “Recommended Lubricants/Service Key” on page 62.

Trencher

Lube Trail Wheel

Lube trail wheel with MPG every 20 hours.

CMW

R150/R230/R300 Operator’s Manual Service - 71

50 Hour

Lube Headshaft Bearing (Headshaft Auger Trencher Only)

Lube headshaft bearing with MPG every 20 hours.

50 Hour

Location Task Notes Power Unit Check battery if equipped Trencher Lube digging boom adjustment screw and stub, if

equipped Lube digging boom stub, if equipped MPG

MPG

Power Unit

Check Battery

Check battery every 50 hours. Keep battery case and terminals clean. Remove all corrosion from terminals with a wire brush. Wash terminals with a weak solution of baking soda and water.

CMW

Service - 72 R150/R230/R300 Operator’s Manual

50 Hour

Trencher

Lube Digging Boom Adjustment Screw and Stub

Lube adjustment screw and stub with MPG every 50 hours.

Lube Digging Boom Stub (Greaseable Boom)

Lube boom stub with MPG every 50 hours.

CMW

R150/R230/R300 Operator’s Manual Service - 73

100 Hour

Location Task Notes Power Unit Change engine oil - R150 GEO

Change engine oil and filter - R230/R300 GEO Change air filter

Power Unit

Change Engine Oil - R150

Change engine oil every 100.

1. Move drain hose (1) to front of unit and drain while oil is still warm.

2. Replace plug.

3. Add 1.6 qt (1.1 L) of GEO at fill neck (2).

IMPORTANT: If operating in extremely dusty conditions, change oil more frequently. Use oil specified in temperature chart found in “Recommended Lubricants/Service Key” on page 62.

Change Engine Oil and Filter - R230/ R300

Change engine oil and filter every 100 hours.

1. Move drain hose (1) to front of unit and drain while oil is still warm.

2. Replace plug.

3. Install new filter (3).

4. Add 2 qt (1.9 L) of GEO at fill neck (2).

IMPORTANT: If operating in extremely dusty conditions, change oil more frequently. Use oil specified in temperature chart found in “Recommended Lubricants/Service Key” on page 62.

CMW

Service - 74 R150/R230/R300 Operator’s Manual

100 Hour

Change Air Filter - R150

Change air filter elements every 100 hours.

IMPORTANT: If operating in extremely dusty conditions, change filter more frequently.

To change:

1. Remove wing nut (6) and air cleaner cover (5).

2. Remove wing nut (4) and remove elements (2, 3).

3. Reverse procedure to install new elements. Ensure gasket (1) is seated properly.

Change Air Filter - R230/R300

Change air filter elements every 100 hours.

IMPORTANT: If operating in extremely dusty conditions, change filter more frequently.

To change:

1. Unlatch and remove air cleaner cover (1).

2. Remove elements (2, 3) and replace.

3. Reverse procedure to install.

CMW

R150/R230/R300 Operator’s Manual Service - 75

250 Hour

Location Task Notes Power Unit Change hydraulic fluid and filter THF

Change fuel filter

Power Unit

Change Hydraulic Fluid and Filter

Change hydraulic fluid and filter every 250 hours.

1. Drain hydraulic fluid at drain (3).

2. Replace plug.

3. Change filter (shown).

4. Add THF at fill neck (1, above) until level is at halfway point on sight glass (2, above).

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Service - 76 R150/R230/R300 Operator’s Manual

250 Hour

Change Fuel Filter

Close fuel tank shutoff (top illustration) and change fuel filter (bottom illustration) every 200 hours. Open fuel tank shutoff before operating unit.

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R150/R230/R300 Operator’s Manual Service - 77

500 Hour

Adjust Ground Drive Pump Neutral (R230/R300 only)

Adjust neutral on ground drive pump every 500 hours or if spring is rusted or worn. Check adjustment with throttle at low speed and hydraulic fluid at operating temperature. Ensure all neutral components are working properly before adjusting.

To adjust

1. Use a hoist or appropriate jack stands to reaise unit until all tires are off the ground.

2. Loosen bolts (1).

3. Start unit and brin g hydraulic fluid to operating temperature.

4. Adjust throttle to full speed.

5. Disengage parking brake. Tires may turn.

6. Slowly rotate cam (2) until tires stop.

IMPORTANT: Tires may not come to a complete stop with unit raised. Adjust to achieve the least tire movement possible.

7. Tighten bolts.

8. Engage parking brake.

9. Shut down unit.

10. Lower unit to ground.

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Service - 78 R150/R230/R300 Operator’s Manual

As Needed

Location Task Notes Power Unit Change fuses 15A, 30A

Clean cooler and screen Adjust ground drive pump speed R230/R300 only Adjust ground drive pump neutral Set cruise control brake Adjust cruise control brake

Power Unit

Change Fuses

Change fuses as needed.

• blue with red stripe wire is 15A

• orange with blue stripe wire is 30A

Clean Cooler and Screen

Clean hydraulic fluid cooler and screen as needed.

IMPORTANT: All units have a cooler but only the R230 and R300 have a screen.

1. Remove bolts (1) and rear cushion (2).

2. Pop out screen (3) and clean.

3. Clean cooler fins (4) with compressed air or spray wash if required. Be careful not to damage fins with high-pressure air or water.

4. Install screen and rear cushion and secure with bolts.

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R150/R230/R300 Operator’s Manual Service - 79

As Needed

Adjust Ground Drive Pump Speed (R230/R300 only)

Adjust ground drive pump speed as desired.

To adjust

1. Remove nut (1) and lock washer.

2. Move linkage (2) to hole that corresponds with desired speed range.

• A is low

•B is medium

•C is high

3. Tighten nut.

Set Cruise Control Brake

Engage or disengage cruise control brake as desired.

To engage, set arm as shown (A). To disengage, move arm to slot (B).

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Service - 80 R150/R230/R300 Operator’s Manual

As Needed

Adjust Cruise Control Brake

Adjust cruise control brake as desired. Loose brake allows more override. Tight brake allows less override.

To adjust

1. Open arm (4) and remove pin.

2. Rotate linkage (1) counterclockwise to tighten or clockwise to loosen.

3. If brake is still loose, loosen jam nut (2) and turn screw (3) clockwise to tighten and counterclockwise to loosen brake.

4. Rotate linkage as needed to adjust.

5. Reinstall arm.

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R150/R230/R300 Operator’s Manual Specifications - 81

Specifications

Chapter Contents

R150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

R230 with InterChange Connection . . . . . . . . . . . 85

R300 with InterChange Connection . . . . . . . . . . . 89

Power Unit with Headshaft Auger Trencher . . . . 93

Power Unit with Independent Auger Trencher . . 96

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Specifications - 82 R150/R230/R300 Operator’s Manual

R150

Dimensions U.S. Metric

L Length 43 in 1.09 m L6 Tractor back to rear axle 26.8 in 681 mm L7 Rear axle to front end mounting 19.2 in 488 mm H Height 53.5 in 1.36 m H4 Ground clearance 5.3 in 135 mm H10 Platform height 10.7 in 272 mm W Width 36 in 914 mm A Angle of departure 25° 25° Mass

R150 968 lb 439 kg R150E 1010 lb 458 kg

Vehicle clearance circle (SAE) wall to wall

Right turn 11.3 ft 3.44 m Left turn 10.5 ft 3.2 m

Dimensions are based on unit equipped with urethane 18 X 9.5-8 tires unless otherwise specified.

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R150/R230/R300 Operator’s Manual Specifications - 83

R150

Operation U.S. Metric

Ground drive speed, forward 3.3 mph 5.3 km/h Ground drive speed, reverse 3.3 mph 5.3 km/h Ground pressure 16 psi 1.2 bar

Power U.S. Metric

Engine: Honda iGX440, gasoline Cooling medium air Number of cylinders 1 Displacement

Bore 3.46 in 88 mm Stroke 2.84 in 72.1 mm Manufacturer’s power rating 15 hp 9.5 kW Rated speed 3600 rpm 3600 rpm

Power Train Parking brake: mechanical, hand operated

Service brake: ground drive speed/direction control brakes machine hydraulically when moved to

neutral position

Tires U.S. Metric

18 X 9.5-8, 2 ply, bar lug

Pressure 12 psi 82.7 kpa Tire assembly mass 22 lb 9.98 kg

Urethane filled 18 X 9.5-8, 2 ply, bar lug

26.7 in

438 cc

Pressure n/a n/a Tire assembly mass 36 lb 16.33 kg

18 X 8.5-8, 2 ply, turf

Pressure 22 psi 151 kpa Tire assembly mass 20 lb 9.07 kg

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Specifications - 84 R150/R230/R300 Operator’s Manual

R150

Hydraulic System U.S. Metric

Auxiliary: gear pump Flow rate 7.4 gpm 28 L/min Pressure 3000 psi 207 bar Ground drive: hydrostat Flow rate 11.4 gpm 43.2 L/min Pressure 1800 psi 124 bar

Fluid Capacities U.S. Metric

Fuel tank 10.9 gal 41.3 L Engine oil 1.6 qt 1.1 L Hydraulic reservoir 7.7 gal 29.1 L Total hydraulic system volume 8.5 gal 32.2 L

Battery (R150E only)

SAE reserve capacity 32 min, SAE cold crank @ 0°F (-18°C) 200 amp

Noise Levels

Operator 89 dBA sound pressure per ISO 6394 Exterior 101 dBA sound power per ISO 6393

Vibration Level

Vibration at the operator's hand duri ng normal operation can be up to 4.1 m/sec² per ISO 5349 Vibration at the operator’s foot during normal operation can be up to 8.5 m/sec² per ISO 2631

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R150/R230/R300 Operator’s Manual Specifications - 85

R230 with InterChange Connection

Dimensions U.S. Metric

L Driving length 70 in 1.78 m L5 Wheelbase 34.2 in 869 mm L6 Tractor back to rear axle 26.8 in 681 mm L7 Rear axle to front end mounting 19.2 in 488 mm L8 Front end mounting to front axle 15 in 381 mm H Height 53.5 in 1.36 m H4 Ground clearance 5.3 in 135 mm H10 Platform height 10.7 in 272 mm W Width 36 in 914 mm A Angle of departure 25° 25°

Mass 1290 lb 585 kg

Vehicle clearance circle (SAE) wall to wall

Right turn 11.3 ft 3.44 m Left turn 10.5 ft 3.2 m

Dimensions are based on unit equipped with urethane 18 X 9.5-8 tires unless otherwise specified.

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Specifications - 86 R150/R230/R300 Operator’s Manual

R230 with InterChange Connection

Operation (based on 18” tires) U.S. Metric

Ground drive speed, forward

Low 3.5 mph 5.6 km/h High 5.0 mph 8.0 km/h

Ground drive speed, reverse

Low 3.5 mph 5.6 km/h High 5.0 mph 8.0 km/h

Ground pressure 10 psi 0.7 bar

Power U.S. Metric

Engine: Kohler CH23S, gasoline Cooling medium air Number of cylinders 2 Displacement

Bore 3.15 in 80 mm Stroke 2.64 in 67 mm Manufacturer’s power rating 23 hp 17.2 kW Rated speed 3600 rpm 3600 rpm

Power Train Parking brake: mechanical, hand operated

Service brake: ground drive speed/direction control brakes machine hydraulically when moved to

neutral position

41.1 in

674 cc

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R150/R230/R300 Operator’s Manual Specifications - 87

R230 with InterChange Connection

Tires U.S. Metric

18 X 9.5-8, 2 ply, bar lug

Pressure 12 psi 82.7 kpa Tire assembly mass 22 lb 9.98 kg

Urethane filled 18 X 9.5-8, 2 ply, bar lug

Pressure n/a n/a Tire assembly mass 36 lb 16.33 kg

Urethane filled 20 X 10-8, 4 ply, bar lug

Pressure n/a n/a Tire assembly mass 49 lb 22.23 kg

18 X 8.5-8, 2 ply, 2 turf

Pressure 22 psi 151 kpa Tire assembly mass 20 lb 9.07 kg

Hydraulic System U.S. Metric

Auxiliary: gear pump Flow rate 12 gpm 46 L/min Pressure 3000 psi 207 bar Ground drive: hydrostat Flow rate 19.3 gpm 73 L/min Pressure 3500 psi 241 bar

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Specifications - 88 R150/R230/R300 Operator’s Manual

R230 with InterChange Connection

Fluid Capacities U.S. Metric

Fuel tank 10.9 gal 41.3 L Engine oil, with filter 2 qt 1.9 L Hydraulic reservoir 7.7 gal 29.1 L Total hydraulic system volume 8.5 gal 32.2 L

Battery

SAE reserve capacity 32 min, SAE cold crank @ 0°F (-18°C) 200 amp

Noise Levels

Operator 90 dBA sound pressure per ISO 6394 Exterior 102 dBA sound power per ISO 6393

Vibration Level

Vibration at the operator's hand duri ng normal operation can be up to 9.9 m/sec² per ISO 5349 Vibration at the operator’s foot during normal operation can be up to 8.5 m/sec² per ISO 2631

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R150/R230/R300 Operator’s Manual Specifications - 89

R300 with InterChange Connection

Dimensions U.S. Metric

Mass 1290 lb 585 kg

Vehicle clearance circle (SAE) wall to wall

Right turn 11.3 ft 3.44 m Left turn 10.5 ft 3.2 m

Dimensions are based on unit equipped with urethane 18 X 9.5-8 tires unless otherwise specified.

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Specifications - 90 R150/R230/R300 Operator’s Manual

R300 with InterChange Connection

Operation (based on 18” tires) U.S. Metric

Ground drive speed, forward

Low 3.5 mph 5.6 km/h High 5.0 mph 8.0 km/h

Ground drive speed, reverse

Low 3.5 mph 5.6 km/h High 5.0 mph 8.0 km/h

Ground pressure 10 psi 0.7 bar

Power U.S. Metric

Engine: Kohler CH750S, gasoline Cooling medium air Number of cylinders 2 Displacement

Bore 3.3 in 83 mm Stroke 2.7 in 69 mm Manufacturer’s power rating 30 hp 22.4 kW Rated speed 3600 rpm 3600 rpm

Power Train Parking brake: mechanical, hand operated

Service brake: ground drive speed/direction control brakes machine hydraulically when moved to

neutral position

45.6 in

747 cc

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R150/R230/R300 Operator’s Manual Specifications - 91

R300 with InterChange Connection

Tires U.S. Metric

18 X 9.5-8, 2 ply, bar lug

Pressure 12 psi 82.7 kpa Tire assembly mass 22 lb 9.98 kg

Urethane filled 18 X 9.5-8, 2 ply, bar lug

Pressure n/a n/a Tire assembly mass 36 lb 16.33 kg

Urethane filled 20 X 10-8, 4 ply, bar lug

Pressure n/a n/a Tire assembly mass 49 lb 22.23 kg

18 X 8.5-8, 2 ply, turf

Pressure 22 psi 151 kpa Tire assembly mass 20 lb 9.07 kg

Hydraulic System U.S. Metric

Auxiliary: gear pump Flow rate 12 gpm 46 L/min Pressure 3000 psi 207 bar Ground drive: hydrostat Flow rate 19.3 gpm 73 L/min Pressure 3500 psi 241 bar

CMW

Specifications - 92 R150/R230/R300 Operator’s Manual

R300 with InterChange Connection

Fluid Capacities U.S. Metric

Fuel tank 10.9 gal 41.3 L Engine oil, with filter 2 qt 1.9 L Hydraulic reservoir 7.7 gal 29.1 L Total hydraulic system volume 8.5 gal 32.2 L

Battery

SAE reserve capacity 32 min, SAE cold crank @ 0°F (-18°C) 200 amp

Noise Levels

Operator 90 dBA sound pressure per ISO 6394 Exterior 103 dBA sound power per ISO 6393

Vibration Level

Vibration at the operator's hand duri ng normal operation can be up to 9.9 m/sec² per ISO 5349 Vibration at the operator’s foot during normal operation can be up to 8.5 m/sec² per ISO 2631

CMW

R150/R230/R300 Operator’s Manual Specifications - 93

Power Unit with Headshaft Auger Trencher

Dimensions U.S. Metric

L Driving length 90.5 in 2.3 m L2 Maximum length 104.5 in 2.65 m L4 Front end length 58.5 in 1.49 m L5 Wheelbase 44.2 in 1.12 m

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Specifications - 94 R150/R230/R300 Operator’s Manual

Power Unit with Headshaft Auger Trencher

Dimensions U.S. Metric

H Driving height 53.5 in 1.36 m H1 Tie-down height 31.7 in 805 mm H3 Maximum front end height 49.3 in 1.25 m D1 Operating depth (maximum) 36 in 914 mm W Width 36 in 914 mm W2 Cutting width 4-8 in 102-203 mm W3 Spoils width 13.8 in 351 mm W4 Centerline of trench, left 18.5 in 470 mm W5 Centerline of trench, right 17.5 in 445 mm W7 Front en d width 34 in 864 mm A Angle of departure 25° 25° A2 Front end travel down (recommended) 60° 60° A3 Front end travel up (recom m e nd ed ) 50° 50° Unit mass 1468 lb 652.3 kg Front end mass w/24” boom and 4” cup toot h ch ain 420 lb 190.5 kg Vehicle clearance circle (SAE) wall to wall

Right turn 11.3 ft 3.44 m Left turn 10.2 ft 3.11 m

Headshaft Speeds @ 3600 engine rpm U.S. Metric R150

Medium speed/medium torque 149 rpm 149 rpm High speed/low torque 183 rpm 183 rpm

R230/R300

Low speed/high torque 186 rpm 186 rpm Medium speed/medium torque 244 rpm 244 rpm

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R150/R230/R300 Operator’s Manual Specifications - 95

Power Unit with Headshaft Auger Trencher

Power Train U.S. Metric

Digging chain drive: hydraulic direct drive Digging chain: 33,000 lb or 35,000 lb Spoils handling drive: mechanical, attaches to the headshaft Chain drive sprocket: forged and tempered

Operation U.S. Metric

Digging chain speed

Minimum 290 ft/min 88.4 m/min Maximum 364 ft/min 111 m/min

Trench cleaner (optional) type: mechanical

Minimum 4 in 102 mm

Maximum 8 in 203 mm Spoils handling: single open end auger Auger size: 18” OD x 2” ID x 8.7” long

Tires

Trail wheel: urethane filled 16 X 6.5-8, 2 ply, bar lug Tire assembly mass 18 lb 8.16 kg

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Specifications - 96 R150/R230/R300 Operator’s Manual

Power Unit with Independent Auger Trencher

Dimensions U.S. Metric

L Driving length 90.5 in 2.3 m L2 Maximum length 104.5 in 2.65 m L4 Front end length 58.5 in 1.49 m L5 Wheelbase 44.2 in 1.12 m

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R150/R230/R300 Operator’s Manual Specifications - 97

Power Unit with Independent Auger Trencher

Dimensions U.S. Metric

H Driving height 53.5 in 1.36 m H1 Tie-down height 31.7 in 805 mm H3 Maximum front end height 49.3 in 1.25 m D1 Operating depth (maximum) 36 in 914 mm W Width 36 in 914 mm W2 Cutting width 4-8 in 102-203 mm W3 Spoils width 16 in 406 mm W4 Centerline of trench, left 18.5 in 470 mm W5 Centerline of trench, right 17.5 in 445 mm W7 Front en d width 33 in 838 mm A Angle of departure 25° 25° A2 Front end travel down (recommended) 60° 60° A3 Front end travel up (recom m e nd ed ) 50° 50° Unit mass 1488 lb 674.9 kg Front end mass w/24” boom and 4” cup toot h ch ain 440 lb 199.6 kg Vehicle clearance circle (SAE) wall to wall

Right turn 11.3 ft 3.44 m

Left turn 10.5 ft 3.2 m

Headshaft Speeds @ 3600 engine rpm U.S. Metric R150

Medium speed/medium torque 149 rpm 149 rpm High speed/low torque 183 rpm 183 rpm

R230/R300

Low speed/high torque 186 rpm 186 rpm Medium speed/medium torque 244 rpm 244 rpm

Power Train U.S. Metric

Digging chain drive: hydraulic direct drive Digging chain: 33,000 lb or 35,000 lb Spoils handling drive: hydraulic, independent Chain drive sprocket: forged and tempered

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Specifications - 98 R150/R230/R300 Operator’s Manual

Power Unit with Independent Auger Trencher

Operation U.S. Metric

Digging chain speed

Minimum 230 ft/min 70.1 m/min

Maximum 364 ft/min 111 m/min Trench cleaner (optional) type: mechanical

Minimum 4 in 102 mm

Maximum 8 in 203 mm Spoils handling: single open end auger Auger size: 6.18” OD x 2” ID x 17.25” long

Tires

Trail wheel: urethane filled 16 X 6.5-8, 2 ply, bar lug Tire assembly mass 18 lb 8.16 kg

Specifications are called out according to SAE recommended procedures. Specifications are general and subject to change without notice. If exact measurements are required, equipment should be weighed and measured. Due to selected options, delivered equipment may not necessarily match that described.

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R150/R230/R300 Operator’s Manual Support - 121

Procedure

Support

Procedure

Notify your dealer immediately of any malfunction or failure of Ditch Witch equipment. Always give model, serial number, and approximate date of your equipment purchase. This information

should be recorded and placed on file by the owner at the time of purchase. 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. Use of

another manufacturer's parts may void warranty consideration.

Resources

Publications

Contact your Ditch Witch dealer for publications and videos covering safety, operation, service, and repair of your equipment.

Ditch Witch Training

For information about on-site, individualized training, contact your Ditch Witch dealer.

CMW

Ditch Witch Zahn User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Overview

Serial Number Location

Intended Use

Equipment Modification

Unit Components

Operator Orientation

About This Manual

Bulleted Lists

Numbered Lists

“Continued” Indicators

Foreword

Content s

Safety

Guidelines

Safety Alert Classifications

Safety Alerts

Emergency Procedures

Electric Strike Description

If an Electric Line is Damaged

If a Gas Line is Damaged

If a Fiber Optic Cable is Damaged

If Machine Catches on Fire

Controls

Gauges and Indicators

Controls

R150/R150E

R230/R300

R150/R230/R300

Prep are

Gather Information

Inspect Site

Identify Hazards

Classify Jobsite

Inspect Jobsite

Select a Classification

Apply Precautions

Check Supplies and Prepare Equipment

Supplies

Fluid Levels

Condition and Function

Accessories

Attach Front End to InterChange Connection

Precautions

Drive

Start Unit

R150

R230/R300

Drive

General Operation

Slope Operation Guidelines

Shut Down

Transport

Lift

Points

Procedure

Haul

Load

Tie Down

Unload

Prepare Unit for Towing

Return Unit to Normal Operation

Trench

Trench

Systems and Equipment

Chain, Teeth, and Sprockets

Chain and Tooth Maintenance

Chain Types

Chain Selection

Optional Equipment

Complete the Job

Restore Jobsite

Backfilling

Rinse Equipment

Stow Tools

Service

Service Precautions