Ditch Witch Zahn User Manual

R150/R230/R300

Operator’s

Manual

CMW®

Issue 1.6

0531173

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

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

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

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.

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

Unit Components

1.	operator platform	4.					front end manifold
2.	engine compartment	5.					articulation joint
3.	control console	6.					InterChange connection (R230 and R300)

Operator Orientation

1.	Front of unit	3.	Rear of unit
2.	Right of unit	4.	Left 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.

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R150/R230/R300 Operator’s Manual

About This 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 procedures that do not have to be performed in a specific order.

Numbered Lists

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

“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 equipment 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 published. For the latest information on Ditch Witch equipment, see your Ditch Witch dealer.

Thank you for buying and using Ditch Witch equipment.

CMW

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

Copyright 2007, 2008, 2009

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 Charles Machine Works, Inc.

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

CMW

R150/R230/R300 Operator’s Manual

Contents - 9

Contents

Overview

1

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

7

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

		Safety	11
		machine safety alerts and emergency procedures
		Controls	21
		machine controls, gauges, and indicators and how to use them
		Prepare	33
		procedures for inspecting and classifying the jobsite, planning the installation path (if
		needed), preparing the jobsite for work, and connecting front ends
		Drive	39
		procedures for startup, cold start, driving, and shutdown
		Transport	43
		procedures for lifting, hauling, and towing
		Trench	51
		procedures for trenching
		Systems and Equipment	55
		chain, teeth, sprockets, and optional equipment
		Complete the Job	59
		procedures for restoring the jobsite and rinsing and storing equipment
		Service	61
		service intervals and instructions for this machine including lubrication, replacement
		of wear items, and basic maintenance
		Specifications	81
		machine specifications including weights, measurements, power ratings, and fluid
		capacities

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Contents - 10			R150/R230/R300 Operator’s Manual
		Support	99
		the warranty policy for this machine, and procedures for obtaining warranty
		consideration and training
		Service Record	103

a record of major service performed on the machine

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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

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 correct tools and machinery, safety equipment, and work methods for jobsite.

•Mark jobsite clearly and keep spectators away.

•Wear personal protective equipment.

•Review jobsite hazards, safety and 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, maintenance, or equipment use.

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R150/R230/R300 Operator’s Manual

Safety - 13

Safety Alert Classifications

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

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.

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

Crushing weight could cause death or serious injury. Use proper procedures and equipment or stay away.

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

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R150/R230/R300 Operator’s Manual

Safety Alerts

Safety - 15

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 and cause injury or death. Stay 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

Emergency Procedures

Before operating any equipment, review emergency procedures and check that all safety precautions 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

Emergency Procedures

If a Fiber Optic Cable is Damaged

Safety - 19

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

Gauges and Indicators

1.

Auxiliary power outlet (R150E/R230/R300

3.

Hydraulic fluid sight glass

only)

4.

Hourmeter (optional)

2.

Fuel sight glass

Item

Description

Notes

1.

Auxiliary power outlet

To operate work lights or

Not available on R150 with rope start.

other 12V devices, plug into

outlet.

2.

Fuel tank sight window

Shows level of fuel in tank.

3.

Hydraulic fluid sight

Shows level of hydraulic fluid

glass

in tank. Maintain fluid at

halfway point on glass.

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R150/R230/R300 Operator’s Manual

Gauges and Indicators

Controls - 23

Item					Description	Notes
4. Hourmeter (optional)					Displays engine operating	Use these times to schedule service.
					time.

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Controls - 24	R150/R230/R300 Operator’s Manual
	Controls
Controls
R150/R150E

1.	Ground drive control	6.	Choke (R150)/manual start switch (R150E)
2.	Traction assist switch	7.	Rope start
3.	Throttle switch	8.	Ignition switch
4.	Front end lift control	9.	Parking brake
5.	Front end drive control	10.	Cruise control pedal

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R150/R230/R300 Operator’s Manual

Controls

Controls - 25

Item				Description	Notes
1.	Ground drive control			To move forward, push.	To make a gradual turn, move control
					halfway between desired directions
				To move backward, pull.	and return to center. Unit will remain
				To turn right, move to right.	articulated until it is returned to center.
					IMPORTANT: As long as control is
				To turn left, move to left.	moved to right or left, unit is
				To go faster in any direction,	articulating and turning is tightened.
				move control farther from
				neutral position.
				To stop, release.
2.	Traction assist switch			To allow maximum power to	Use when working on a slope to
				tires, press top.	lessen undesired movement.

To return to normal operation, press bottom.

3.	Throttle switch			To set engine speed for
				operation, press top.
				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					Choke (R150)	This valve regulates air/fuel mixture.
	switch					To help start cold engine,
						close valve.
						Manual start switch (R150E)	IMPORTANT: R150E units have
						To manually start engine	automatic choke feature.
						when electric starter doesn’t
						work, move switch to right,
						turn on power switch and pull
						rope start.
7.	Rope start					To start engine, pull rope.	Ignition switch must be on for this
							control to function.
							If engine does not start after three
							pulls, turn power switch off and check
							for fuel blockage or electrical system
							problems.
8.	Ignition switch					R150
						To start engine, insert key and
						turn clockwise. Pull rope start.
						To stop engine, turn key
						counterclockwise.
						R150E	IMPORTANT:
						To start engine, insert key and	• If engine does not start, turn key
						turn clockwise.	to OFF and then restart.
						To stop engine, turn key	• Do not allow starter motor to run
							continuously for more than 20
						counterclockwise.
							seconds.

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R150/R230/R300 Operator’s Manual

Controls

Controls - 27

Item					Description	Notes
9. Parking brake lever					To engage, move handle to	IMPORTANT:
					left.	• Move unit slightly to ensure
					To disengage, move handle	parking brake pins are engaged.
					to right.	• It might be necessary to move
						unit slightly to disengage parking
						brake.
10. Cruise control pedal					To maintain ground drive and	NOTICE: Pedal must return to neutral
					front end drive settings, press	when released. Never tie down or use
					pedal and release handles.	anything other than foot to hold pedal
						down.

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

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Controls - 28

R150/R230/R300 Operator’s Manual

Controls

R230/R300

1.	Ground drive control	6.		Choke
2.	Traction assist switch	7.		Throttle
3.	Front end lift control	8.		Ignition switch
4.	Front end drive control	9.		Parking brake
5.	Remote throttle control (optional)	10.		Cruise control pedal

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R150/R230/R300 Operator’s Manual

Controls

Controls - 29

Item				Description	Notes
1.	Ground drive control			To move forward, push.	To make a gradual turn, move control
					halfway between desired directions
				To move backward, pull.	and return to center. Unit will remain
				To turn right, move to right.	articulated until it is returned to center.
					IMPORTANT: As long as control is
				To turn left, move to left.	moved to right or left, unit is
				To go faster in any direction,	articulating and turning is tightened.
				move control farther from
				neutral position.
				To stop, release.
2.	Traction assist switch			To allow maximum power to	Use when working on a slope to
				tires, press top.	lessen undesired track movement.

To return to normal operation, press bottom.

3.	Front end lift control			To retract primary cylinder or
				lower trencher, push.	IMPORTANT: Front end will drop
				To float, push forward to
				detent.	when unit is put in float position.
				To extend primary cylinder or
				raise trencher, pull.
				To retract secondary cylinder,
				move to left.
				To extend secondary cylinder,
				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.

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