MV800 Operator’s Manual CMW® Issue 1.
MV800 Operator’s Manual Overview - 1 Overview Chapter Contents Serial Number Location . . . . . . . . . . . . . . . . . . . . . . 2 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Equipment Modification . . . . . . . . . . . . . . . . . . . . . 3 Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Operator Orientation. . . . . . . . . . . . . . . . . . . . . . . . . 4 About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 4 • Bulleted Lists.
MV800 Operator’s Manual Overview - 2 Serial Number Location Serial Number Location Record serial numbers and date of purchase in spaces provided. MV800 serial number is located as shown. Date of manufacture Date of purchase MV800 serial number (shown) Engine serial number Blower serial number Water pump serial number Trailer serial number Intended Use The MV800 is a self-contained vacuum excavation unit designed to remove used drilling fluid from the jobsite and to expose existing buried utilities.
MV800 Operator’s Manual Overview - 3 Equipment Modification 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.
MV800 Operator’s Manual Overview - 4 Operator Orientation 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 towing vehicle. 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.
MV800 Operator’s Manual Foreword - 5 Reporting Safety Defects Foreword This manual is an important part of your equipment. It provides safety information and operation instructions to help you use and maintain your Ditch Witch® 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.
MV800 Operator’s Manual Foreword - 6 MV800 Operator’s Manual Issue number 1.0/OM-9/14 Part number 053-2767 Copyright 2014 by The Charles Machine Works, Inc. , Ditch Witch, and CMW are registered trademarks of The Charles Machine Works, Inc. U.S. patents pending.
MV800 Operator’s Manual Contents - 7 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 5 part number, revision level, and publication date of this manual, and factory contact information Safety 9 machine safety alerts and emergency procedures Controls 19 machine controls, gauges, and indicators and how to use them Operation Overview 27 an overview for completing a jo
MV800 Operator’s Manual Contents - 8 Service Record 101 a record of major service performed on the machine Appendix additional information about Ditch CMW® 103 Witch® equipment
MV800 Operator’s Manual Safety - 9 Safety Chapter Contents Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Emergency Procedures . . . . . . . . . . . . . . . . . . . . . 11 • Electric Strike Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 • If an Electric Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 • If a Gas Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety - 10 MV800 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.
MV800 Operator’s Manual Safety - 11 Emergency Procedures Emergency Procedures Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. 274-050 Before operating any equipment, review emergency procedures and check that all safety precautions have been taken. EMERGENCY SHUTDOWN - Turn ignition switch to stop position or push remote engine stop button (if equipped). Electric Strike Description Electric shock.
Safety - 12 MV800 Operator’s Manual Emergency Procedures If an Electric Line is Damaged If you suspect an electric line has been damaged and you are on truck or trailer, DO NOT MOVE. Remain on truck or trailer and take the following actions. The order and degree of action will depend on the situation. • Warn people nearby that an electric strike has occurred. Instruct them to leave the area and contact utility. • Do not allow anyone into area until given permission by utility company.
MV800 Operator’s Manual Safety - 13 Emergency Procedures If a Gas Line is Damaged Fire or explosion possible. Fumes could ignite and cause burns. No smoking, no flame, no spark. 275-419 (2P) Explosion possible. Serious injury or equipment damage could occur. Follow directions carefully. If you suspect a gas line has been damaged, take the following actions. The order and degree of action will depend on the situation. • Immediately shut off engine(s), if this can be done safely and quickly.
Safety - 14 MV800 Operator’s Manual Emergency Procedures If a Fiber Optic Cable is Damaged Do not look into cut ends of fiber optic or unidentified cable. Vision damage can occur. Contact utility company. If Machine Catches on Fire Perform emergency shutdown procedure and then take the following actions. The order and degree of action will depend on the situation. • Immediately move battery disconnect switch (if equipped and accessible) to disconnect position.
MV800 Operator’s Manual Safety - 15 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.
MV800 Operator’s Manual Safety - 16 Machine Safety Alerts Machine Safety Alerts 275-146 1 • Secure equipment and accessories with chain and binder. • Check brakes and lights prior to use. • Use proper size coupler. • Maintain adequate distance for stopping and passing vehicles. • Block wheels when parked. • Check tire condition and inflation frequently. • Failure to follow these rules may result in personal injury. Lift point. See Transport chapter for more information.
MV800 Operator’s Manual Safety - 17 Machine Safety Alerts 3 Contents under pressure. Relieve pressure before opening. Death or injury could occur. 270-2732 Use breathing protection when exposed to silica 4 5 6 7 dust. 270-4952 Exposure to high noise levels may cause hearing loss. Wear hearing protection. 700-009 (2-P) Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment.
MV800 Operator’s Manual Safety - 18 Machine Safety Alerts Vacuum can suffocate. Keep hose end away from 11 12 13 face. 273-205 Pressurized fluid or air could pierce skin and cause severe injury. Refer to operator’s manual for proper use. 270-6035 Crushing weight could cause death or serious injury. Stay away. 275-326 Moving parts could cut off hand or foot. Stay away. 14 15 CMW® 275-184 Crushing weight. Place cylinder lock on extended cylinder and secure.
MV800 Operator’s Manual Controls - 19 Controls Chapter Contents Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Operator’s Station . . . . . . . . . . . . . . . . . . . . . . . . . 21 Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MV800 Operator’s Manual Controls - 20 Engine Engine 1. Throttle 3. Ignition switch 2. Choke Item Description Notes 1. Throttle To increase engine speed, move to right. IMPORTANT: Run engine at full throttle during operation. To decrease engine speed, move to left. 2. Choke To help start cold engine, pull knob. When engine has warmed, push in completely. 3. Ignition switch To start engine, insert key and turn clockwise.
MV800 Operator’s Manual Controls - 21 Operator Station Operator Station 1. Water pressure switch 5. Hourmeter 2. Water pressure control 6. Flow direction control (optional) 3. Water pressure gauge 7. Battery disconnect switch 4. Auxiliary outlet 8. Tethered tank control outlet Item Description 1. Water pressure switch To turn on water pump, press top. Notes To turn off water pump, move to center position. c00ic114t.eps To bypass low water indication, press bottom.
MV800 Operator’s Manual Controls - 22 Operator Station Item Description 2. Water pressure control To increase water pressure, turn clockwise. Notes To decrease water pressure, turn counterclockwise. c00ic113t.eps 3. Water pressure gauge Displays water pressure when water pressure switch is on and spray wand is in use. 4. Auxiliary outlet To operate work lights or other 12V devices, plug into outlet. Outlet has power only when ignition switch is on. 5. Hourmeter Displays engine operating time.
MV800 Operator’s Manual Controls - 23 Operator Station Item Description Notes 7. Battery disconnect switch To connect, turn clockwise. IMPORTANT: Use battery disconnect switch when servicing, welding, and during long-term storage. To disconnect, turn counterclockwise. _ + _ + c00ic063t.eps 8. Tethered tank control outlet Connection for tethered tank control. Tethered tank control To lift and lower tank, set hydraulic function switch to the tank position, then UP c00ic064t.
MV800 Operator’s Manual Controls - 24 Machine Machine 1. Inlet valve 6. Antifreeze tank supply valve (optional) 2. Drain/Outlet valve 7. Water tank drain (optional) 3. Vacuum filter drain 8. Water tank supply valve (optional) 4. Vacuum gauge 9. Hydraulic function switch (optional) 5. Reverse flow gauge (optional) Item Description Notes 1. Inlet valve To close valve (stop suction), rotate up. NOTICE: Do not idle engine with inlet valve closed. To open valve (start suction), rotate down. 2.
MV800 Operator’s Manual Controls - 25 Machine Item Description 3. Vacuum filter drain To drain vacuum filter canister, rotate up. Notes To close drain, rotate down. 4. Vacuum gauge Displays blower vacuum reading in inches of mercury. Vacuum relief valve opens when vacuum reaches 15” (381 mm). 5. Reverse flow gauge Displays reverse flow pressure. 6. Antifreeze tank supply valve To open valve (send antifreeze through pump and water lance), rotate counterclockwise.
MV800 Operator’s Manual Controls - 26 Machine Item Description Notes 8. Water tank supply valve To open valve (send water from the water tank through the pump and water lance), rotate counterclockwise. IMPORTANT: Water tank supply valve or antifreeze supply valve must be open when pump is running or pump will be damaged. To close valve (stop water flow), rotate clockwise. c00ic603h.eps 9. Hydraulic function switch To lift and lower tank, push down. To open and close door, pull up.
MV800 Operator’s Manual Operation Overview - 27 Operation Overview Chapter Contents Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Setting Up at Jobsite . . . . . . . . . . . . . . . . . . . . . . . 28 Vacuuming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Potholing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Leaving Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Storing Equipment . . . . . . . . . . . . . . . . .
Operation Overview - 28 MV800 Operator’s Manual Planning Planning 1. Gather information about jobsite (page 32). 2. Inspect jobsite (page 33). 3. Check supplies and prepare equipment (page 35). Setting Up at Jobsite 1. Prepare jobsite (page 34). 2. Leave unit hitched to towing vehicle or properly stabilized if trailer-mounted unit. 3. Block trailer wheels if trailer-mounted unit. Vacuuming 1. Connect hoses (page 42). 2. Start unit (page 44). 3. Remove debris (page 45). 4. Disconnect hoses. 5.
MV800 Operator’s Manual Operation Overview - 29 Potholing Potholing 1. Connect hoses (page 42). 2. Start unit (page 42). 3. Pothole (page 46). 4. Disconnect hoses. 5. Drain tank (page 48). Leaving Jobsite 1. Rinse unit and tools (page 57). 2. Stow tools (page 57). Storing Equipment 1. For cold weather storage, antifreeze vacuum excavation unit (page 56). 2. For long-term storage, disconnect battery disconnect switch (page 22).
Operation Overview - 30 MV800 Operator’s Manual Storing Equipment CMW®
MV800 Operator’s Manual Prepare - 31 Prepare Chapter Contents Gather Information . . . . . . . . . . . . . . . . . . . . . . . . . 32 • Arrange for Traffic Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 • Prepare for Working Near Existing Utilities . . . . . . . . . . . . . . . . . . . . . .32 • Plan for Emergency Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Inspect Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prepare - 32 MV800 Operator’s Manual Gather Information Gather Information A successful job begins before the excavation. The first step in planning is reviewing information already available about the job and jobsite. Arrange for Traffic Control If working near a road or other traffic area, contact local authorities about safety procedures and regulations.
MV800 Operator’s Manual Prepare - 33 Inspect Jobsite Inspect Jobsite • Follow U.S. Department of Labor regulations on excavating and trenching (Part 1926, Subpart 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 working. Also contact any utilities that do not participate in the One-Call service.
MV800 Operator’s Manual Prepare - 34 Prepare Jobsite Prepare Jobsite Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. 274-050 To help avoid injury: • Classify jobsite as electric if jobsite classification is in question or if the possibility of unmarked electric utilities exists. • Expose lines by hand before digging.Cutting high voltage cable can cause electrocution.
MV800 Operator’s Manual Prepare - 35 Check Supplies and Prepare Equipment Check Supplies and Prepare Equipment Assemble Accessories Fire Extinguisher If required, 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. Lighting Kit If you will need additional light, plug lighting kit into provided outlet.
Prepare - 36 MV800 Operator’s Manual Check Supplies and Prepare Equipment Prepare Equipment Fluid Levels • fuel • battery • engine oil • blower oil Condition and Function • filters (air, oil) • belts • blower • tires • hoses and valves • couplers and fittings • water tank CMW®
MV800 Operator’s Manual Transport - 37 Transport Chapter Contents Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 • Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 • Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Haul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 • Inspect Trailer . . . . . . . . . . . . . . . .
MV800 Operator’s Manual Transport - 38 Lift Lift Crushing weight could cause death or serious injury. Stay away. 275-326 Points Lifting points are identified by lifting decals. Lifting at other points is unsafe and can damage machinery. Procedure Power Pack Use a crane capable of supporting 1500 lb (680 kg). Attach lifting device to corners and lift as shown.
MV800 Operator’s Manual Transport - 39 Haul Tank Use crane capable of supporting the 2000 lb (907 kg). Use top lift point (1) as shown. Use end lift point (2) to drain tank if machine is disabled. 1 2 NOTICE: • Relieve pressure in tank before storing or transporting. • Only lift empty water or spoils tanks. j04omo33t.eps Haul Crushing weight could cause death or serious injury. Stay away. 275-326 To help avoid injury: Do not haul or move trailer unless tank is fully lowered and horizontal.
Transport - 40 MV800 Operator’s Manual Haul Hitch Trailer 1. Back tow vehicle to trailer. 2. Put manual transmission into first or reverse gear or automatic transmission into park. Turn off ignition. Set parking brake. 3. Connect trailer drawbar, lunette or coupler to tow vehicle hitch and lock in place with lock pin. If needed, adjust drawbar, lunette or coupler height (shown) to level load. 4. Connect safety chains to tow vehicle chain keepers (cross-shaped slots on bumper of tow vehicle).
MV800 Operator’s Manual Vacuum and Pothole - 41 Vacuum and Pothole Chapter Contents Connect Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Determine Tank Fill Level . . . . . . . . . . . . . . . . . . . 43 • 800-gal Vacuum Tank on T14MV Trailer . . . . . . . . . . . . . . . . . . . . . . . .43 Start Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 • Standard Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MV800 Operator’s Manual Vacuum and Pothole - 42 Connect Hoses Connect Hoses 1. Remove vacuum hoses from storage. 2. If potholing, remove 2-in-1 potholing tool or basic potholing tool from storage. 3. Connect hoses. Secure all locking clamps. 4. Ensure drain/outlet valve is closed. 5. If potholing, connect water pressure hose.
MV800 Operator’s Manual Vacuum and Pothole - 43 Determine Tank Fill Level Determine Tank Fill Level Use these reference charts to help determine how full of various materials the vacuum tank can be without overloading trailer. Exceeding the maximum fill level will overload the trailer. Never exceed the trailer capacity. You can exceed the vacuum tank lifting capacity if you drain the tank down to the lifting capacity before lifting tank.
Vacuum and Pothole - 44 MV800 Operator’s Manual Start Unit Start Unit EMERGENCY SHUTDOWN: Turn ignition switch to STOP. Standard Procedure 1. Open tank inlet valve. NOTICE: Avoid idling engine with inlet valve closed. 2. If equipped with reverse flow, ensure vacuum is in “vacuum” mode before starting. 3. Insert key. 4. Turn key clockwise. See page 20 for more information.
MV800 Operator’s Manual Vacuum and Pothole - 45 Remove Debris Remove Debris EMERGENCY SHUTDOWN: Turn ignition switch to STOP. Procedure 1. Position vacuum hose in area to be excavated. 2. Start engine. Vacuum can suffocate. Keep hose end away from face. 273-205 Fire or explosion possible. Do not vacuum flammable or combustible substances. 273-483 Read operator’s manual. Know how to use all controls. Your safety is at stake. 273-475 To help avoid injury: Do not excavate hazardous or toxic materials.
MV800 Operator’s Manual Vacuum and Pothole - 46 Pothole Pothole EMERGENCY SHUTDOWN: Turn ignition switch to STOP. 1. Start engine. Vacuum can suffocate. Keep hose end away from face. 273-205 Fire or explosion possible. Do not vacuum flammable or combustible substances. 273-483 2. Open inlet valve. NOTICE: Avoid idling engine with inlet valve closed. 3. Open water tank valve. 4. Move water pump switch to on. 5. Position tool over area to be excavated and begin pothole.
MV800 Operator’s Manual Vacuum and Pothole - 47 Pothole 6. Adjust water pressure as needed to match soil conditions and/or material of utility being exposed. Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. 274-050 To help avoid injury: Test water pressure on a sample of the utility line material to be exposed. Adjust pressure until no damage occurs to the material. High pressure water can cut utility lines.
MV800 Operator’s Manual Vacuum and Pothole - 48 Drain Tank Drain Tank EMERGENCY SHUTDOWN: Turn ignition switch to STOP. 1. Ensure that unit is hitched to vehicle. See “Hitch Trailer” on page 40. 2. Haul unit to approved dumping area Read operator’s manual. Know how to use all controls. Your safety is at stake. 273-475 To help avoid injury: • Do not unhitch unit from tow vehicle before or during dumping. A freestanding unit can become unstable when tilting tank.
MV800 Operator’s Manual Vacuum and Pothole - 49 Drain Tank 9. If further draining is necessary, open tank door. See “Open/Close Tank Door” on page 52. Crushing weight could cause death or serious injury. Stay away. 275-326 To help avoid injury: Use tools (provided with unit) if unit must be serviced with tank door up. 10. Tilt tank up fully. Allow tank to drain completely. 11. Connect water pressure hose to water lance. 12. Turn water pump switch on. Adjust water pressure. 13.
MV800 Operator’s Manual Vacuum and Pothole - 50 Unload to Another Tank Unload to Another Tank Optional reverse flow mode can be used to transfer vacuumed material to another tank or disposal site. Read operator’s manual. Know how to use all controls. Your safety is at stake. 273-475 To help avoid injury: • Keep unit in “vacuum” mode unless pressure is needed. • Restrain hose prior to pressurization. Unrestrained hose may cause property damage, injury or death.
MV800 Operator’s Manual Vacuum and Pothole - 51 Unload to Another Tank 5. Move valve handle counterclockwise to engage “reverse flow” mode and start engine. Material will flow into offboard tank. 6. Increase throttle as desired to transfer material. 7. When transfer is complete, throttle down completely and turn off engine. Close vac tank drain/outlet valve. 8. Close offboard tank inlet valve and disconnect hose from offboard tank inlet valve. 9. Move handle clockwise to “vacuum” mode and turn on engine.
MV800 Operator’s Manual Vacuum and Pothole - 52 Open/Close Tank Door Open/Close Tank Door Standard Door Open Crushing weight could cause death or serious injury. Stay away. 275-326 To help avoid injury: Do not raise tank with door held closed only by vacuum. Door may suddenly open and possibly injure someone. NOTICE: Do not drive with tank or door raised. IMPORTANT: Depressurize tank before emptying vacuum air filter canister, cleaning filter, clearing hoses or opening any doors. 1.
MV800 Operator’s Manual Vacuum and Pothole - 53 Open/Close Tank Door Hydraulic Door (Optional) Open Crushing weight could cause death or serious injury. Stay away. 275-326 To help avoid injury: Do not raise tank with door held closed only by vacuum. Door may suddenly open and possibly injure someone. NOTICE: Do not drive with tank or door raised. IMPORTANT: Depressurize tank before emptying vacuum air filter canister, cleaning filter, clearing hoses or opening any doors. 1.
Vacuum and Pothole - 54 MV800 Operator’s Manual Open/Close Tank Door Close 1. Fully open door to disengage optional door lift latch (1) from pin (2). Latch cover (3) must be down for tank door to close. 2. Close door. 3. Close tank inlet valve. 4. Pull stop pin (2) up and rotate door latches toward tank. 5. Turn handles (1) clockwise until door touches seal on both sides. 6. Repeat tightening until both door latches are tight.
MV800 Operator’s Manual Complete the Job - 55 Complete the Job Chapter Contents Antifreeze Fluid Excavation Unit . . . . . . . . . . . . . 56 • Add Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 • Reclaim Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Rinse Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Complete the Job - 56 MV800 Operator’s Manual Antifreeze Fluid Excavation Unit Antifreeze Fluid Excavation Unit Add Antifreeze Follow these steps for overnight or long-term storage of unit during cold weather. 1. Fill antifreeze tank with a propylene-glycol based antifreeze. 2. Ensure that water tank valve is closed. 3. Open antifreeze tank valve. 4. Connect water pressure hose to water lance. 5. Start engine. 6. Move water pump switch to on. If freshwater tank is empty, move to bypass. 7.
MV800 Operator’s Manual Complete the Job - 57 Rinse Equipment Rinse Equipment Pressurized fluid or air could pierce skin and cause severe injury. Refer to operator’s manual for proper use. 270-6035 Spray water onto equipment to remove dirt and mud. Use water lance. Thoroughly rinse inside of tank and around door seal Confined space will cause suffocation. Use proper procedures for entering or stay away. 273-200 To help avoid injury: Enter tank only if necessary. Follow U.S.
Complete the Job - 58 MV800 Operator’s Manual Stow Tools CMW®
MV800 Operator’s Manual Service - 59 Service Chapter Contents Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . 60 Recommended Lubricants/Service Key . . . . . . . . 62 Each Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 10 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 100 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MV800 Operator’s Manual Service - 60 Service Precautions Service Precautions Read operator’s manual. Know how to use all controls. Your safety is at stake. 273-475 To help avoid injury: • Unless otherwise instructed, all service should be performed with engine off. • Refer to engine manufacturer’s manual for engine maintenance instructions. Working Under Raised Debris Tank Crushing weight. Place cylinder lock on extended cylinder and secure. 273-231 1. Raise vacuum tank. 2.
MV800 Operator’s Manual Service - 61 Service Precautions Working Under Raised Tank Door Crushing weight could cause death or serious injury. Stay away. 275-326 Standard Door Do not work under raised tank door. Hydraulic Door (Optional) 1. Raise tank door. 2. Ensure latch engages fully. Welding Precaution NOTICE: Welding can damage electronics. • Disconnect battery to prevent damage to battery.
MV800 Operator’s Manual Service - 62 Recommended Lubricants/Service Key Recommended Lubricants/Service Key Item Description GEO Gasoline engine oil meeting API service classification CF-4 or E1-96 and SAE viscosity recommended by engine manufacturer (SAE 15W40) SGL Synthetic gear oil (ISO 100), cmw p/n 256-044 MPG Multipurpose grease meeting ASTM D217 and NLGI 5 HTG High temperature, NLGI #2 premium grade, petroleum-based grease with high temperature resistance and good mechanical stability NDO
MV800 Operator’s Manual Service - 63 Recommended Lubricants/Service Key Engine Oil Temperature Chart SAE 30 SAE 10W-30 SAE 5W-30 Synthetic SAE 5W-30 F -20 C -30 -20 0 10 20 0 40 10 60 20 80 30 100 40 j32om079t.eps Temperature range anticipated before next oil change IMPORTANT: If temperature is below 40°F (4°C), using SAE 30 will result in hard starting. If temperature is above 80°F (27°C), using 10W-30 can cause increased oil consumption. Check oil level more frequently.
MV800 Operator’s Manual Service - 64 Each Use Each Use Location Task Notes Trailer Check torque of hitch bolts and verify proper hitch height 160 ft•lb (217 N•m) Check tire pressure and lug nut torque 80 psi (5.5 bar); 90-120 ft•lb (122-163 N•m) Check lights and reflectors Trailer Check Hitch Bolts and Verify Proper Hitch Height Check that trailer hitch bolts are properly tightened. Tighten bolts to 160 ft•lb (217 N•m).
MV800 Operator’s Manual Service - 65 Each Use Check Trailer Lights and Reflectors Check lights and reflectors for correct operation and cleanliness.
MV800 Operator’s Manual Service - 66 10 Hour 10 Hour Location Task VACUUM SYSTEM Check engine air filter service indicator Check engine oil level Notes GEO Check hydraulic hoses Check hydraulic fluid level THF Check blower oil level SGL Check blower belt tension Check water pump oil level Clean water pump filter Check tension of water pump belts Clean vacuum air filter Check spray nozzle Drain vacuum air filter canister DEBRIS TANK Check strobe light Check vacuum tank door seals/fittings Check
MV800 Operator’s Manual Service - 67 10 Hour Vacuum System Check Engine Air Filter Check air filter every 10 hours. Press dust ejector valve to release dust. Change air filter elements when air filter restriction indicator (1) reaches the red zone. NOTICE: Only open the air filter canister when air restriction is indicated. Change the elements, do not attempt to clean them. • Compressed air or water may damage filter element. • Tapping filter elements to loosen dirt may damage the element. .
MV800 Operator’s Manual Service - 68 10 Hour Check Hydraulic Hoses Pressurized fluid or air could pierce skin and cause severe injury. Refer to operator’s manual for proper use. 270-6035 To help avoid injury: • Before disconnecting a hydraulic line, turn engine off and operate all controls to relieve pressure. Lower, block, or support any raised component with a hoist. Cover connection with heavy cloth and loosen connector nut slightly to relieve residual pressure. Catch all fluid in a container.
MV800 Operator’s Manual Service - 69 10 Hour Check Hydraulic Fluid Level Check hydraulic fluid level every 10 hours. Maintain fluid level at 3/4 tank when engine is off and fluid is cool. Add THF at hydraulic fluid fill (shown) as necessary. Check Blower Oil Level With frame level, check blower oil at sight glass (3) every 10 hours. Add SGL at fill (2) as necessary to maintain oil level at halfway point on sight glass (3). Do not overfill.
Service - 70 MV800 Operator’s Manual 10 Hour Check Water Pump Oil Level With frame level, check water pump oil at sight glass (2) every 10 hours. Add NDO at fill (1) as necessary to keep oil at halfway mark on sight glass. Clean Water Pump Filter Clean water pump filter every 10 hours and replace as needed. 1. Open filter housing. 2. Remove element and rinse housing thoroughly with water. 3. Inspect element for signs of collapse and for brittle or broken rubber seals on the ends of the element.
MV800 Operator’s Manual Service - 71 10 Hour Clean Vacuum Air Filter Use breathing protection when exposed to silica dust. 270-4952 Clean filter every 10 hours or as needed. To clean filter: 1. Remove filter from canister. 2. Run low pressure water into inside of filter. NOTICE: Do not use high pressure water to clean filter. Filter will be damaged. 3. Allow filter to dry completely before returning to canister. Check Spray Nozzle Check spray nozzle every 10 hours.
Service - 72 MV800 Operator’s Manual 10 Hour Drain Vacuum Air Filter Canister IMPORTANT: Depressurize tank before emptying vacuum air filter canister, cleaning filter, clearing hoses or opening any doors. Drain canister at drain (2) every 10 hours or when water is visible in sight glass (1). Debris Tank Check Strobe Light Check strobe light for proper function every 10 hours. When ignition is on, strobe light should be flashing. Repair if necessary.
MV800 Operator’s Manual Service - 73 10 Hour Check Vacuum Tank Door Seals and Fittings Check door seal every 10 hours for wear or damage. Repair if necessary. Check for leaks and loose fittings every 10 hours. Repair or replace if necessary. Check Tank Deflector Check tank deflector every 10 hours for buildup, wear, or damage. Clean or replace as needed.
MV800 Operator’s Manual Service - 74 50 Hour 50 Hour Location Task Notes VACUUM SYSTEM Change engine oil and filter Initial service, GEO Change fuel filters Initial service Check battery Check water pressure hoses Check vacuum relief valve Lube blower bearings Change water pump oil DEBRIS TANK CMW® Lube tank pivot pins Initial service, NDO
MV800 Operator’s Manual Service - 75 50 Hour Vacuum System Change Engine Oil and Filter (Initial Service) Change engine oil and filter after 50 hours, and every 100 hours thereafter. Drain oil (4), change filter (3), and add 2.5 qt (2.3 L) of GEO at fill (2). IMPORTANT: Use oil specified in temperature chart found in “Recommended Lubricants/ Service Key” on page 62. Change Fuel Filter (Initial) Replace filter after the first 50 hours of operation, and every 100 hours thereafter. 1. Remove filter. 2.
Service - 76 MV800 Operator’s Manual 50 Hour Check Battery Keep battery clean and free of corrosion. Apply coat of grease to cable clamps after cleaning. In cold weather, battery loses some starting ability. Closely watch voltmeter for signs of battery discharge. If battery will not hold charge, see your Ditch Witch® dealer for replacement battery. IMPORTANT: Use battery disconnect switch when servicing, welding, and during long-term storage.
MV800 Operator’s Manual Service - 77 50 Hour Lube Blower Bearings Wipe two zerks clean and lube every 50 hours with HTG. Inject grease into zerk until clean grease comes out of relief fittings. NOTICE: Do not inject grease too quickly. Drive shaft seal damage could occur. Change Water Pump Oil Change oil after the first 50 hours of operation and every 100 hours thereafter. Change oil more frequently if working in dusty conditions. • Drain at drain plug (3) while oil is warm.
MV800 Operator’s Manual Service - 78 100 Hour 100 Hour Location Task Notes VACUUM SYSTEM Change engine oil and filter GEO Change fuel filters Change blower oil initial service, SGL Change hydraulic fluid DC unit initial service, THF Change water pump oil NDO Vacuum System Change Engine Oil and Filter (Regular Service) Change engine oil and filter every 100 hours. Drain oil (4), change filter (3), and add 2.5 qt (2.3 L) of GEO at fill (2).
MV800 Operator’s Manual Service - 79 100 Hour Change Fuel Filter Replace filter every 100 hours. 1. Remove filter. 2. Install new filter. Apply fuel oil thinly over the gasket and hand-tighten. Change Blower Oil Change oil after the first 100 hours of operation, and every 1000 hours thereafter. Change oil more frequently if working in dusty conditions. • Drain at drain plug (4) while oil is warm. • Add SGL at fill (2) until oil is at halfway point on sight glass (3).
Service - 80 MV800 Operator’s Manual 100 Hour Change Hydraulic Fluid Change hydraulic fluid after the first 100 hours, and every 1000 hours thereafter. Drain hydraulic fluid (2), add THF at hydraulic fluid fill (1) and check level. Change Water Pump Oil Change oil after the first 25 hours of operation and every 100 hours thereafter. Change oil more frequently if working in dusty conditions. • Drain at drain plug (3) while oil is warm.
MV800 Operator’s Manual Service - 81 1000 Hour 1000 Hour Location Task Notes VACUUM SYSTEM Change blower oil SGL Change hydraulic fluid THF Vacuum System Change Blower Oil Change oil every 1000 hours. Change oil more frequently if working in dusty conditions. • Drain at drain plug (4) while oil is warm. • Add SGL at fill (2) until oil is at halfway point on sight glass (3). Change Hydraulic Fluid Change hydraulic fluid every 1000 hours.
MV800 Operator’s Manual Service - 82 2000 Hour 2000 Hour Location Task VACUUM SYSTEM Replace water pump belts Replace blower belt Vacuum System Replace Water Pump Belts Replace belt every 2000 hours. Replace Blower Belt Replace belt every 2000 hours.
MV800 Operator’s Manual Service - 83 As Needed As Needed Location Task VACUUM SYSTEM Change water pump filter Notes Lube blower for longterm storage Change blower relief air filter Check battery DEBRIS TANK Clean primary shutoff valve Vacuum System Change Water Pump Filter 1. Open filter housing. 2. Remove element and rinse housing thoroughly with clean water. 3. Install new element and close filter housing.
Service - 84 MV800 Operator’s Manual As Needed Change Blower Relief Air Filter Check air filter whenever vacuum gauge goes over 16” (406 mm) of mercury. Change as needed. NOTICE: Operating system above 16” (406 mm) of mercury may result in blower damage. 1. Remove clamp. 2. Remove filter and discard. 3. Install new filter. 4. Replace clamp. Lube Reverse Flow 4-Way Valve Lube reverse flow 4-way valve at zerk (shown) with MPG as needed.
MV800 Operator’s Manual Service - 85 As Needed Check Battery Check battery as needed. Keep battery clean and terminals free of corrosion. To clean: 1. Turn battery disconnect switch, if equipped, to the off position. 2. Ensure that no ignition sources are near batteries. 3. Loosen and remove battery cable clamps carefully, negative (-) cable first. 4. Clean cable clamps and terminals to remove dull glaze. 5. Check for signs of internal corrosion in cables. 6.
MV800 Operator’s Manual Service - 86 As Needed Charge Battery Explosion possible. Serious injury or equipment damage could occur. Follow directions carefully. To help avoid injury: • Use a single 12V maximum source for charging. Do not connect to rapid chargers or dual batteries. • Use caution and wear personal protective equipment such as safety eyewear, when charging or cleaning battery. • Keep sparks, flames, and any ignition source away from batteries at all times.
MV800 Operator’s Manual Service - 87 As Needed Charging Procedure (Engine Off) 1. Park service vehicle close to disabled equipment but do not allow vehicles to touch. Engage parking brake in both vehicles. 2. Turn the ignition switch to the OFF position in both vehicles, and turn off all electrical loads. Disconnect the machine controller. 3. Inspect battery in disabled vehicle (B) for signs of cracking, bulging, leaking, or other damage.
Service - 88 MV800 Operator’s Manual As Needed Debris Tank Clean Primary Shut-off Valve Clean primary shut-off valve as needed. Replace primary shut-off valve as needed. To clean: 1. Open tank door. See “Drain Tank” on page 48. 2. Spray valve housing inside vacuum tank with high-pressure water. 3. Store water pressure hose. 4. Close tank door. See “Drain Tank” on page 48. To remove: 1. Remove nuts and bolts (1). 2. Remove cover (2). 3. Remove ball (3). 4. Clean ball and housing with high-pressure water.
MV800 Operator’s Manual Service - 89 200 Mile 200 Mile Trailer Adjust Electric Brakes (Initial) Adjust brakes after 200 miles (320 km). 1. Place adequate jack stands under frame rails and remove wheels. 2. Remove cover from adjusting slot on bottom of backing plate. 3. Rotate adjuster starwheel with screwdriver or brake spoon to expand brake shoes. Adjust until drum is very difficult to turn by hand. 4. Rotate starwheel the other direction until drum turns with slight drag. 5.
Service - 90 MV800 Operator’s Manual 3000 Mile 3000 Mile Trailer Adjust Electric Brakes Adjust brakes every 3000 miles (5000 km). 1. Place adequate jack stands under frame rails and remove wheels. 2. Remove cover from adjusting slot on bottom of backing plate. 3. Rotate adjuster starwheel with screwdriver or brake spoon to expand brake shoes. Adjust until drum is very difficult to turn by hand. 4. Rotate starwheel the other direction until drum turns with slight drag. 5.
MV800 Operator’s Manual Service - 91 12,000 Mile 12,000 Mile Location Task Trailer Inspect brake shoes and linings Notes Adjust and lubricate bearings Trailer Inspect Brake Shoes and Linings Inspect shoes and linings every 12 months or 12,000 miles (20 000 km) for wear. When lining is worn to 1/16” (2 mm) or less, replace linings. Replace shoe and lining if contaminated by oil.
Service - 92 MV800 Operator’s Manual 12,000 Mile Adjust and Lubricate Bearings 1. Place adequate jack stands under frame rails and remove wheels. 2. Unscrew grease cap (11) while holding the hub stationary. 3. Bend locking tang (14) down from outer spindle nut (13) and remove spindle nut (3). 4. Remove tang washer, unscrew inner spindle nut and remove spindle washer (16). 5. Remove hub from spindle. Do not drop outer bearing cone. 6. Pry seal (2) from hub and remove inner bearing cone (3). 7.
MV800 Operator’s Manual Specifications - 93 Specifications Dimensions U.S. Metric L Length, T14MV trailer 208 in 5.2 m H Height 91.5 in 2.3 m W Width 96.5 in 2.5 m Empty 4995 lb 2265 kg Full 10,840 lb 4917 kg Empty 5590 lb 2536 kg Full water tank, empty vac tank 6425 lb 2914 kg Empty water tank, full (water) vac tank 11,670 lb 5294 kg Full water tank, full (water) vac tank 12,510 lb 5675 kg Vac Tank U.S. Metric Capacity 730 gal 2763 L Length 98 in 2.
Specifications - 94 Engine MV800 Operator’s Manual U.S. Metric Briggs & Stratton® Vanguard, gasoline Cooling medium air Aspiration natural Number of cylinders 2 Displacement 54.68 in3 896 cc Bore 3.37 in 86 mm Stroke 3.07 in 78.5 mm Engine manufacturer’s gross power rating (per SAE J1940) 31 hp 23.1 kW Rated engine speed 3600 rpm 3600 rpm Hydraulic system U.S. Metric Pressure 2500 psi 172 bar Drive type 12V DC Tank lift cylinder size (2) 2.5 in 63.
MV800 Operator’s Manual Specifications - 95 Water system U.S. Metric Maximum pressure 3000 psi 207 bar Flow 4 gpm 15.1 L/min Hose reel capacity (locking) 50 ft 15.2 m Antifreeze 50/50 water/antifreeze mix Clutch type electric with auto de-clutch Fluid capacities U.S. Metric Engine oil with filter 4.2 qt 4L Fuel tank 6.9 gal 26.1 L Vacuum pump 1.5 qt 1.4 L Hydraulic reservoir 2.0 gal 7.6 L Water pump 41 oz 1.
Specifications - 96 T14MV Trailer MV800 Operator’s Manual U.S. Metric Clearance (at jack foot pad) 13 in 330 mm Adj. coupler height 18-26 in 457-660 mm Width between fenders 76 in 1.9 m Width outside fenders 96 in 2.4 m Number of axles 2 Coupler (square mount drawbar) 3 in or 2.5 in Type of brakes electric Lug nut torque 90-120 ft•lb 122-163 N•m Hitch bolt torque 160 ft•lb 217 N•m Electrical system 12V DC LT215/85R16 load range E 80 psi 5.
MV800 Operator’s Manual Support - 97 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.
MV800 Operator’s Manual Warranty - 98 Warranty Ditch Witch® Equipment and Replacement Parts Limited Warranty Policy Subject to the limitation and exclusions herein, free replacement parts will be provided at any authorized Ditch Witch dealership for any Ditch Witch equipment or parts manufactured by The Charles Machine Works, Inc. (CMW) that fail due to a defect in material or workmanship within one (1) year of first commercial use.
MV800 Operator’s Manual Service Record - 101 Service Record Service Performed Date Hours CMW®
Service Record - 102 Service Performed CMW® MV800 Operator’s Manual Date Hours
MV800 Operator’s Manual Appendix - 103 Appendix Chapter Contents Tire Safety Information CMW®
TIRE SAFETY INFORMATION 1.1. STEPS FOR DETERMINING CORRECT LOAD LIMIT – TRAILER Determining the load limits of a trailer includes more than understanding the load limits of the tires alone. On all trailers there is a Federal certification/VIN label that is located on the forward half of the left (road) side of the unit. This certification/VIN label will indicate the trailer’s Gross Vehicle Weight Rating (GVWR). This is the most the fully loaded trailer can weigh.
The Tire Information Placard is attached adjacent to or near the trailer’s VIN (Certification) label at the left front of the trailer. 1.1.2. TRAILERS OVER 10,000 POUNDS GVWR (NOTE: These trailers are not required to have a tire information placard on the trailer.) 1. Determine the empty weight of your trailer by weighing the trailer using a public scale or other means. This step does not have to be repeated. 2.
Innerliner separation - the parting of the innerliner from cord material in the carcass. Light truck (LT) tire - a tire designated by its manufacturer as primarily intended for use on lightweight trucks or multipurpose passenger vehicles. Load rating - the maximum load that a tire is rated to carry for a given inflation pressure. Maximum load rating - the load rating for a tire at the maximum permissible inflation pressure for that tire.
1.4. TIRE SAFETY - EVERYTHING RIDES ON IT The National Traffic Safety Administration (NHTSA) has published a brochure (DOT HS 809 361) that discusses all aspects of Tire Safety, as required by CFR 575.6. This brochure is reproduced in part below. It can be obtained and downloaded from NHTSA, free of charge, from the following web site: http://www.nhtsa.dot.gov/cars/rules/TireSafety/ridesonit/tires_index.
1.5.2. UNDERSTANDING TIRE PRESSURE AND LOAD LIMITS Tire inflation pressure is the level of air in the tire that provides it with load-carrying capacity and affects the overall performance of the trailer. The tire inflation pressure is a number that indicates the amount of air pressure– measured in pounds per square inch (psi) or kilopascals (kpa) –a tire requires to be properly inflated.
1.5.5. TIRE SIZE To maintain tire safety, purchase new tires that are the same size as the trailer's original tires or another size recommended by the manufacturer. Look at the tire information placard, the owner's manual, or the sidewall of the tire you are replacing to find this information. If you have any doubt about the correct size to choose, consult with your dealer. 1.5.6.
1.5.9.2. Information on Light Truck Tires Please refer to the diagram below. Tires for light trucks have other markings besides those found on the sidewalls of passenger tires. LT - indicates the tire is for light trucks or trailers. ST - indicates the tire is for trailer use only. Max. Load Dual kg (lbs) at kPa (psi) Cold - indicates the maximum load and tire pressure when the tire is used as a dual, that is, when four tires are put on each axle. Max.
