CMW | HT220 | Operator`s manual | CMW HT220 Operator`s manual

HT220
Operator’s
Manual
CMW®
Issue 2.0
Original Instruction
053-1292
HT220 Operator’s Manual
Overview - 2
Overview
Chapter Contents
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . 3
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Equipment Modification . . . . . . . . . . . . . . . . . . . . . . 4
Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operator Orientation. . . . . . . . . . . . . . . . . . . . . . . . . 6
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 6
•
Bulleted Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
•
Numbered Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
•
“Continued” Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CMW
HT220 Operator’s Manual
Overview - 3
Serial Number Location
Serial Number Location
Record serial numbers and date of purchase in spaces provided. HT220 serial number is located as
shown.
Date of manufacture
Date of purchase
HT220 serial number
Engine serial number
CMW
HT220 Operator’s Manual
Overview - 4
Intended Use
Intended Use
The HT220 is a large track trencher designed dig trenches up to 24” (609 mm)wide and 96” (2.44 m) deep.
The trencher’s hard metal teeth remove very hard, rocky ground and thinly crush it. The result is an even,
rectangular-shaped trench ready for laying pipes or cables.
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.
The HT220 should be used with genuine Ditch Witch chain, teeth, and sprockets. It should be operated,
serviced, and repaired only by persons familiar with its 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.
CMW
HT220 Operator’s Manual
Overview - 5
Unit Components
Unit Components
1. engine compartment
6. trench cleaner
2. operator’s station
7. stabilizer
3. hydraulic reservoir
8. digging boom
4. fuel tank
9. trench cleaner shoe
5. conveyor
CMW
HT220 Operator’s Manual
Overview - 6
Operator Orientation
Operator Orientation
1. Front of unit
3. Rear of unit
2. Right of unit
4. Left of unit
Operator faces the left side of the unit while
operating the controls.
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.
CMW
Overview - 7
HT220 Operator’s Manual
About This Manual
CMW
HT220 Operator’s Manual
Foreword - 8
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. If you need assistance in locating a
dealer, visit our website at www.ditchwitch.com or write to the following address:
The Charles Machine Works, Inc.
Attn: Marketing Department
PO Box 66
Perry, OK 73077-0066
USA
The descriptions and specifications in this manual are subject to change without notice. The Charles
Machine Works, Inc. reserves the right to improve equipment. Some product improvements may have
taken place after this manual was published. For the latest information on Ditch Witch equipment, see your
Ditch Witch dealer.
Thank you for buying and using Ditch Witch equipment.
CMW
HT220 Operator’s Manual
Foreword - 9
HT220 Tier 3
Operator’s Manual
Issue number 2.0/OM-09/11
Part number 053-1292
Copyright 2008, 2009, 2010, 2011
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.
CMW
HT220 Operator’s Manual
Contents - 10
Contents
Overview
2
Foreword
8
Safety
12
Controls
22
Operation Overview
46
Prepare
48
Drive
54
Transport
62
Trench
70
Systems and Equipment
74
Complete the Job
78
Service
80
machine serial number, information about the type of work this machine is designed
to perform, basic machine components, and how to use this manual
part number, revision level, and publication date of this manual, and factory contact
information
machine safety alerts and emergency procedures
machine controls, gauges, and indicators and how to use them
an overview for completing a job with this machine: planning, setting up, installing
product, and restoring the jobsite; with cross references to detailed procedures
procedures for inspecting and classifying the jobsite, planning the installation path,
and preparing the jobsite for work
procedures for startup, cold start, driving, and shutdown
procedures for lifting, hauling, and towing
procedures for trenching
chain, teeth, sprockets, and optional equipment
procedures for backfilling and restoring the jobsite and rinsing and storing
equipment
service intervals and instructions for this machine including lubrication, replacement
of wear items, and basic maintenance
CMW
Contents - 11
HT220 Tier 3 Operator’s Manual
Specifications
120
Support
97
Service Record
130
machine specifications including weights, measurements, power ratings, and fluid
capacities
the warranty policy for this machine, and procedures for obtaining warranty
consideration and training
a record of major service performed on the machine
CMW
HT220 Operator’s Manual
Safety - 12
Safety
Chapter Contents
Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety Alert Classifications . . . . . . . . . . . . . . . . . . 14
Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Emergency Procedures . . . . . . . . . . . . . . . . . . . . . 18
•
Electric Strike Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
•
If an Electric Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
•
If a Gas Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
•
If a Fiber Optic Cable is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
•
If Machine Catches on Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
CMW
Safety - 13
HT220 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 from your Ditch Witch dealer.
•
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 may be present.
•
Contact your Ditch Witch dealer if you have any question about operation, maintenance, or equipment
use.
CMW
HT220 Operator’s Manual
Safety - 14
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.
serious injury.
serious injury.
indicates an imminently hazardous situation which, if not avoided, will result in death or
indicates a potentially hazardous situation which, if not avoided, could result in death or
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.
CMW
HT220 Operator’s Manual
Safety - 15
Safety Alerts
Safety Alerts
away.
Moving digging teeth will kill you or cut off arm or leg. Stay
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.
CMW
HT220 Operator’s Manual
Safety - 16
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.
Fall possible. Riders can fall from machine and be injured or killed. Only
operator is allowed on machine.
Rollover possible. If machine rolls over, you could be thrown from seat and
killed or crushed. Wear seat belt.
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.
CMW
HT220 Operator’s Manual
Safety - 17
Safety Alerts
Moving traffic - hazardous situation. Death or serious injury could result.
Avoid moving vehicles, wear high visibility clothing, post appropriate warning signs.
Hot pressurized cooling system fluid could cause serious burns. Allow to
cool before servicing.
Flying objects may cause injury. Wear hard hat and safety glasses.
Hot parts may cause burns. Do not touch until cool.
protection.
Exposure to high noise levels may cause hearing loss. Wear hearing
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).
CMW
HT220 Operator’s Manual
Safety - 18
Emergency Procedures
Emergency Procedures
Jobsite hazards could cause death or serious injury. Use
correct equipment and work methods. Use and maintain proper safety
equipment.
Before operating any equipment, review emergency procedures and check that all safety precautions have
been taken.
EMERGENCY SHUTDOWN - Turn ignition switch to stop position or push emergency engine stop
button (if equipped).
Electric Strike Description
Electric shock. Contacting electric lines will cause death or serious injury.
Know location of lines and stay away.
When working near electric cables, remember the following:
•
Electricity follows all paths to ground, not just path of least resistance.
•
Pipes, hoses, and cables will conduct electricity back to all equipment.
•
Low voltage current can injure or kill. Many work-related electrocutions result from contact with less
than 440 volts.
Most electric strikes are not noticeable, but indications of a strike include:
•
power outage
•
smoke
•
explosion
•
popping noises
•
arcing electricity
If any of these occur, assume an electric strike has occurred.
CMW
Safety - 19
HT220 Operator’s Manual
Emergency Procedures
If an Electric Line is Damaged
If you suspect an electric line has been damaged and you are on tractor, DO NOT MOVE. Remain on
tractor 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 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 tractor, DO NOT TOUCH TRACTOR.
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.
CMW
HT220 Operator’s Manual
Safety - 20
Emergency Procedures
If a Gas Line is Damaged
Fire or explosion possible. Fumes could ignite and cause burns. No
smoking, no flame, no spark.
Explosion possible. Serious injury or equipment damage could occur.
Follow directions carefully.
If you suspect a gas line has been damaged, take the following actions. The order and degree of action will
depend on the situation.
•
Immediately shut off engine(s), if this can be done safely and quickly.
•
Remove any ignition source(s), if this can be done safely and quickly.
•
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.
CMW
Safety - 21
HT220 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.
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.
CMW
HT220 Operator’s Manual
Controls - 22
Controls
Chapter Contents
Center Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
•
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
•
Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
•
Trenching Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
•
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
•
Drive Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Diagnostic Display . . . . . . . . . . . . . . . . . . . . . . . . . 38
Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Top Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Engine Compartment . . . . . . . . . . . . . . . . . . . . . . . 43
Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
CMW
HT220 Operator’s Manual
Controls - 23
Center Console
Center Console
Switches
1. Throttle
4. Light Switch
2. Engine Ignition Switch
5. Horn
3. Low Hydraulic Fluid Test Switch
Item
Description
1. Throttle
To increase throttle, turn knob
counterclockwise.
To idle, push knob in.
CMW
Notes
HT220 Operator’s Manual
Controls - 24
Center Console
Item
Description
2. Engine ignition switch
To start engine, insert key and
turn clockwise.
Notes
To stop engine, turn
counterclockwise.
3. Low hydraulic fluid test
switch
To check for low hydraulic
fluid, move to down position.
4. Light switch
To turn on lights, move to up
position.
Switch is normally centered.
To turn off lights, move to
down position.
5. Horn
To sound horn, press.
CMW
HT220 Operator’s Manual
Controls - 25
Center Console
Indicators
1. Maintenance indicator
6. Left track filter indicator
2. Wait to start indicator
7. Double filter indicator
3. Warning ignition “ON” indicator
8. Right track filter indicator
4. Low hydraulic fluid indicator
9. Single filter indicator
5. Air filter indicator
10. Digging filter indicator
Item
Description
1. Maintenance indicator
Light comes on when the
engine needs maintenance.
CMW
Notes
HT220 Operator’s Manual
Controls - 26
Center Console
Item
Description
2. Wait to start indicator
Light goes out when engine is
ready to start.
3. Warning ignition “On”
indicator
Buzzer sounds when engine
is not running and the ignition
switch is on.
4. Low hydraulic fluid
indicator
Light comes on when low fluid
switch is pressed and fluid is
low.
5. Air filter indicator
Light comes on when the air
filter is dirty.
Notes
CMW
HT220 Operator’s Manual
Controls - 27
Center Console
Item
Description
6. Left track filter indicator
Light comes on when the left
track filter needs replacing.
7. Double filter indicator
Light comes on when the
double filter needs replacing.
8. Right track filter
indicator
Light comes on when the right
track filter needs replacing.
9. Single filter indicator
Light comes on when the
single filter needs replacing.
10. Digging filter indicator
Light comes on when the
digging filter needs replacing.
CMW
Notes
HT220 Operator’s Manual
Controls - 28
Center Console
Trenching Controls
1. Conveyor shift control
7. Stabilizer control
2. Conveyor direction control
8. Auto stabilizer control
3. Conveyor control (truck option)
9. Boom lift control
4. Conveyor speed control (truck option)
10. Cruise control set control
5. Conveyor speed control
11. Trencher drive control
6. Trench cleaner control
Item
Description
1. Conveyor shift control
To shift left, move to up
position.
Notes
To shift right, move to down
position.
CMW
HT220 Operator’s Manual
Controls - 29
Center Console
Item
Description
2. Conveyor direction
control
To dump spoil to the right,
move to up position.
Notes
To dump spoil to the left,
move to down position.
3. Conveyor direction
control (truck option)
To dump spoil to the right,
move to up position.
Optional
To dump spoil to the left,
move to down position.
4. Conveyor speed control
(truck option)
To increase conveyor belt
speed, turn clockwise.
To decrease conveyor belt
speed, turn counterclockwise.
5. Conveyor speed control
To increase conveyor belt
speed, turn clockwise.
To decrease conveyor belt
speed, turn counterclockwise.
CMW
Optional
HT220 Operator’s Manual
Controls - 30
Center Console
Item
Description
6. Trench cleaner control
To raise trench cleaner, move
to up position.
Notes
To lower trench cleaner, move
to down position.
7. Stabilizer control
To raise stabilizers, move to
up position.
To lower stabilizers, move to
down position.
8. Auto stabilizer control
For automatic stabilizers,
move to up position.
For manual stabilizers, move
to down position.
9. Boom lift control
To raise boom, move to up
position.
To lower boom, move to down
position.
10. Cruise control set
control
To set cruise control, turn
knob.
CMW
HT220 Operator’s Manual
Controls - 31
Center Console
Item
Description
11. Trencher drive control
To rotate trencher forward,
move up.
To rotate trencher backward,
move down.
CMW
Notes
HT220 Operator’s Manual
Controls - 32
Center Console
Gauges
1. Diagnostic display gauge
5. Fuel gauge
2. Hydraulic fluid temperature gauge
6. Trencher pressure gauge
3. Left track pressure gauge
7. Equipment system pressure gauge
4. Right track pressure gauge
Item
Description
Notes
1. Diagnostic Display
Gauge
Digital display monitors
engine functions.
See “Top Console” on page 41.
CMW
HT220 Operator’s Manual
Controls - 33
Center Console
Item
Description
Notes
2. Hydraulic fluid
temperature gauge
Displays hydraulic fluid
temperature.
Do not exceed 190° F (88° C). Stop
engine and wait until cool.
3. Left track pressure
gauge
Displays hydraulic fluid
pressure at the left track.
If pressure exceeds 5,000 PSI (344
bar), stop engine and have unit
repaired.
4. Right track pressure
gauge
Displays hydraulic fluid
pressure at the right track.
If pressure exceeds 5,000 PSI (344
bar), stop engine and have unit
repaired.
5. Fuel gauge
Displays fuel level in tank.
Use only #2 diesel fuel.
Fuel tank holds 114 gal (431 L).
CMW
HT220 Operator’s Manual
Controls - 34
Center Console
Item
Description
Notes
6. Trencher pressure
gauge
Displays hydraulic fluid
pressure at the trencher.
If pressure exceeds 5,000 PSI (344
bar) stop engine and have unit
repaired.
7. Equipment system
pressure gauge
Displays hydraulic system
pressure.
If pressure exceeds 2,500 PSI (172
bar) stop engine and have unit
repaired.
CMW
HT220 Operator’s Manual
Controls - 35
Center Console
Drive Controls
1. Cruise control switch
6. Direction control
2. Sensitivity control
7. Radius control
3. auto - manual switch
8. Emergency engine stop
4. Ground drive speed
9. Parking brake
5. Steering control
Item
Description
1. Cruise control switch
To position cruise control to
low, move to up position.
To position cruise control to
medium, move to down
position.
To position cruise control to
high, move to center position.
CMW
Notes
HT220 Operator’s Manual
Controls - 36
Center Console
Item
Description
2. Sensitivity control
To decrease sensitivity, turn
left.
Notes
To increase sensitivity, turn
right.
3. Auto - manual switch
To engage cruise control,
move to up position.
To disengage cruise control,
move to down position.
4. Ground drive speed
To drive in high range, move
to up position.
To drive in low range, move to
down position.
5. Steering control
To steer machine left, move
up.
Detent lever is normally centered.
To steer machine right, move
down.
6. Direction control
To move machine forward,
move up.
Detent lever is normally centered.
To move machine backward,
move down.
CMW
HT220 Operator’s Manual
Controls - 37
Center Console
Item
Description
7. Radius control
To increase pressure on the
left track, turn knob to left.
Notes
To increase pressure on the
right track, turn knob to the
right.
To equalize pressure, turn
knob to center.
8. Emergency engine stop
To stop engine, press button.
To reset emergency stop, turn
switch to the right.
9. Parking brake
To engage brake, move to up
position.
To disengage brake, move to
down position.
CMW
Do not use emergency engine stop to
stop engine on a regular basis.
HT220 Operator’s Manual
Controls - 38
Diagnostic Display
Diagnostic Display
1. Enter key
3. Menu key
2. Arrow keys
Item
Description
1. Enter key
To select the highlighted
parameter on the screen,
press the ENTER key.
Notes
CMW
HT220 Operator’s Manual
Controls - 39
Diagnostic Display
Item
Description
2. Arrow keys
To scroll through the screen
toward the right or downward,
press the Right Arrow key.
To scroll through the screen
toward the left or upward,
press the Left Arrow key.
3. Menu key
CMW
To enter or exit the menu
screens, press the Menu key.
Notes
HT220 Operator’s Manual
Controls - 40
Seat
Seat
1. Seat slide control
3. Seat belt
2. Seat swivel control
Item
Description
1. Seat swivel control
To slide seat, move control
away from seat.
2. Seat slide control
To swivel seat, move control
toward back of seat.
3. Seat belt
To fasten, insert latch into
buckle. Adjust until seat belt
is low and tight.
Notes
To release, lift top of buckle.
CMW
HT220 Operator’s Manual
Controls - 41
Top Console
Top Console
1. Fan power control
7. Temperature control
2. Ext
8. Cab light switch
3. Climate control circuit breaker
9. Defrost
4. Display
10. Auto
5. Cab pressurizer switch
11. On
6. Econ
12. Off
Item
Description
1. Fan power control
To raise the rate of air flow,
press control up.
To lower the rate of air flow,
press control down.
2. EXT control
CMW
To change temperature
display from Fahrenheit to or
from Celsius, press.
Notes
HT220 Operator’s Manual
Controls - 42
Top Console
Item
Description
3. Climate control circuit
breaker
Press to reset climate control.
4. Display
Displays climate control
temperature setting.
5. Cab pressurizer switch
To pressurize cab, move
switch up.
Notes
To depressurize cab, move
switch down.
6. Econ
To conserve energy, press
once.
7. Temperature control
To raise temperature, press
up.
To lower temperature, press
down.
8. Cab light switch
To turn cab light on, turn
switch to the ON position.
To turn cab light off, turn
switch to the OFF position.
9. Defrost
To start defrost, press once.
To stop defrost, press twice.
10. Auto
To adjust temperature
automatically, press.
To adjust temperature
manually, press again.
11. On
To turn climate control on,
press.
12. Off
To turn climate control off,
press.
CMW
HT220 Operator’s Manual
Controls - 43
Engine Compartment
Engine Compartment
1. Master disconnect (24V)
3. Coolant Delivery Valve
2. Master disconnect (0V)
Item
Description
1. Circuit breaker lever
To connect the battery to the
electrical system, rotate
clockwise.
To disconnect the battery
from the electrical system,
rotate counterclockwise.
2. Master disconnect (0V)
To connect the battery to the
electrical system, rotate
clockwise.
To disconnect the battery
from the electrical system,
rotate counterclockwise.
CMW
Notes
HT220 Operator’s Manual
Controls - 44
Engine Compartment
Item
Description
Notes
3. Coolant delivery valve
To turn heater ON, turn valve
inline.
Ensure that air conditioner switch is in
the ‘OFF’ position before opening the
heater valves.
To turn heater OFF, turn valve
perpendicular.
CMW
HT220 Operator’s Manual
Controls - 45
Emergency Stop
Emergency Stop
1. Emergency engine stop button
2. Operator alert button
Item
Description
Notes
1. Emergency engine stop
button
To stop machine immediately,
press button.
To release the stop function, the
button must be pulled “out” or twisted
clockwise to the “out” position. The
switches must be reset in order for the
engine to start.
Do not use emergency engine stop to
stop engine on a regular basis.
2. Operator alert button
CMW
To alert operator of one’s
presence or danger, press
button.
HT220 Operator’s Manual
Operation Overview - 46
Operation Overview
Chapter Contents
Planning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Trenching. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Leaving Jobsite. . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
CMW
Operation Overview - 47
HT220 Operator’s Manual
Planning
Planning
1. Gather information about jobsite. See page 49.
2. Inspect jobsite. See page 50.
3. Classify jobsite. See page 51.
4. Select chain and teeth to match your soil type, if necessary. See page 75.
5. Check supplies and prepare equipment. See page 53.
6. Haul equipment to jobsite. See page 66.
Trenching
1. Start unit. See page 55.
2. Position tractor and controls. See page 71.
3. Begin trenching. See page 72.
4. Complete the installation. See page 72.
5. Shut down tractor. See page 59.
Leaving Jobsite
1. Rinse equipment. See page 79.
2. Stow tools. See page 79.
3. Haul equipment away from jobsite. See page 66.
CMW
HT220 Operator’s Manual
Prepare - 48
Prepare
Chapter Contents
Gather Information . . . . . . . . . . . . . . . . . . . . . . . . . 49
•
Review Job Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
•
Notify One-Call Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
•
Arrange for Traffic Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
•
Plan for Emergency Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Inspect Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
•
Identify Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Classify Jobsite. . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
•
Inspect Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
•
Select a Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
•
Apply Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Check Supplies and Prepare Equipment . . . . . . . 53
•
Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
•
Fluid Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
•
Condition and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
•
Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
CMW
Prepare - 49
HT220 Operator’s Manual
Gather Information
Gather Information
A successful job begins before you dig. The first 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 existing or planned structures, elevations, or
proposed work that may be taking place at the same time.
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.
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.
CMW
HT220 Operator’s Manual
Prepare - 50
Inspect Site
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 51.)
•
traffic
•
access
•
soil type and condition
Identify Hazards
Identify safety hazards and classify jobsite. See “Classify Jobsite” on page 51.
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.
CMW
Prepare - 51
HT220 Operator’s Manual
Classify Jobsite
Classify 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 service by dialing 811 (USA only) to have underground utilities located. A
One-Call referral number, 888-258-0808, is also available for both the USA and Canada. You should
also call any utility companies which do not participate in the One-Call service.
•
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
•
Have an experienced locating equipment operator sweep area within 20’ (6 m) to each side of trench
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, granite, or concrete which is capable of producing
crystalline silica (quartz) dust
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 jobsite before working.
CMW
HT220 Operator’s Manual
Prepare - 52
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
Jobsite hazards could cause death or serious injury. Use correct
equipment and work methods. Use and maintain proper safety equipment.
NOTICE: Cutting, drilling or working materials such as, concrete, sand or rock containing quartz may
result in exposure to silica dust. Use water spray or other means to control dust. If workers are exposed
to dust they must wear appropriate breathing protection. Silica dust may cause lung disease and is
known to the State of California to cause cancer.
CMW
Prepare - 53
HT220 Operator’s Manual
Check Supplies and Prepare Equipment
Check Supplies and Prepare Equipment
Supplies
•
fuel
•
keys
•
personal protective equipment, such as hard hat and safety glasses
•
digging teeth
Fluid Levels
•
fuel
•
hydraulic fluid
•
battery
•
engine oil
•
transmission fluid
Condition and Function
•
digging chain and teeth
•
fan belts
•
light bulbs
•
filters (air, oil, hydraulic)
•
tracks
•
pumps and motors
•
hoses and valves
•
signs, guards, and shields
Accessories
Fire Extinguisher
Check fire extinguisher charge regularly.
CMW
HT220 Operator’s Manual
Drive - 54
Drive
Chapter Contents
Start Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
CMW
HT220 Operator’s Manual
Drive - 55
Start Unit
Start Unit
Before operating tractor, read engine manufacturer’s starting and operating instructions. Follow
instructions for new engine break-in.
Runaway possible. Machine could run over you or others. Learn how to
use all controls. Start and operate only from operator’s position.
Incorrect procedures could result in death, injury, or property damage.
Learn to use equipment correctly.
NOTICE:
•
Read operator’s manual before operating equipment. Follow instructions carefully. Contact your
Ditch Witch dealership for operation information or demonstration.
•
Wear hard hat, safety glasses, and other protective equipment required by job. Do not wear jewelry
or loose clothing that can catch on controls.
Rollover possible. If machine rolls over, you could be thrown from seat
and killed or crushed. Wear seat belt.
1. Fasten and adjust seat belt.
2. Check that all controls are in neutral before starting.
3. Check that parking brake is engaged.
4. Move throttle to half open.
CMW
HT220 Operator’s Manual
Drive - 56
Start Unit
5. Turn ignition switch to the run position (key on, engine off). Cold start wait indicator will light.
6. When cold start wait indicator goes off, turn ignition switch all the way clockwise to start tractor.
Warning alarm will sound. Indicators will light.
•
If engine does not start within 20 seconds, release the ignition switch. Allow starter to cool before
attempting to start the unit again.
•
If engine does not crank, check battery disconnect. See page 43 for battery disconnect
information.
Improper control function could cause death or serious injury. If
control does not work as described in instructions, stop machine and have it
serviced.
NOTICE: If warning alarm does not sound, have machine repaired.
7. Run engine at half-throttle or less for five minutes before operating tractor. During warm-up, check that
all controls work properly.
IMPORTANT: Some operations will not function if any controls are not in the neutral position
upon start up. If some functions do not work, turn ignition key to the off position and ensure that
all controls are in the neutral position.
CMW
HT220 Operator’s Manual
Drive - 57
Drive
Drive
EMERGENCY SHUTDOWN: Press the emergency stop button to stop.
General Operation
1. Verify that parking brake is disengaged.
2. Adjust throttle to about half way.
3. Adjust boom lift switch to raise boom.
4. Adjust the direction control lever to move unit forward or backward.
5. Adjust steering control lever to adjust the direction.
6. Change engine speed with throttle.
Moving traffic – hazardous situation. Death or serious injury could result.
Avoid moving vehicles, wear high visibility clothing, post appropriate warning signs.
NOTICE: Drive carefully in congested areas. Know machine’s clearance and turning radius.
Rollover possible – If machine rolls over, you could be thrown from seat
and killed or crushed. Wear seat belt.
NOTICE: Keep attachments low when operating on slope. Drive slowly and cautiously.
CMW
HT220 Operator’s Manual
Drive - 58
Drive
Safe Slope Operation
Tipover possible. Machine can tip over and crush you.
• Always operate with heavy end uphill.
• Drive cautiously at all times.
• Never jerk control levers. Use a steady even motion.
• Do not park unit on slope without lowering boom to the ground,
returning all controls to neutral position, shutting down unit, and applying
parking brake.
Operating safely on a slope depends upon many factors including:
•
Distribution of machine weight, including front loading and absence of load
•
Height of load
•
Even or rough ground conditions
•
Potential for ground giving way causing unplanned tilt forward, reverse or sideways
•
Nearness of ditches, ruts, stumps or other obstructions and sudden changes in slope
•
Speed
•
Turning
•
Braking performance
•
Operator skill
These varying factors make it impractical to specify a maximum safe operating angle in this manual. It is
therefore important for the operator to be aware of these conditions and adjust operation accordingly.
Maximum engine angle and braking performance are two absolute limits which must never be exceeded.
These maximums are stated below since they are design limits. These design limits usually exceed the
operating limits and must never be used alone to establish safe operating angle for variable conditions.
Maximum engine lubrication angle – 41°
Maximum service brake retarding force – equal to traction of both tracks.
Maximum secondary brake retarding force – equal to traction of one track.
Maximum park brake holding force – equal to traction of both tracks.
CMW
Drive - 59
HT220 Operator’s Manual
Shut Down
Shut Down
1. Move direction control levers to the neutral position.
2. Lower boom to ground.
3. Engage parking brake.
4. Reduce engine speed to a minimum.
5. Wait five minutes for engine to cool down.
6. Turn ignition switch to STOP.
7. Turn off the air conditioner and the lights, if on.
8. If leaving the machine unattended, remove key and lock the following: cab window, door, engine
compartment doors, tool compartment door and the tank locking caps.
CMW
HT220 Operator’s Manual
Drive - 60
Start After Emergency Stop
Start After Emergency Stop
1. Turn all panel controls in use at the moment of the emergency stop to the neutral position.
2. Turn the emergency stop push-button counterclockwise.
3. Turn the key to the start position.
4. Start the machine by following the standard procedure. See “Start Unit” on page 55.
CMW
Drive - 61
HT220 Operator’s Manual
Start After Emergency Stop
CMW
HT220 Operator’s Manual
Transport - 62
Transport
Chapter Contents
Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
•
Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
•
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
•
Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
•
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Haul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
•
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Tow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
•
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
CMW
Transport - 63
HT220 Operator’s Manual
Lift
Lift
Crushing weight. If load falls or moves it could kill or crush you. Use
proper procedures and equipment or stay away.
Incorrect procedures could result in death, injury, or property damage.
Learn to use equipment correctly.
Points
Lifting points are identified by lifting decals. Lifting at other points is unsafe
and can damage machinery.
CMW
HT220 Operator’s Manual
Transport - 64
Lift
Procedure
Tractor
Use a crane capable of supporting the equipment's size and weight. See “Specifications” on page 120.
Use indicated lift points (shown).
CMW
HT220 Operator’s Manual
Transport - 65
Tie Down
Tie Down
Incorrect procedures could result in death, injury, or property damage.
Learn to use equipment correctly.
Points
Tiedown points are identified by tiedown decals. Securing to trailer at other
points is unsafe and can damage machinery.
Procedure
Attach chains at front and rear tiedown points. Make sure chains are tight before transporting unit. Lower
boom and secure unit.
CMW
HT220 Operator’s Manual
Transport - 66
Haul
Haul
Incorrect procedures could result in death, injury, or property damage.
Learn to use equipment correctly.
NOTICE:
•
Read trailer operator’s manual before loading or transporting your machine. Incorrectly loaded
machine can slip or cause trailer sway.
•
Attach trailer to tow vehicle before loading or unloading.
•
Park, load, and unload trailer on level ground.
•
Check that unit and trailer do not exceed size or weight regulations.
•
Ensure that tow vehicle has proper tow capacity rating.
Procedure
Refer to trailer owner’s manual and local and regional laws for correct hauling procedures.
Load
Crushing weight. If load falls or moves it could kill or crush you. Use
proper procedures and equipment or stay away.
NOTICE:
•
Attach trailer to tow vehicle before loading or unloading.
•
Load and unload trailer on level ground.
•
Put manual transmission into first or reverse gear or automatic transmission into park. Turn off
ignition. Set parking brake.
•
Block trailer wheels.
•
Incorrect loading can cause trailer swaying.
Rollover possible. If machine rolls over, you could be thrown from seat
and killed or crushed. Wear seat belt.
CMW
HT220 Operator’s Manual
Transport - 67
Haul
1. Fasten and adjust seat belt.
2. Start tractor. See page 56 for proper start-up procedures.
3. Raise trenching boom, but keep it low. Move ground drive speed switch to low range.
4. Release parking brake.
5. Use speed and direction controls to slowly drive unit onto trailer until tiedown position is reached.
6. Engage parking brake.
7. Lower boom to trailer bed and turn tractor off. See page 56 for proper shutdown procedures.
8. Attach chains to tractor where tiedown decals are located. See page 65.
Unload
Crushing weight. If load falls or moves it could kill or crush you. Use
proper procedures and equipment or stay away.
NOTICE:
•
Attach trailer to tow vehicle before loading or unloading.
•
Load and unload trailer on level ground.
•
Put manual transmission into first or reverse gear or automatic transmission into park. Turn off
ignition. Set parking brake.
•
Block trailer wheels.
•
Incorrect loading can cause trailer swaying.
Rollover possible. If machine rolls over, you could be thrown from seat
and killed or crushed. Wear seat belt.
1. Lower trailer or ramps.
2. Remove chains from tiedowns.
3. Fasten and adjust seat belt.
4. Start tractor. See page 54 for proper start-up procedures.
5. Raise trencher boom, but keep it low.
6. Move ground drive speed switch to low range.
7. Disengage parking brake.
8. Use speed and direction controls to slowly back unit down trailer or ramps.
CMW
HT220 Operator’s Manual
Transport - 68
Tow
Tow
Incorrect procedures could result in death, injury, or property damage.
Learn to use equipment correctly.
Under normal conditions, tractor should not be towed. If tractor becomes disabled and towing is
necessary:
•
Do not tow for more than 200 yd (180 m).
•
Tow at less than 3 mph (4.8 km/h).
•
Use maximum towing force of 1.5 times unit weight.
Procedure
Incorrect procedures could result in death, injury, or property damage.
Learn to use equipment correctly.
Connect Tow Cables
1. Connect the tow cables or chains to the eyes on the front of the undercarriage.
2. Clevis pins may be added to the eyes to aid in the lining up of cables or chains.
3. Wrap a chain or cable around the boom, chain and baseplates.
4. Hook one tow vehicle in the front, and another in the back to aid in braking. Avoid towing over long
distances. Do not exceed 3 mph (4.8 km/h).
CMW
Transport - 69
HT220 Operator’s Manual
Tow
Disconnect Brakes
1. Block tracks to immobilize unit.
2. Disconnect the hydraulic brake hoses and cap the valve to keep contaminants out.
3. Connect a tee between the two disconnected hoses to provide equal pressure to each gearbox.
4. Connect a hand pump containing hydraulic fluid to the tee.
5. Pump to 500 psi but do not exceed 500 psi. This will release the brake.
Remove Ground Drive Motors
1. Remove the ground drive motor plates and unbolt the ground drive motor. Do not remove the hydraulic
hoses. Support the motors by placing them on the lower support or by tying them up. Do not let them
drag on the ground.
2. Tow machine slowly.
3. When towing is complete, reattach the brake line and motors so that the machine will not move after
disconnecting.
CMW
HT220 Operator’s Manual
Trench - 70
Trench
Chapter Contents
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
•
Trenching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
CMW
HT220 Operator’s Manual
Trench - 71
Setup
Setup
EMERGENCY SHUTDOWN: Press the emergency stop button to stop.
Crushing weight could cause death or serious injury. Use proper
procedures and equipment or stay away.
Jobsite hazards could cause death or serious injury. Use
correct equipment and work methods. Use and maintain proper safety
equipment.
NOTICE: Comply with all utility notification regulations before digging.
Incorrect procedures can result in death, injury, or property damage.
Learn to use equipment correctly.
1. Fasten and adjust seat belt.
2. Start tractor. See page 55 for start-up procedures.
3. Drive to starting point. Move in line with planned trench.
4. Push throttle to low.
5. Lower boom to just above ground.
6. Engage parking brake.
CMW
HT220 Operator’s Manual
Trench - 72
Operation
Operation
Jobsite hazards could cause death or serious injury. Use correct
equipment and work methods. Use and maintain proper safety equipment.
NOTICE: Cutting, drilling or working materials such as, concrete, sand or rock containing quartz may
result in exposure to silica dust. Use water spray or other means to control dust. If workers are exposed
to dust they must wear appropriate breathing protection. Silica dust may cause lung disease and is
known to the State of California to cause cancer.
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 electrocution. Expose lines by hand before
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
1. Select the desired direction and position for conveyors to run and operate them at a moderate speed.
2. Lift the trench cleaner completely.
IMPORTANT: The only function of the trench cleaner is keeping the trench bottom clean. It must
not be used for pushing or pulling anything. Make sure it does not get caught in the trench for any
reason and the shoe is free to slide on its support.
CMW
HT220 Operator’s Manual
Trench - 73
Operation
3. Place the chain operation control in the forward direction (or digging direction) at the desired speed.
Moving digging teeth will cause death or serious injury. Stay away.
NOTICE:
•
Ensure parking brake is engaged.
•
Machine might jerk when digging starts. Allow 15’ (3 m) between digging teeth and obstacle.
•
Keep everyone at least 15’ (5 m) from machine, attachments, and their range of movement.
4. Slowly lower the digging boom taking care not to stall the digging chain.
5. Release the parking brake.
6. Adjust the direction control lever to move the machine forward.
7. Ensure that the pressure values on the chain and track circuit pressure gauges do not exceed the
maximum values. See “Gauges” on page 31.
8. Operate engine at full throttle under load for most productive trenching. If soil conditions permit,
operating in this range gives longer engine life and more efficient use of available engine power.
9. If an object becomes lodged in the digging chain:
•
Move speed/direction control to neutral.
•
Raise boom slightly to clear bottom of trench.
•
Move transmission lever to reverse.
•
Chain should reverse and release object.
10. After digging enough space for the trench cleaner, lower it.
Note: When digging on slopes, it might be necessary to set the parking brake until the trencher
reaches the desired digging depth. Under such circumstances, release the parking brake before
operating the direction control.
CMW
HT220 Operator’s Manual
Systems and Equipment - 74
Systems and Equipment
Chapter Contents
Chain, Teeth, and Sprockets . . . . . . . . . . . . . . . . . 75
•
Chain and Tooth Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
•
Chain Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
•
Chain Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . 77
•
Tractor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
•
Trencher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
HT220 Operator’s Manual
Systems and Equipment - 75
Chain, Teeth, and Sprockets
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 page 118.
•
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 cutting
alternating side bar
prevents spoil compaction on chain
bolt-on adapters
allow easy configuration changes
Shark Chain II
versatile, virtually maintenance-free
combination
provides pick and shovel effect
HT220 Operator’s Manual
Systems and Equipment - 76
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
Soft Soil
Medium
Soil
Hard Soil
Rocky
Soil
Sticky
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
4
3
2
1
2
4
Shark Chain II
4
3
2
1
1
4
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
rocky soil
chunk rock, glacial till, cobble, rip rap, gravel
sticky soil
gumbo, sticky clays
Systems and Equipment - 77
HT220 Operator’s Manual
Optional Equipment
Optional Equipment
See your Ditch Witch dealer for more information about the following optional equipment.
Tractor
Equipment
Description
light kit
p/n 215-1191
window cover kit
p/n 190-1174
Trencher
Equipment
Description
truck conveyor
p/n 140-1081
carbide bit
p/n 135-1015
spade bit
p/n 135-1016
trench cleaners
restraint bar
p/n 140-1073
4’, 6’ (1.2, 1.8 m) depth
p/n 140-1074
8’ (2.4 m) depth
p/n 140-1075
4’ (1.2 m) double chain
p/n 140-1069
6’ (1.8 m) double chain
p/n 140-1071
trench cleaner shoes
shoe cleaner 12” (30.5 cm)
p/n 140-1076
shoe cleaner 14” (35.5 cm)
p/n 140-1077
shoe cleaner 16” (40.6 cm)
p/n 140-1078
shoe cleaner 18” (45.7 cm)
p/n 140-1079
shoe cleaner 24” (61 cm)
p/n 140-1080
HT220 Operator’s Manual
Complete the Job - 78
Complete the Job
Chapter Contents
Rinse Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Stow Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
CMW
Complete the Job - 79
HT220 Operator’s Manual
Rinse Equipment
Rinse Equipment
Spray water onto equipment to remove dirt and mud.
NOTICE: Do not spray water into the cab. Electrical components could be damaged. Wipe down
instead.
Stow Tools
Make sure all tools and accessories are loaded and properly secured on trailer.
CMW
HT220 Operator’s Manual
Service - 80
Service
Chapter Contents
Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . 81
Lubrication Overview . . . . . . . . . . . . . . . . . . . . . . . 82
Recommended Lubricants/Service Key . . . . . . . 84
•
Engine Oil Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
10 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
100 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
250 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
500 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1500 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
As Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
HT220 Operator’s Manual
Service - 81
Service Precautions
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 attachments to ground.
Welding Precaution
NOTICE: Welding can damage electronics.
•
Disconnect battery at battery disconnect switch before welding to prevent damage to battery.
Do not turn off battery disconnect switch with engine running or alternator and other electronic
devices may be damaged.
•
Connect welder ground clamp close to welding point and make sure no electronic components
are in the ground path.
•
Always disconnect the ECU ground connection from the frame, harness connections to the ECU,
and other electronic components prior to welding on machine or attachments.
Cleaning Precaution
NOTICE: When cleaning equipment, do not spray electrical components with water.
HT220 Operator’s Manual
Lubrication Overview
Lubrication Overview
Lubrication Overview (left)
Service - 82
Service - 83
HT220 Operator’s Manual
Lubrication Overview
Lubrication Overview (right)
HT220 Operator’s Manual
Service - 84
Recommended Lubricants/Service Key
Recommended Lubricants/Service Key
Item
Description
DEO
Diesel engine oil meeting API service classification CI-4 ALEA E5 and SAE viscosity
recommended by engine manufacturer (SAE 15W40)
MPG
Multipurpose grease meeting ASTM D217 and NLGI 5
MPL
Multipurpose gear oil meeting API service classification GL-5 (SAE 80W90)
THF
Tractor hydraulic fluid, similar to Phillips 66 HG, Mobilfluid 423, Chevron Tractor
Hydraulic Fluid, Texaco TDH Oil, or equivalent
DEAC
Cat EC-1 Extended Life Coolant (ELC)
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 extreme conditions, service machine more frequently.
Use only recommended lubricants. Fill to capacities listed in “Specifications” on page 120.
For more information on engine lubrication and maintenance, see your Cummins® engine manual.
NOTICE:
•
Use only genuine Ditch Witch parts, filters, approved lubricants, TJC, and approved coolants to
maintain warranty.
•
Use the “Service Record” on page 130 to record all required service to your machine.
HT220 Operator’s Manual
Service - 85
Recommended Lubricants/Service Key
Engine Oil Selection Chart
Select oil based on ambient temperature range expected before next oil change.
Approved Fuel
The engine is this unit is designed to run on diesel fuel. Use only high-quality fuel meeting ASTM D975 No.
2D, EN590, or equivalent. At temperatures below 32°F (0°C), winter fuel blends are acceptable. See
engine operation manual for more information.
IMPORTANT: Fuel sulfur content should be less than 5000 ppm (0.5%). Worldwide, fuel sulfur
regulations vary widely. Fuel used should always comply with local regulations. If using lube oil meeting
API CJ-4 (or other low SAPS equivalent) and fuel with sulfur content above 15 ppm (0.0015%, ULSD in
U.S.), reduce oil change interval to 250 hours.
Biodiesel blends up to 5% (B5) are approved for use in this unit. The fuel used must meet the
specifications for diesel fuel shown above. Extra attention is needed when using biodiesel, especially when
operating in cold weather or storing fuel. Contact your Ditch Witch dealer or the engine manufacturer for
more information.
HT220 Operator’s Manual
Service - 86
4 Hour
4 Hour
Location
Task
TRENCHER
Lube flywheel gearbox
Lube pivot bearings
Lube digging chain shaft bearing
Lube Flywheel Gearbox
Lube zerks with MPG every 4 hours.
Lube Pivot Bearings (Left & Right)
Lube zerks with MPG every 4 hours.
Notes
left and right
Service - 87
HT220 Operator’s Manual
4 Hour
Lube Digging Chain Shaft Bearing
Lube zerks with MPG every 4 hours.
HT220 Operator’s Manual
Service - 88
10 Hour
10 Hour
Location
Task
TRACTOR
Check emergency stop
Notes
Lube torque post
Lube cab door hinges
Check engine oil level
Check engine coolant level
Check air filters
Check cab air cleaner filters
Check hydraulic fluid level
Check hydraulic hoses
Check gearboxes and coupler
Clean cooling systems
Check nuts and bolts
TRENCHER
Lube conveyor
left and right
Lube stabilizer pins
left and right
Check and adjust conveyor belts
Check hydraulic cylinder rods
Check tail roller
Lube trench cleaner cylinder pins
Lube digging boom cylinder pins
Check digging chain
Check digging teeth
Check chain baseplates and toothstops
Check boom and wearplates
Check chain sprocket
Service - 89
HT220 Operator’s Manual
10 Hour
Check Emergency Stop
Test function of each emergency stop buttons
(shown) every 10 hours. See “Start After
Emergency Stop” on page 57.
1. Turn ignition switch to the on position but do
not start the engine.
2. Press an emergency stop button. See “Start
After Emergency Stop” on page 57.
3. Repeat process for each emergency stop
button. Service machine as required.
Lube Torque Post
Lube zerks with MPG every 10 hours.
Lube Cab Door Hinges
Lube cab door hinges with MPG every 10 hours.
HT220 Operator’s Manual
10 Hour
Check Engine Oil Level
Check engine oil level at dipstick (1) every 10
hours.
Add DEO (1) at fill as needed.
Ensure that engine oil level is correct and inspect
for contamination.
Typical signs of oil contamination are:
•
oil discoloration
•
water in the oil
Change oil and filter if contaminants are present.
Check Engine Coolant level
Check engine coolant level every 10 hours.
Ensure that level is at the maximum level and
inspect for signs of contamination.
Check Air Filter Light
Check air filter light every 10 hours or more
frequently if operating extremely dusty conditions.
The main filter can be cleaned up to six times
before replacing. The secondary filter must not be
reused.
Replace air filters as necessary. See “Change
Engine Air Filters” on page 105.
Service - 90
Service - 91
HT220 Operator’s Manual
10 Hour
Check Cab Air Cleaner Filters
Check cab air cleaner every 10 hours.
Replace as necessary.
Check Hydraulic Fluid Level
Inspect hydraulic fluid level every 10 hours.
If the fluid level is not visible through the sight
glass (2) then add fluid at fill (1) until fluid can be
seen through the sight glass (2).
The level must be checked when fluid is cold.
Lock the tank plug after each refilling.
HT220 Operator’s Manual
Service - 92
10 Hour
Check Hydraulic Hoses
away.
Fluid or air pressure could pierce skin and cause injury or death. Stay
NOTICE: Escaping pressurized fluid can cause injury or pierce skin and poison.
•
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.
•
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.
Inspect the hydraulic lines every 10 hours.
Check the condition of hoses and lines and
replace those that appear damaged.
Service - 93
HT220 Operator’s Manual
10 Hour
Check Gearbox and Coupler
Check gearboxes every 10 hours.
Inspect the flywheel gearbox (1), the two track
gearboxes (2) and the engine pump drive (3) to
spot possible leakages.
The flywheel gearbox cases and the coupler case
are all equipped with an air vent, oil level tank plug
and drain plug.
The track gearboxes are equipped with oil level
tank plug and drain plug for inspection. Rotate the
gearbox until the oil drain plug is in the lowest
position.
Fill all gearboxes to indicated level with MPL.
Change the oil in the gearboxes and in the coupler every 500 hours and each time any contamination is
detected. Unscrew a level plug to allow a small amount of oil to leak out and inspect for sediments that
may call for an unscheduled lubricant change.
Note: There are two separate and specific zones that require lubrication in the digging chain flywheel
gearbox. These zones are separated and failure to service both zones can bring premature breakage to
the flywheel.
Clean Cooling System
Clean engine and hydraulic fluid radiators every
10 hours.
Possible forms of obstructions include: dust
layers, oil layers, leaves, twigs and other objects
that may cause obstructions and lower the cooling
efficiency. Clean any obstructions to allow a
proper air flow and cooling action.
HT220 Operator’s Manual
10 Hour
Check Nuts and Bolts
Check nuts and bolts every 10 hours.
Check that there are no loose fasteners. If any
fasteners are loose, tighten them to the correct
torque specifications.
IMPORTANT: Check the chain digging plates
retaining screws.
Service - 94
Service - 95
HT220 Operator’s Manual
10 Hour
Trencher
Lube Conveyor (Left and Right)
Lube zerks with MPG every 10 hours.
Lube Stabilizer Pins (Left and Right)
Lube zerks with MPG every 10 hours.
HT220 Operator’s Manual
Service - 96
10 Hour
Check and Adjust Conveyor Belts
Check conveyor belts every 10 hours.
Ensure that belt (1) is not excessively worn and is
set at the proper tension. Too much tension will
cause excessive friction between the belt and the
side sills, performance loss and premature wear.
A loose belt may cause the driving drum to slip
and stop the belt movement.
The belt must neither be so tight that it gets out of
the guides, nor so loose it sags until touching the
conveyor frame. Stop operation and make
adjustments as needed.
If conveyor belts are worn, see “Replace Conveyor Belt” on page 117.
Allow for material load to increase tension.
To adjust:
Loosen screws (3) and adjust tension at screws (2). Tighten all adjusting screws (2,3) on each drum to
keep it perpendicular to the belt direction.
Check Hydraulic Cylinder Rods
Check hydraulic cylinder rods every 10 hours.
Check that the rods are not nicked or damaged
and that they do not show signs of oil leakage.
Clean and ream, if necessary. If this is not done,
the scraper ring and the rod packing may get
broken.
Service - 97
HT220 Operator’s Manual
10 Hour
Check Tail Roller
Check tail roller every 10 hours.
Check that the tail roller does not show excessive
wear signs and that the bearings (shown) do not
have any backlash. Make sure that the seals do
not leak.
For tail roller lubrication, see “Lube Tail Roller” on
page 102.
Lube Trench Cleaner Cylinder Pins
Lube zerks with MPG every 10 hours.
Lube Digging Boom Cylinder Pins
(Right and Left)
Lube zerks with MPG every 10 hours.
HT220 Operator’s Manual
10 Hour
Check Digging Chain
Inspect Digging Chain
Inspect for excessive wear (shown) and proper
tension every 10 hours.
The proper limit is 2” - 2.5” (5.08 cm - 6.35 cm)
sag (A) on a cold chain with baseplates installed,
measured at the point of greatest sag with the
boom in a horizontal position. Do not adjust chain
when it is hot.
Proper distance (A) is measured from the chain
point that is furthest from the boom.
Adjust chain tension as needed. “Adjust Digging Chain Tension” on page 118.
Check Digging Teeth
Inspect digging teeth every 10 hours.
Replace teeth when the carbide tip:
•
splinters or breaks.
•
rounds, flattens or becomes square.
•
is broken or not functioning properly.
Service - 98
Service - 99
HT220 Operator’s Manual
10 Hour
Check Chain Baseplates and Toothstops
The machine is equipped with specific-width
tooth-stop plates (1).
The tooth-stop plates and pockets are provided
with a hard metal coating in their easily-worn
parts. This coating must always be preserved to
guarantee the life of the tooth-stop pocket plates.
The machine operator must take note of the
hardened parts and preserve them. The
antirollover plates (not provided on the narrow
chain) are originally installed on the tooth-stop
plates. The machine operator must overhaul these
plates.
During assembly, make the plates touch the ground in ascending order (from the right side, in clockwise
ascending order) and by turning their teeth toward the digging direction.
Check the screws (3) and the locknuts (2) of the chain plates regularly. Use only high-tensile screws, nuts
and washers (8 grade).
Check plate nuts and screws daily. Their loosening may cause the chain to break and the plate to get
damaged.
Check Boom and Wearplates
Check wearplates every 10 hours.
These plates (shown) must be replaced
periodically in order to avoid damage to the boom
and to the excavation material internal recess.
If the wearplate is worn out to the extent that the
digging chain “nicks” the boom, the wearplate
must be “rotated” or replaced. A hard metal
coating applied to the severest wear position will
extend the plate life. See “Replace Wearplate” on
page 119.
HT220 Operator’s Manual
10 Hour
Check Chain Sprocket
Check digging chain sprocket every 10 hours.
Check that the sprocket is not damaged or
exceedingly worn. Replace or rotate the sprocket
if the other side is not worn. Avoid any “hook”
effect that takes place when the sprocket is
exceedingly worn.
“Hook” effects happen when the sprocket tooth
profile does not allow the chain sprocket to get
easily disconnected during the tooth rotation
because of excessive wear.
Service - 100
HT220 Operator’s Manual
Service - 101
50 Hour
50 Hour
Location
Task
TRACTOR
Inspect undercarriage pins and bushings
TRENCHER
Check and adjust digging chain gearbox and flywheel
fluid level
Lube tail roller
Tractor
Check Undercarriage Pins and
Keepers
Check undercarriage pins and keepers every 50
hours.
Visually inspect for proper pin keeper position as
well as excess movement. Inspect keeper bolts for
loosening.
Trencher
Check Digging Chain Gearbox and
Flywheel Fluid Level
Check fluid levels in the flywheel gearbox every
50 hours.
There are two points (3-6) per gearbox. Check the
gearboxes when the oil is cold. Add lubricant if the
level is low. Should any leakage be noticed, fill
more frequently. Find the causes and fix them.
To fill, remove the respective breather (1 or 2) and
fill with oil.
Notes
HT220 Operator’s Manual
50 Hour
Lube Tail Roller
Lube tail roller every 50 hours.
Short Boom
IMPORTANT: Schedule lubrication during an
idle time to prevent water from oxidizing the
bearings.
Remove cap and lube with MPG.
IMPORTANT:
•
Do not mix different greases.
•
Lube more frequently in case the seals are
worn and schedule a change of seals for
the next maintenance.
Standard Boom
1. Unscrew the endcap center port.
2. Lube standard tail roller with DEO (both sides must be serviced).
Service - 102
HT220 Operator’s Manual
Service - 103
100 Hour
100 Hour
Location
Task
TRENCHER
Check rubber mount supports
Notes
Check undercarriage rollers
Clean breathers
Check track tension
Lube hydraulic motors
Change engine air filters
Change engine oil (initial)
Change engine oil filter (initial)
Check Rubber Mounts
Check rubber mounts every 100 hours.
Check the bolt tightness and rubber condition.
If the rubber is worn or cracked, replace as
necessary. If mounts are loose, tighten according
to specifications.
Check Undercarriage Rollers
Check undercarriage rollers every 100 hours.
Inspect for leaks and “out of round” wearing.
Replace as necessary.
splined shafts
HT220 Operator’s Manual
100 Hour
Check Breathers
Check breathers (shown) every 100 hours.
Check that there are no obstructions or sediment
build-up. Clean the breathers as needed with oilbased solvent.
Do not carry out the operation using flammable
solvents or standing near a fire, sparks or other
flammable sources.
Check Track Tension
Check track tension every 10 hours.
Correct tension (A) is 3/8” (10 cm) chain sag
between the conveyor rollers. If distance (A) is
greater than 3/8” (10 cm), see“Adjust Track
Tension” on page 117.
Service - 104
HT220 Operator’s Manual
Service - 105
100 Hour
Lubricate Hydraulic Motor Splines
Lubricate all hydraulic motor and flywheel gearbox
drive motor splines every 100 hours.
1. Unbolt and slide motors out of position.
2. Lubricate the female spline with a heavy-duty
wheel bearing grease.
3. Re-bolt the drive motors in position, and
tighten fasteners properly.
Hydraulic Motor Bolt Torque Values
Size
Torque
1/2” - 13NC
58 ft•lb
5/8” - 11NC
115 ft•lb
Note: All hydraulic motor bolts are either 1/2” or 5/8” bolts. Correct identification of bolt size is a must.
Failure to correctly identify a bolt before tightening may lead to stripped holes, broken bolts, improperly
loaded bearings, etc.
Change Engine Air Filters
Change engine air filters every 100 hours.
The main air filter can be cleaned up to six times
before replacing. The secondary filter must not be
reused.
Replace filters as necessary.
HT220 Operator’s Manual
100 Hour
Change Engine Oil and Filter (initial)
Change the engine oil and filter after first 100
hours and at 250 hours.
1. Place a container, capable of holding 27 qt (26
L) of oil, below drain plug (3).
2. Remove drain plug (3) and allow oil to drain.
3. Change engine oil filter. See “Change Engine
Oil Filter”, below.
4. Add DEO at fill neck (1). See “Fluid
Capacities” on page 123.
5. Use dipstick to indicate the proper oil level (2).
Change Engine Oil Filter (initial)
1. Remove engine oil filter (shown).
2. Clean the gasket surface of the filter head.
Note: The gasket can stick on the filter
head. Make sure it is removed before
installing the new filter.
3. Fill new filter with clean oil before installation.
Apply a light film of oil to the gasket sealing
surface before installing the filter.
Note: Mechanical overtightening of filter
can distort the threads or damage the
filter element seal. Install the filter as
specified by the filter manufacturer.
Service - 106
HT220 Operator’s Manual
Service - 107
250 Hour
250 Hour
Location
Task
TRACTOR
Change engine oil and filter
Check engine oil breather
Inspect engine belts
Change hydraulic filters (initial)
Change Engine Oil and Filter
Change the engine oil and filter after first 100
hours and at 250 hours.
1. Place a container, capable of holding 27 qt (26
liters) of oil, below drain plug (3).
2. Remove drain plug (3) and allow oil to drain.
3. Change engine oil filter. See “Change Engine
Oil Filter” below.
4. Replace drain plug.
5. Refill with DEO at fill neck (1). See “Fluid
Capacities” on page 123.
6. Use dipstick to indicate the proper oil level (2).
Change Engine Oil Filter
7. Remove engine oil filter (shown).
8. Clean the gasket surface of the filter head.
Note: The gasket can stick on the filter
head. Make sure it is removed before
installing the new filter.
9. Fill new filter with clean oil before installation.
Apply a light film of oil to the gasket sealing
surface before installing the filter.
Note: Mechanical overtightening of filter
can distort the threads or damage the
filter element seal. Install the filter as
specified by the filter manufacturer.
Notes
HT220 Operator’s Manual
250 Hour
Check Engine Oil Breather
Check engine oil breather every 250 hours.
Clean or replace as necessary.
Check Engine Belts
Check engine belt tension every 250 hours.
Check that the air conditioner compressor belt is
correctly tightened. Tighten the belt if loose.
Replace the belt if it is worn.
Check and replace the radiator fan belt, if
necessary.
Check the belt tightener bearing and the fan
bearing.
Service - 108
Service - 109
HT220 Operator’s Manual
250 Hour
Change Hydraulic Filters (Initial)
Change hydraulic filters every 250 hours.
Replace the hydraulic filters:
1. Close all six valves on the hydraulic fluid tank.
2. Clean the external filter casings.
3. Loosen and remove the filter casing.
4. Remove all filtering elements (1-5) by
loosening them from the heads and clean the
casing and all other parts with a nonflammable solvent.
5. Install new filter elements.
6. Open all valves of the hydraulic tank.
IMPORTANT: Make sure that the tank valves are completely open.
7. After opening the valves, wait three minutes before starting the engine.
8. All operating controls must be in neutral (idle) position.
9. Start the engine and let it run for 5 minutes without performing any additional functions. At this stage, it
is possible to hear an unusual sound caused by the air getting into the system during filter
replacement.
10. Turn the diesel engine off and wait 2 minutes (this operation enables the air bubbles to surface and to
be expelled more quickly).
11. Start the diesel engine again and let it idle without using the machine at all for 3 minutes.
12. Operate the trench cleaner. If this function makes a harsh sound, immediately stop using the control
and wait for one more minute with the engine idling (the noise means that air is in the circuit).
13. Repeat the trench cleaner operation but immediately release the control if the noise persists. In that
case, turn the engine off and repeat the procedure.
14. If the trench cleaner is operated again and no more harsh sounds are heard, ensure the other controls
work properly (boom lifting, side conveyor, swivel conveyor, belts, etc.).
15. If harsh sounds are still perceived, immediately release the controls and wait one more minute with the
engine idling. When all controls are working properly, the machine can be operated.
16. Fill the hydraulic tank to the proper level (use the sight glass to determine the proper level).
HT220 Operator’s Manual
Service - 110
500 Hour
500 Hour
Location
Task
TRACTOR
Change ground drive gearbox oil
Change coupler oil
Change hydraulic fluid
Change hydraulic filters
Replace fluid suction filters
Check parking brakes
Trencher
Change digging chain gearbox and flywheel oil
Change digging boom tail roller gaskets
Change Ground Drive Gearbox Oil
Change ground drive gearbox oil every 500 hours.
1. Place a container under drain plug (1) and
remove drain plug.
2. Remove oil level plug (2) and allow oil to
drain.
3. Reinstall oil level plug (1).
4. Add MPL.
5. Service breather with respective gearbox.
Change Coupler Fluid
Change coupler fluid every 500 hours.
IMPORTANT: The engine-pump/coupler,
flywheel gearbox, and the two track gearboxes
must be serviced at the same time.
The flywheel gearbox cases and the coupler case
are all equipped with air vent (1), oil level tank
plug (2) and drain plug (3).
Notes
Service - 111
HT220 Operator’s Manual
500 Hour
Change Hydraulic Fluid
Change hydraulic fluid and filters every 500 hours.
Drain hydraulic fluid from the tank (3) into a
container suitable for transport or disposal.
Remove breather (1) and add hydraulic fluid. Use
the sight glass (2) to ensure that the proper
amount of hydraulic fluid has been added.
Change Hydraulic Filters
Replace the hydraulic oil filters every 500 hours.
1. Close all six valves on the hydraulic fluid tank.
2. Clean the external filter casings.
3. Loosen and remove the filter casing.
4. Remove all filtering elements (1-5) by
unscrewing them from the relevant heads.
Clean the casing and all other parts with a
non-flammable solvent.
5. Mount new filter elements.
IMPORTANT: Make sure that the tank
valves are completely open.
6. Open all valves of the hydraulic tank.
7. After opening the valves, wait three minutes before starting the engine.
8. All operating controls must be in neutral (idle) position.
HT220 Operator’s Manual
Service - 112
500 Hour
Replace Hydraulic Fluid Suction Filter
Replace hydraulic fluid suction filter every 500
hours.
1. Remove the tank suction filter.
2. Clean the suction filter and breather, the
magnetic plug and relevant wire net filter with
non-flammable solvent.
3. Mount the suction filter.
4. Apply silicone on plug and tank then mount
them back together. Pay attention that excess
silicone does not fall in the tank.
5. Tighten the plug bolts with sealant and
reinstall the breather in the plug.
6. Fill with hydraulic fluid.
IMPORTANT:
•
Change the hydraulic filters following this procedure.
•
Do not mix any hydraulic oils produced by different oil companies.
•
The machine is equipped with the oil indicated in the machine configuration card. This oil must be
used for operations to be carried out at ambient temperatures between -13° - 104°F (-25° - 40° C).
For operations with colder or hotter temperatures, please contact your Ditch Witch dealer.
Check Parking Brakes
Check the parking brake and replace the brake
discs every 500 hours.
Service - 113
HT220 Operator’s Manual
500 Hour
Change Flywheel Gearbox Fluid
Change flywheel gearbox fluid every 500 hours.
IMPORTANT: The engine-pump/coupler,
flywheel gearbox, and the two track gearboxes
must be serviced at the same time.
1. To fill, remove the breathers (1, 2).
2. Remove the plugs (3, 6) marked "OIL LEVEL"
on the gearbox (7) and flywheel (8).
3. Fill with suitable oil until it leaks out of the oil
level holes.
4. When the oil is to be changed, use the drain
plugs marked "OIL DRAIN" (4,5).
Replace Tail Roller Gaskets
Replace tail roller gaskets every 500 hours.
Disassemble the tail roller, check the bearing
conditions and replace the grease retainer
gaskets.
HT220 Operator’s Manual
Service - 114
1500 Hour
1500 Hour
Location
Task
TRENCHER
Exchange flywheel gearbox
Exchange Flywheel Gearbox
Schedule flywheel gearbox to be exchanged
every 1500 hours.
Notes
HT220 Operator’s Manual
Service - 115
2000 Hour
2000 Hour
Location
Task
Notes
TRACTOR
Change engine coolant
Change Engine Coolant
Hot parts may cause burns. Do not touch until cool.
NOTICE: Do not remove the pressure cap from a hot engine. Wait until the coolant
temperature is below 122° F (50° C) before removing the pressure cap. Heated coolant
spray or steam can cause personal injury.
Change engine coolant every 2000 hours.
Drain cooling system at drain (2) every two years
or 2000 hours. Add approved coolant according to
instructions below. Refill capacity is 23 qt (21.8 L).
NOTICE:
•
The use of non-approved coolant may lead
to engine damage or premature engine
failure and will void engine warranty.
•
See “Recommended Lubricants/Service
Key” on page 84 for list of approved
coolants.
HT220 Operator’s Manual
Service - 116
2000 Hour
To Flush:
Hot parts may cause burns. Do not touch until cool.
NOTICE: Do not remove the pressure cap from a hot engine. Wait until the coolant
temperature is below 122° F (50° C) before removing the pressure cap. Heated coolant
spray or steam can cause personal injury.
1. Fill the system with a mixture of sodium carbonate and water (or a commercially available equivalent).
2. Operate the engine for 5 minutes with the coolant temperature above 176° F (80° C).
3. Shut the engine off and drain the cooling system.
4. Fill the cooling system with good-quality water.
5. Operate the engine for 5 minutes with the coolant temperature above 176° F (80° C).
Shut the engine off, and drain the cooling system.
To fill:
1. Add coolant at radiator fill (2) at a rate of 3 gpm (11.4 L/min) or less until full.
2. Run engine with thermostat open (>195°F/90°C engine temperature) for several minutes.
3. Stop engine and let it cool.
4. Maintain coolant level at halfway point on sight glass (3).
HT220 Operator’s Manual
Service - 117
As Needed
As Needed
Location
Task
TRACTOR
Adjust track tension
TRENCHER
Replace conveyor belt
Notes
Adjust digging chain
Replace wearplate
Adjust Track Tension
Adjust tension as needed.
Check the track chain to make sure that it is
suitably tightened. See “Check Track Tension” on
page 104.
To adjust, use the tensioner located on the
undercarriage external sides.
IMPORTANT: Do not tighten the track.
Replace Conveyor Belt
Replace conveyor belt as needed.
1. With the engine running, move the conveyor
toward the right side of the machine (to
maximum translation point), by operating the
panel controls. Turn engine off after
adjustment.
2. Loosen the belt (1) tension by loosening the
adjusting tie-rods (2).
3. Slip off the two hydraulic motors directly
connected with the motor shafts of the
conveyor.
4. Remove the retaining locking pins of the
security dowels (3) of the connecting rods.
5. Remove the four conveyor retaining bulkheads (one front left, one front right, one rear left, one rear
right).
6. Slip off the conveyor from one side of the machine.
HT220 Operator’s Manual
Service - 118
As Needed
7. Remove the lateral hose-end fitting sideboards (without removing the rubber from the metal
sideboards).
8. Disassemble the motor roller (left or right).
9. Remove the “old” belt or cut it if unusable.
10. Fit the new belt starting from the end without roller.
11. Reinsert the previously disassembled motor roller and reassemble repeating the above-mentioned
operations in reverse order.
Adjust Digging Chain Tension
Adjust digging chain tension as needed.
1. Loosen (by one turn) the twelve screws that
keep the gibs in place below the digging boom
(6) on both sides.
2. Loosen (by one turn) the twelve screws that
hold the gibs sideways (1).
3. Loosen (by one turn) the 12 screws that
fasten the digging boom on both sides (2).
4. Clean and lube the four tightening screws (3)
and loosen the four locknuts (4).
5. Adjust the chain tension by tightening the four
tightening screws when necessary (3).
6. Insert one of two shims (5) when the screw travel is not enough to adjust the tension.
7. Remove the boom screws (2) when slot length too tight and reinsert.
8. After achieving the proper tension, tighten the twelve screws that keep the gib in place from below;
start from the external screws.
9. Tighten the twelve screws that keep the gibs in place below the digging boom (6).
10. Tighten the twelve screws that hold the gibs sideways (1).
11. Tighten the twelve screws that fasten the digging boom on both sides (2).
12. Tighten and lock the four tensioning screws with their four locknuts (4).
13. Check that the twelve screws that keep the gibs in place from below are all properly tightened.
NOTICE:
•
Excessive tension in the digging chain could cause premature damage to the bearings of the
digging gearbox.
•
Possible chain wear and breakage caused by worn-out sprockets, incorrect tension or excessively
worn baseplate antiroller plates will not be covered by warranty.
•
The chain adjustment must be carried out when the chain is cold and the baseplates assembled. Do
not adjust the chain when it is hot.
Service - 119
HT220 Operator’s Manual
As Needed
Replace Wearplate
Replace wearplate as needed.
1. Inspect wearplate (shown).
1. Turn all battery disconnects to the off position.
See “Battery Disconnects” on page 43.
2. Cut the welds holding the wearplate to the
boom.
3. Inspect bottom surface of wearplate. Use
bottom surface of wearplate if it has not been
used.
4. Weld new wearplate onto digging boom.
5. Connect batteries.
HT220 Operator’s Manual
Specifications - 120
HT220 Trencher
Specifications
HT220 Trencher
Dimensions
U.S.
Metric
22°
22°
single chain boom
12-18 in
305-460 mm
double chain boom
24 in
610 mm
H1
Operating height
112.2 in
2.85 m
H4
Engine compartment clearance
17.71 in
450 mm
H10
Trench depth, maximum
4’ boom
48 in
1.2 m
5’ boom
60 in
1.5 m
6’ boom
72 in
1.8 m
8’ boom
96 in
2.4 m
A2
Angle of approach
W10
Trench width, maximum
Specifications - 121
HT220 Operator’s Manual
HT220 Trencher
L
Length, transport (with trench cleaner)
4’ boom
302 in
7.66 m
5’ boom
315 in
8m
6’ boom
331 in
8.4 m
8’ boom
358 in
9.1 m
L2
Pitch - length from center drive sprocket to center idler
112 in
2.84 m
L4
Engine compartment
60 in
1.54 m
Spoil discharge reach, minimum to maximum
17-20 in
4.3-5.1 m
W
Width, transport (with 20”/51 cm Track Pads)
88 in
2.24 m
W4
Width, track
20 in
510 mm
W10
Trench width, maximum
24 in
610 mm
U.S.
Metric
Low range
1.2 mph
2.0 km/h
High range
2.1 mph
3.3 km/h
Low range
0-1.2 mph
0-2.0 km/h
High range
0-2.1 mph
0-3.3 km/h
Digging chain speed @ 2200 rpm
0-650 fpm
0-200 m/min
Allowable operating weight, maximum
46,297 lb
21,000 kg
Operation
Forward, infinitely variable speed
Reverse, infinitely variable speed
Operator orientation: facing left of vehicle in full view of all operations
HT220 Operator’s Manual
Specifications - 122
HT220 Trencher
Power
U.S.
Metric
Displacement
409 in3
6.7 L
Bore
4.21 in
107 mm
Stroke
4.88 in
124 mm
Engine manufacturer’s maximum gross power
220 hp
164 kW
Rated speed (no load)
2,200 rpm
2,200 rpm
Engine: Cummins QSB 6.7, diesel
Cooling medium: Cat EC-1 Extended Life Coolant (ELC)
Injection: direct
Aspiration: turbocharged and charge air cooled
Number of cylinders: 6 in-line
Power Train
Ground drive transmission: hydrostatic
Dual path hydrostatic: planetary transmissions capable of full counter rotation with single lever steering,
single lever direction.
Service brake: wet disc, spring applied, hydraulic release
Parking brake: wet disc, spring applied, hydraulic release
Trencher drive: hydrostatic
Specifications - 123
HT220 Operator’s Manual
HT220 Trencher
Hydraulic System
U.S.
Metric
Maximum flow
46 gpm
174 L/min
Maximum pressure
2,610 psi
180 bar
Maximum flow
34 gpm
129 L/min
Maximum pressure
4,206 psi
290 bar
Maximum flow
64 gpm
242 L/min
Maximum pressure
5,280 psi
364 bar
Ground drive pump capacity at 2,200 rpm
13.6 gpm
51.5 L/min
Ground drive pump relief setting
5,000 psi
344.7 bar
5,000 psi
344.7 bar
Hydraulic fluid maximum temperature
176° F
80° C
Pump flow
45 gpm
170 L/min
Pressure setting
2,600 psi
180 bar
Fluid Capacities
U.S.
Metric
Fuel tank
114 gal
431 L
Engine oil
26.5 qt
100.3 L
Flywheel compartment
2 pt
0.9 L
Gearbox
20 qt
9.5 L
Hydraulic reservoir
85 gal
290 L
Hydraulic system
87 gal
322 L
Type: pressure and flow compensated (load sensing)
Ground drive: closed loop
Digging drive: closed loop
Chain pump pressure
Maximum
Service pump pressure
Batteries
Group 49, SAE reserve capacity rating 150 minutes, SAE cold crank rating 825 amps
HT220 Operator’s Manual
Specifications - 124
HT220 Trencher
Noise Levels
Operator sound pressure level is 81 dBA per ISO 6394
Exterior sound power level is 111 dBA per ISO 6393
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.
Specifications - 125
HT220 Operator’s Manual
HT220 Trencher
HT220 Operator’s Manual
Support - 126
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
HT220 Operator’s Manual
Warranty - 127
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 (Exception: 2 years for all SK5 attachments). Free labor will be provided at
any authorized Ditch Witch dealership for installation of parts under this warranty during the first year following “initial commercial”
use of the serial-numbered Ditch Witch equipment on which it is installed. The customer is responsible for transporting their
equipment to an authorized Ditch Witch dealership for all warranty work.
Exclusions from Product Warranty
•
All incidental or consequential damages.
•
All defects, damages, or injuries caused by misuse, abuse, improper installation, alteration, neglect, or uses other than those for
which products were intended.
•
All defects, damages, or injuries caused by improper training, operation, or servicing of products in a manner inconsistent with
manufacturer’s recommendations.
•
All engines and engine accessories (these are covered by original manufacturer’s warranty).
•
Tires, belts, and other parts which may be subject to another manufacturer’s warranty (such warranty will be available to
purchaser).
•
ALL IMPLIED WARRANTIES NOT EXPRESSLY STATED HEREIN, INCLUDING ANY WARRANTY OF FITNESS FOR A
PARTICULAR PURPOSE AND MERCHANTABILITY.
IF THE PRODUCTS ARE PURCHASED FOR COMMERCIAL PURPOSES, AS DEFINED BY THE UNIFORM COMMERCIAL
CODE, THEN THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE FACE HEREOF AND THERE ARE NO IMPLIED
WARRANTIES OF ANY KIND WHICH EXTEND TO A COMMERCIAL BUYER. ALL OTHER PROVISIONS OF THIS LIMITED
WARRANTY APPLY INCLUDING THE DUTIES IMPOSED.
Ditch Witch products have been tested to deliver acceptable performance in most conditions. This does not imply they will deliver
acceptable performance in all conditions. Therefore, to assure suitability, products should be operated under anticipated working
conditions prior to purchase.
Defects will be determined by an inspection within thirty (30) days of the date of failure of the product or part by CMW or its
authorized
dealer. CMW will provide the location of its inspection facilities or its nearest authorized dealer upon inquiry. CMW reserves the right
to supply remanufactured replacements parts under this warranty as it deems appropriate.
Extended warranties are available upon request from your local Ditch Witch dealer or CMW.
Some states do not allow exclusion or limitation of incidental or consequential damages, so above limitation of exclusion may not
apply. Further, some states do not allow exclusion of or limitation of how long an implied warranty lasts, so the above limitation may
not apply. This limited warranty gives product owner specific legal rights and the product owner may also have other rights whi
ch vary
from state to state.
For information regarding this limited warranty, contact CMW’s Product Support department, P.O. Box 66, Perry, OK 73077-0066, or
contact your local Ditch Witch dealer.
First version: 1/91; Latest version: 7/05
CMW
HT115 Operator’s Manual
Service Record - 130
Service Record
Service Performed
Date
Hours
CMW
Service Record - 131
Service Performed
CMW
HT115 Operator’s Manual
Date
Hours
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