Super Products MUD DOG Operator'S Manual Download

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Super Products LLC Publication: 0004175

PRE-OPERATION

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Summary of Contents for MUD DOG

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Page 2: ...Normal adjustments and maintenance services This limited warranty does not cover any damage to nonfunctioning or malfunctioning of the equipment or any components or parts comprising the equipment due...

Page 3: ...Workers Before You Begin Construction Work 1 10 Working with Tools and Equipment 1 10 Chemical and Biological Hazard Safety 1 11 Chemicals and Diesel Engine Exhaust 1 11 Sewer Gas Hazard 1 11 Chemical...

Page 4: ...0 Debris Body Dumping Safety and Hazard Warnings 1 31 Sewer Gas Safety and Hazard Warnings 1 32 Confined Space Hazard 1 32 Trenching Hazards 1 33 De energize and Lockout Procedures 1 34 Hazards With E...

Page 5: ...ance General Information 4 1 Preventive Maintenance Instructions 4 1 Lubrication Recommendation Chart 4 1 Maintenance Schedule 4 2 Maintenance Items 4 4 Boom 4 4 Debris Body 4 4 Electrical System 4 4...

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Page 7: ...ion or repair The Safety Alert Symbol combined with a Signal Word as seen below is used throughout this manual and on decals which are attached to the equipment The Safety Alert Symbol means ATTENTION...

Page 8: ...Pictographs are used throughout this manual to help bring your visual attention to safety issues Figure 1 1 NOTE If you want a translation of this safety section in Spanish or French please contact Tr...

Page 9: ...ditions This should always include Hard hat Safety shoes Safety glasses goggles or face shield Heavy gloves chemical resistant Hearing protection Reflective clothing WARNING Never wear loose clothing...

Page 10: ...n Using Pressurized Air or Water Figure 1 3 When using pressurized air or water for cleaning or material erosion movement you should use the following Face Shield Wet Weather Protective Suit Waterproo...

Page 11: ...hazardous or unknown substances Do not wear loose clothing or jewelry to avoid injury from entanglement in rotating parts Keep body and limbs away from suction inlets Do not open or close the tailgat...

Page 12: ...t ventilation Mounting and Dismounting Truck or Equipment Only mount or dismount when truck and moving parts are stopped Always use three point contact when climbing on or dismounting equipment Walkwa...

Page 13: ...ip Over WARNING Truck driver must have valid and appropriate training license before transporting liquids on public roads Slow down on curves to prevent truck from tipping over Always ensure unit is o...

Page 14: ...damaged walkway or steps Keep grab handles steps and walkways free of mud oil grease and other foreign material Clean non skid surface material as required Ground level personnel must be present whene...

Page 15: ...and nozzles ejecting hydraulic fluid CAUTION Tank contents may be under pressure Allow oil to cool before removing cap slowly Relieve oil pressure before removing cap slowly Stay away from hot oil tha...

Page 16: ...erwise or an electrician verifies that the line is not energized and has been grounded In construction work an overhead power line safety component should be part of your employer s overall safety and...

Page 17: ...r Operation of this equipment under certain conditions may generate airborne dust particles that could contain crystalline silica In those conditions personal protective equipment including an appropr...

Page 18: ...Check for low hanging electric or telephone wires and power cables on the ground Look out for and avoid other personnel machinery and vehicles in the area Use a spotter if you do not have clear view...

Page 19: ...avoid equipment turning over Truck has a high center of gravity when carrying a loaded debris body Use extreme caution when transporting at highway speeds Slow down for sharp corners to avoid tipping...

Page 20: ...s and barricade tape to prevent bystanders from entering potentially hazardous areas and to keep them away from machinery Prepare for Working Near Existing Utilities Boots must have high tops and meet...

Page 21: ...onditions cannot be controlled Visibility Conditions When Operating Operate in daylight or with lights that provide adequate visibility to perform job safely Make sure passersby steep slopes ditches d...

Page 22: ...ment conduct a walk around inspection of the equipment for proper operation Repair any improperly functioning broken or damaged equipment before operating Inspect the job site for unsafe conditions an...

Page 23: ...kly as possible at any sign of danger Seek medical attention immediately Do not attach hose pipe or accessories with the vacuum on The vacuum can trap fingers hands and feet with enough force to crush...

Page 24: ...pment Never use an air mover machine for vacuuming hydrocarbon or flammable materials unless the flash point of the material is 150 F or higher Pressurized or pump off loading is not permitted unless...

Page 25: ...ept as close as possible to the person working at the end of the vacuum hose maximum of thirty feet away If there is more than one operator there must be a separate T type valve for each operator 2 Pl...

Page 26: ...rd to the vacuum relief valve 3 Insert the male plug into the end of the vacuum relief valve or vacuum inlet hose whichever is at the inlet point 4 With the vacuum relief valve closed start up the vac...

Page 27: ...ch as bracelets and necklaces unless they are under tight fitting clothing Do not use hands or feet to remove obstructions from the end of the hose Keep all body extremities and clothing away from the...

Page 28: ...ety person should continue to be in a position to observe all vacuum hose operators until those operators have moved a safe distance from the end of all vacuum work hoses After vacuum operation is com...

Page 29: ...to end of inlet vacuum hose 4 Start up the vacuum pump per operating procedure in manual 5 With unit at full vacuum press the VENT OPEN button on the remote and verify that the vacuum relief door has...

Page 30: ...m for final equipment and job site cleanups or for cleaning debris buildups on the inside of body DANGER Always bleed the pressure from the handgun before disconnecting it from the high pressure handg...

Page 31: ...ent Technology Association publishes a variety of industrial related information that owners and operators can obtain This material includes specifications repair and inspection information for high p...

Page 32: ...explosion It has been known to occur in grain elevators underground mines flour mills crushers etc The dust itself need not be an explosive or flammable substance The safe operation of transferring p...

Page 33: ...mends that a monitor for hazardous hydrocarbon concentrations be installed in the exhaust stream of the vacuum pump to continuously monitor for lower explosive level LEL The monitor must be properly c...

Page 34: ...t the trip point of the temperature switches at or below the flash point of the material being picked up If the exhaust temperature reaches the set point of the temperature switch the valves would ope...

Page 35: ...and a known electrical ground such as a water pipe plant ground loop system or metal stake driven into the ground sufficiently deep to ensure an electrical ground Bolt wire to truck frame do not weld...

Page 36: ...object causing a spark The entire unit should be grounded as described previously and only static dissipating hoses should be used It is essential the truck engine exhaust is directed away from the bl...

Page 37: ...hen positioning the debris body to the dump station Your vision especially to the side and rear of the debris body may be reduced by the size of the debris body Use mirrors to aid vision If you cannot...

Page 38: ...be otherwise For example confinement limited access and restricted airflow can result in hazardous conditions that would not normally arise in an open workplace The terms permit required confined spa...

Page 39: ...SAFETY Super Products LLC Publication 0004175 1 33 1 Trenching Hazards NOTE Reference to OSHA regulations are for informational purposes only and not intended as legal advice...

Page 40: ...rgy isolation devices in a safe or off position They provide protection by preventing machines or equipment from becoming energized because they are positive restraints that no one can remove without...

Page 41: ...oting by standing on solid flat surfaces when getting on equipment to perform work Follow manufacturer s instructions in handling oils solvents cleansers and other chemical agents Do not change any fa...

Page 42: ...ab and chassis configuration If any decal provided by Super Products is missing or becomes illegible a replacement decal can be requested from Super Products at no charge and should be replaced immedi...

Page 43: ...48 5 Rotating shafts can be dangerous WARNING 3050 01179 1 40 6 Suction line valve CAUTION 3050 01286 1 49 7 Manual override INSTRUCTION 3050 01219 1 50 8 Water Tank Fill INSTRUCTION 3050 00579 1 51 9...

Page 44: ...Recirculation INSTRUCTION 3050 00205 1 58 5 Air Purge Valve CAUTION 3050 01233 1 60 6 Drain Here INSTRUCTION 3050 00024 1 61 7 High Pressure INSTRUCTION 3050 00896 1 62 8 Hose Reel INSTRUCTION 3050 00...

Page 45: ...binet Interior ITEM DESCRIPTION TYPE PART NO SEE FIG 1 Antifreeze Supply INSTRUCTION 3050 00573 1 68 2 Rotating shafts can be dangerous WARNING 3050 01179 1 40 3 Drain Here INSTRUCTION 3050 00024 1 61...

Page 46: ...1 71 2 Pinch Point Hazards WARNING 3050 01201 1 72 3 Crushing Hazards WARNING 0003403 1 46 4 Anchor Point INSTRUCTION 3050 01222 1 73 5 Remote Grease INSTRUCTION 3050 01200 1 74 6 Remote Grease INSTRU...

Page 47: ...423 3 Software Parameters INSTRUCTIONS 0003392 1 76 4 Second Highest Gear INSTRUCTIONS 0002445 1 77 5 Drop Suspension Air INSTRUCTIONS 3050 01230 1 78 6 Disengage Hydraulic Pump CAUTION 0024915 1 79 7...

Page 48: ...lication 0004175 SAFETY 1 ITEM DESCRIPTION TYPE PART NO SEE FIG 1 High Pressure Hazard WARNING 0007437 1 65 2 Debris Level INSTRUCTION 0003050 3 Sludge Open Closed INSTRUCTION 0024633 4 Sludge Water T...

Page 49: ...s LLC Publication 0004175 1 43 1 Decals Figure 1 39 Figure 1 40 Figure 1 41 Figure 1 42 Figure 1 43 Figure 1 44 Part no 3050 00479 Part no 3050 01179 Part no 3050 00433 Part no 0028252 Part no 0003403...

Page 50: ...er Products LLC Publication 0004175 SAFETY 1 Figure 1 45 Figure 1 46 Figure 1 47 Figure 1 48 Figure 1 49 Part no 3050 01174 Part no 0007448 Part no 0029444 Part no 3050 00051 Part no 3050 01286 EMERGE...

Page 51: ...TY Super Products LLC Publication 0004175 1 45 1 Figure 1 50 Figure 1 51 Figure 1 52 Figure 1 53 Figure 1 54 Part no 3050 01219 Part no 3050 00579 Part no 3050 01218 Part no 3050 01196 Part no 3050 00...

Page 52: ...1 46 Super Products LLC Publication 0004175 SAFETY 1 Figure 1 55 Part no 0033284...

Page 53: ...SAFETY Super Products LLC Publication 0004175 1 47 1 Figure 1 56 Figure 1 57 Figure 1 58 Figure 1 59 Part no 0033284 Part no 3050 00116 Part no 3050 00205 Part no 3050 00014...

Page 54: ...FETY 1 Figure 1 60 Figure 1 61 Figure 1 62 Figure 1 63 Figure 1 64 Figure 1 65 Figure 1 66 Figure 1 67 Part no 3050 01233 Part no 3050 00024 Part no 3050 00896 Part no 3050 00780 Part no 3050 00772 Pa...

Page 55: ...cts LLC Publication 0004175 1 49 1 Figure 1 68 Figure 1 69 Figure 1 70 Figure 1 71 Figure 1 72 Figure 1 73 Part no 3050 00573 Part no 3050 01009 Part no 3050 00572 Part no 0007541 Part no 3000 01201 P...

Page 56: ...cation 0004175 SAFETY 1 Figure 1 74 Figure 1 75 Figure 1 76 Figure 1 77 Figure 1 78 Figure 1 79 Figure 1 80 Part no 3050 01200 Part no 3050 01278 Part no 0003392 Part no 0002445 Part no 3050 01230 Par...

Page 57: ...SAFETY Super Products LLC Publication 0004175 1 51 1 Part no 0033298 Figure 1 81 Figure 1 82 Figure 1 83 Part no 0035784 Part no 0026568...

Page 58: ...body tailgate enough so that the tailgate pins rest against the tailgate props Figure 1 85 5 Shut the truck engine off and remove the keys Lowering the Debris Body Tailgate and Storing the Props 1 En...

Page 59: ...the final filter is clean and that the access cover is secure 9 Make sure the fresh water fill pipe strainer is clean 10 Close the water tank drain valve located above the rear bumper 11 Conduct a co...

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Page 61: ...dous reduction in air velocity An air backed elbow allows the material to make a 90 bend as it enters the body while minimizing elbow wear The air exits the body at the top front section where the bal...

Page 62: ...2 2 Super Products LLC Publication 0004175 PRE OPERATION 2 Figure 2 1 Figure 2 2...

Page 63: ...y through the vacuum tube to the body This requires the vacuum pump be operating at a fast enough speed to produce the required airflow to capture the material NOTE It should be noted that the most ef...

Page 64: ...5 over to the final filter 6 7 The air goes from the outside of the filter 6 to the inside of the filter Any remaining material ten microns or larger is captured on the outside of the filter 8 The air...

Page 65: ...tween the driver s and passenger seat labeled Rear Axle Pull up on the lever until it is fully engaged It may be necessary to feather the clutch in order to get full engagement A green light will come...

Page 66: ...idle 7 Transfer Case Vacuum Pump Disengagement Manual Transmission with Manual Shift or Air Shift Transfer Case a Fully depress the clutch pedal b Wait five to ten seconds for the driveline and vacuum...

Page 67: ...as described elsewhere in this manual section Otherwise use only the emergency relief valves approved by Super Products Failure to comply with this requirement could cause bodily injury for which Supe...

Page 68: ...r multiple smaller hoses are used at work area c Eight 8 inch diameter hose can not be handled by the average man without great physical exertion Normally fed with shovels wheel barrows or multiple sm...

Page 69: ...d onto the end of the lance The water system is used to loosen soils as well as for general cleanup Various nozzles are available depending on soil conditions A drain valve allows for draining the tan...

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Page 71: ...n fuel tank instantaneous gallons per hour Press Mode button to view blower hour meter Winter Recirculation Switch Dump Dig Mode switch Dump mode enables dumping functions Dig mode enables boom functi...

Page 72: ...pressing the STOP button the operator should take a few minutes to fully assess the situation and correct any hazards or safety issues Note the engine will not restart until both STOP buttons are rese...

Page 73: ...lve clockwise several turns pressure gauge should read 1600 to 2100 psi For cartridge valves push in outer pin then push or pull Knurled Collar for desired function For D03 Valves push spool left or r...

Page 74: ...sition 4 With manual transmission slowly release clutch 5 Make sure boom hose transport lock if equipped is released first before operating boom 6 At the control panel in the main storage cabin locate...

Page 75: ...anual control valve lever is in the main water pump position 8 Turn on the water pump by either turning the water pump speed dial on the control panel clockwise to desired water pump speed or press wa...

Page 76: ...rigger to start the water flow The Water Heater EN LED is lit The Water Heater EN signal enables the water heater relay RY3 which sends power to water heater When the Water Heater EN signal passes thr...

Page 77: ...valve 7 Point the handgun in a safe direction and pull the trigger until no more water comes out This will take about 2 minutes less than 1 minute without the heater 8 Close the air purge ball valve...

Page 78: ...ce from the handgun 11 Connect the handgun to the high pressure water hose from the reel 12 Confirm winter recirculation switch is off and flow control dial is at zero 13 Start the engine and engage t...

Page 79: ...threaded connections regularly Make them secure and leak proof Alter equipment in any manner If repairs are necessary use only genuine factory repair parts available from Super Products Make sure the...

Page 80: ...erial out of the body Release this button at any time to pause the process An Eject switch is also provided on the rear right had corner of the cabinet 10 Connect water hose to body flusher connection...

Page 81: ...rough it by blocking off the inlet hose and engaging the vacuum pump Allow the vacuum to build up some and then open the drain valve The drain hose must be disconnected when you do this Make sure all...

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Page 83: ...ve Maintenance Instructions We urge you to protect your investment by servicing it according to the maintenance schedule listed on the following pages Regular maintenance will insure maximum unit perf...

Page 84: ...2 Lubricate Tailgate Latch Hydraulic 5 Clean Lubricate Inspect Tailgate Pivot 1 Lubricate Inspect Tailgate Hinge 2 Lubricate Inspect Tailgate Latch Rollers Lower 3 Clean Inspect Lubricate Seal around...

Page 85: ...Lubricate WATER SYSTEM Suction Strainer Clean Inspect Water Tanks Clean Water Tank Connections Inspect Ball Valves Inspect Adjust Pressure Gauge Inspect Handgun Connections Clean Inspect Drain System...

Page 86: ...c Cylinder Inspect rubber seal around pusher plate telescopic cylinder to make sure it is tight and not damaged 7 Float Ball Clean float ball daily or after each load Inspect ball weekly for dents and...

Page 87: ...s for proper operation or leaks daily 7 Drain System In freezing weather drain entire water system and hose See detailed drain system instructions located in this manual 8 Regulator Inspect regulator...

Page 88: ...ed with standard 5 8 flat washers After fully opening latches remove the wedge roller bolts and add a flat washer Retighten roller bolts securely and recheck wedge adjustment as above Recheck leakage...

Page 89: ...with a pry bar so there is an equal gap on both sides of the body See Fig 2 9 Tighten bottom pads to 40 ft lbs each side 10 Move the plate backward 2 feet then back to narrowest point 11 Tighten to 75...

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Page 91: ...ny Troubleshooting you must call our Customer Service Representatives at 262 784 7100 The Basic Troubleshooting Process 1 Prepare tools information and safety equipment 2 Define the symptom What is th...

Page 92: ...or damaged Adjust repair or replace any missing or leaking gaskets Gasket from inspection door missing or damaged Repair or replace gasket Tailgate gasket damaged or not sealing Repair or replace sea...

Page 93: ...ing on dirt Shift the hydraulic cartridge valve using the manual override This may free the fouled valve A dirty cartridge valve may need to be cleaned or replaced Change the hydraulic filter Weak or...

Page 94: ...t or material accumulated on collar shaft roller or tailgate surface Remove all accumulated dirt and material Rollers or shaft binding or frozen Lubricate rollers and shaft Free binding parts Wireless...

Page 95: ...No hydraulic pressure Electrical malfunction Use manual override to verify electrical malfunction Turn proportional control valve on water control manifold counterclockwise several turns with a 3mm Al...

Page 96: ...al Troubleshooting Electrical malfunction LED light on solenoid coil connector should light up when function is pressed Electrical connector lost continuity Unplug connector inspect for damage add ele...

Page 97: ...STOP switch restart work mode E Stop Remote Button Vent door opens engine RPM drops to idle speed and all functions stop working Remote E Stop button pressed Cycle REMOTE CONTROL switch off then back...

Page 98: ...ck VENT DOOR OPEN EN input LED is lit on the control module Check VENT DOOR OPEN output LED is lit on the control module Chassis air and vent door open signal is not present at valve body See Common E...

Page 99: ...still lit Perform manual override to verify electrical issue Will NOT close Pusher plate not fully retracted due to interference Check via clean out port that pusher plate is fully retracted Clean deb...

Page 100: ...working See Pendant Control No hydraulic pressure See No hydraulic oil pressure Solenoid failed Perform manual override to verify electrical issue Boom speed too Low hydraulic system pressure See No...

Page 101: ...h is closing when water is flowing See Common Electrical Problems Thermostat switch failure Verify thermostat switch is closed See Common Electrical Problems Water heater enable signal not present at...

Page 102: ...control system is in lock out model Water heater master control switch off then back on Observe burner operation See Beckett oil burner manual Use Beckett Service Tool for troubleshooting Exhaust outp...

Page 103: ...t Other electrical problem See Common Electrical Problems Remote Control Wireless remote not functioning Remote Throttle not enabled See Remote Throttle Control Weak or no signal received Check that t...

Page 104: ...cause of over current Loss of power after period of time Circuit breaker tripped by device drawing too current that is too close to the maximum amperage rating Determine cause of over current Control...

Page 105: ...t an incandescent lamp to the circuit and wiggle wires Using wire jumpers temporarily connect power and ground to get device to work CAUTION Incorrect wiring may damage device Function failed Device f...

Page 106: ...PROX SW and the Throttle EN LED will light on the chassis module The dash may display a parking brake error message and the speedometer may show road speed until engine PTO mode is established PTO mo...

Page 107: ...nd hold the shift and retract buttons on the remote control The pusher plate will start to retract and the engine RPM will increase 10 When the pusher plate is fully retracted the retract prox switch...

Page 108: ...5 18 Super Products LLC Publication 0004175 TROUBLESHOOTING 5 Hydraulic Schematic...

Page 109: ...TROUBLESHOOTING Super Products LLC Publication 0004175 5 19 5 Electrical Block Diagram...

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Page 111: ...andle 9400 00132 Reducer 8 Male X 6 Female Aluminum 3000 00929 8 x 36 Tube 8510 01373 8 x 60 Tube 8510 01374 8 x 84 Tube 8510 01375 6 Dig Tube 9010 00798 6 O ring Gasket 3500 00206 8 O ring Gasket 350...

Page 112: ...M 3000PSI 6 0027520 Repair Kit For 0027520 0027521 Nozzle Rip Saw 6 9GPM 3000PSI 8 0027518 Repair Kit For 0027518 0027519 Nozzle Rip Saw 8 7GPM 3000PSI 10 0026363 Repair Kit For 0026363 0026364 Nozzle...

Page 113: ...ssembly Water 6000 01793 Hose 50 X 100 For Hose Reel 3000 03248 Hose 50 X 50 3643 60000 Unloader 6000 02095 Cover Water Tank 7310 01873 Gauge Water Pressure 6000 01316 Ball Valve Bypass 6000 01150 Bal...

Page 114: ...03243 Thermostat Assembly 7310 02763 Relief Valve 7310 02984 Transformer Ignitor 7310 02761 Current Sensor Repl 5500 03189 Needs Mod 7310 03366 Heat Coil Assembly 750 Upper Lower 7310 03268 Insulatio...

Page 115: ...3259 Mud Flap 3500 00674 Latch Rod Tailgate 1010 00967 End Yoke For Latch Rods 3000 01475 Jam Nut For Latch Rods 0044 00008 Bolt Latch 4510 00215 Assembly Tailgate Roller 0002609 Prop Body 0001143 Pro...

Page 116: ...00 00524 Gasket Air Filter Housing 90 0005155 Blower Roots 1125DVJ 6000 02217 Seal Drive Roots 1125DVJ 7300 02622 Wing Nut Filter 8510 02157 Gasket Relief Valve 3500 00014 Clamp 10 Hose 3000 00139 Cyl...

Page 117: ...ump Prop Valve 5500 01545 Display Digital 5500 03052 Controller Axiomatic W Pump Radar 5500 03092 Potentiometer 5K Control Cabinet 5500 02070 Rotary Switch Cabinet Heater 5500 01457 Pendant Wireless K...

Page 118: ...364 Coil Proportional Valve Boom 7310 03033 Cartridge Proportional Valve Boom 7310 03032 Cylinder Body Lift Field Service 0007529 Cylinder Pusher Plate 12 Yard 0005769 0005769 Cylinder Pusher Plate 16...

Page 119: ...9 6 Light Stop Tail Turn LED 5500 01903 Light Back Up LED 5500 01904 Harness Interface DOT 0008371 Light Cord Reel 5500 00810 Light Boom LED 0031776 Light Bar Rear ID 9010 01002 Light Cargo LED 5500...

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Page 121: ...Debris Body Tailgate Props 1 52 Decal Location 1 36 De Energize and Lockout Procedures 1 34 DEF Maintenance 4 2 Determine Maximum Turning Speed Before Operating on Roads or Uneven Ground 1 13 Determi...

Page 122: ...Electrical Hazard Warnings 1 10 Preparation Before Traveling to Worksite 1 53 Prepare for Working Near Existing Utilities 1 14 Prepare the Job Site 1 15 Pre Start Checklist 1 18 Preventive Maintenanc...

Page 123: ...Operation 1 18 Vacuum Operation Safety 1 17 Vacuum Relief Valve Safety 1 19 Vacuum Relief Valves 1 19 Vacuum System 2 3 Visibility Conditions When Operating 1 6 1 15 Visual Attention Safety 1 2 W Wat...

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Page 126: ...quire additional information regarding the operation of your Mud Dog Vacuum Excavator Super Products LLC Publication 0004175 2020 Super Products LLC 4 2020 130 W BOXHORN DR MUKWONAGO WI 53149 P 800 83...

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