Ditch Witch Welder PR95 User's Manual
Contents
1. diusjejeeq uoiM YING JO eueN diusjejeeq uoiM VINA jo eueN SJOQUINN elas Sseuosseooy sjueuliuoenv SJOQUINN jeues Seuosseooy sjueuiuoepv SJequunN elas Sseuosseooy sjueuiuoepnv SJequunwN elas Sseuosseooy sjueuiuo epnv SJOQUNN 1 9 S9IJOSS9IDY SIJUSWYIBHY SJOQUNN 1 0 S HOSS OV S U UVUSEYV jeues Jepoy jeues Japo apog B LV Y IM suoyd apo B LV YIIM JequinN suoyd UOJEN diz ejes UOEN d z aje s Aunoo MO Aunoo MO xog O d JO sseJppy 9a 11s xog O d JO sseJppy 1eeJjs uonuenv uonuenv euieN Auedwos s jaseyoind euieN Auedwosy s saseyoind UONEWJOJU y JUL JO Sd aseald UONEWJOJU y JUL JO d SSBald p189 1 u231M u iq p189 uornessiB s u231M u iq PR95 Operator s Manual Service Record 93 Service Record Service Performed Date Hours CMW Service Record 94 PR95 Operator s Manual Service Performed Date Hours CMW2. 30 HevlevvvobPlan eee 30 e Notify One Call Services 30 Examine Pullback Material 30 Arrange for Traffic Control 30 e Plan for Emergency Services 30 hee R sesso R RB 31 Identify Hazards o EEEE REEERE EEA 32 e Select Exit and Burster Pit Locations 33 Plan Bore Path ccu danced ween a seeds 34 Prepare gobsite 34 Mark Burst Path sre n eb rax RER Rena 34 Prepare Entry Point 35 Check Supplies and Prepare Equipment 36 e Check SupplieS 22 36 Prepare Equipment o ees 37 e Assemble Accessories 37 Prepare 29 Prepare CMW Prepare 30 PR95 Operator s Manual Gather Information Gather information A successful job begins before the burst The first step in planning is reviewing information already available about the job and jobsite Review Job Plan Review blueprints or other plans and make sure you have taken enlargement during pullback into account 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 Cal
3. MPG Multipurpose grease meeting ASTM D217 and NLGI 5 o THF Tractor hydraulic fluid similar to Phillips 66 HG Mobilfluid 423 Chevron Tractor Hydraulic Fluid Texaco TDH Oil Shell Tellus or equivalent AC Automotive type antifreeze coolant meeting ASTM D3306 b Check level of fluid or lubricant Check condition w Filter Change replace adjust service or test CMW PR95 Operator s Manual Service 63 Recommended Lubricants Service Key Proper lubrication and maintenance protects Ditch VVitch 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 Fluid Capacities on page 88 For more information on engine lubrication and maintenance see your Kubota 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 93 to record all required service to your machine Engine Oil Temperature Chart SAE VISCOSITY GRADES SAE30 SAE10W 30 SAE10W 40 SAE20 SAE10VV 30 SAE10VV 40 SAE10VV SAE10VV 30 SAE10VV 40 AMBIENT TEMPERATURE t18om049a eps Temperature range anticipated before next oil change Approved Coolant Add only only automotive type antifreeze coolant meeting ASTM D3306 NOTICE Do not use di
4. 1 6 J190m033h eps PR95 Operator s Manual 50 Hour Lube Large Hydraulic Cylinders Rear Lube 2 zerks vvith MPG every 50 hours Lube Small Front Cylinders Lower Area Lube 2 zerks vvith MPG every 50 hours Service 71 J190m037h eps J190m034h eps CMW Service 72 Povver Unit Check Radiator Check radiator fins for dirt grass and other foreign matter every 50 hours Check more often if operating in dusty or grassy conditions Clean as needed To clean Clean fins with compressed air or spray wash Open rear hood and spray through radiator toward engine If grease and oil are present on radiator spray with solvent and allow to soak overnight PR95 Operator s Manual 50 Hour J190m023h eps IMPORTANT Be careful not to damage fins with high pressure air or water Change Engine Oil amp Filter Initial Service Change engine oil and filter after 50 hours Drain oil 4 change filter 3 and add 14 qt 13 L of DEO at fill 2 IMPORTANT If operating in extremely dusty conditions change oil more frequently Use oil specified in temperature chart found in Recommended Lubricants Service Key on page 62 CMW J190m027h eps PR95 Operator s Man
5. CMW Systems and Equipment 52 Bursting String Pilot Rods PR95 Operator s Manual Bursting String Type Uses 1 fiber pilot rod used in pipes vvith considerable joint misalignment 2 flexible pilot used in pipes with curves rod also used in failing pipes 3 standard used in pipes without joint pilot rod misalignment CMW Dum q J190m069h eps PR95 Operator s Manual Systems and Equipment 53 Bursting String Bursting Heads Identification IMPORTANT Ensure identification numbers on stop rod system and bursting head match Stop rods and bursting heads are each marked with an identification number The length of the stop rod and chain is optimized for each bursting head Always use matched components to prevent DO shackle and new pipe damage during installation NG J190m089h eps Components 1 X 2 IMPORTANT Standard cutting head is shown O P d Component Description 4 1 rear of bursting fits OD of nevv pipe head being installed 2 knife cuts existing pipe 3 7 bursting fits inside existing pipe S E re 5 AL L3 x 4 stop rod connects rods in 5 4 existing pipe to towing J190m071h eps head 5 d link and chain attaches new pipe to on stop rod stop rod system CMW Systems and Eq
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7. Stow Components Stow Components 1 Install all covers 2 Load components onto trailer 3 Secure all components on trailer Restore Jobsite Fill in entry and bursting pits CMW PR95 Operator s Manual Chapter Contents Service Precautions 60 Recommended Lubricants Service Key 62 Each USG cics aa a ede cee eee dees AE 64 TO HOUT ues aaa rasa 66 90 HOUF erica e 69 200 PIQUE gt ass ess pres 73 250 THOU escasa AR 75 400 HOU so ar R PANA b 74 1000 HOUR ab i 76 As Needed 77 Service 59 Service CMW Service 60 PR95 Operator s Manual Service Precautions Service Precautions AWARNING Welding Precaution Washing Precaution PR95 Operator s Manual Service 61 Service Precautions Opening Closing Povver Unit Hood To open 1 Remove pins 2 Lift hood 3 Engage prop rod 2 into holder 1 as shown To close Disengage prop rod from holder Stovv prop rod Carefully close hood BP OD c Install pins J190m083h eps CMW Service 62 PR95 Operator s Manual Recommended Lubricants Service Key Recommended Lubricants Service Key Item Description 6 DEO Diesel engine oil meeting or exceeding CD per the API service classification or E3 per the European Automobile Manufacturer s Association ACEA and SAE viscosity recommended by engine manufacturer
8. Warn people nearby that an electric strike has occurred Instruct them to leave the area and contact utility e Contact utility company to shut off power Do not return to area or allow anyone into area until given permission by utility company If you suspect an electric line has been damaged and you are off other piece of equipment DO NOT TOUCH EQUIPMENT Take the following actions The order and degree of action will depend on the situation LEAVE AREA e Contact utility company to shut off power Do not return to area or allow anyone into area until given permission by utility company CMW PR95 Operator s Manual Safety 17 Emergency Procedures If a Gas Line is Damaged If you suspect a gas line has been damaged take the following actions The order and degree of action will depend on the situation Immediately shut off engine s if this can be done safely and quickly PAN 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 e 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 If a Fiber Optic Cable is Damaged Do not look into cut ends of fiber optic or unidentified cable Vision
9. nax Bu MN j190m076h eps Length A Width B Length C Width D U S metric U S metric U S metric U S metric PR95 12 3 6 m 5 1 5 m 10 3 m 3 1 m Exit pit dimensions depend on pipe depth and product being installed Requirements j190m128h eps Exit Pit 1 Must be in line with existing pipe Sloped back end aids new pipe entry Burster Pit 2 e Must be in line with existing pipe Must allow burster to be level with existing pipe CMW Prepare 36 PR95 Operator s Manual Check Supplies and Prepare Equipment Check Supplies and Prepare Equipment Check Supplies marking flags or paint fuel keys cutting heads clevis barrier cones and tape spray lubricant such as VVD 40 personal protective equipment such as hard hat and safety glasses notepad and pencil CMW PR95 Operator s Manual Check Supplies and Prepare Equipment Prepare Equipment Fluid Levels fuel hydraulic fluid engine coolant battery charge engine oil Condition and Function filters air oil hydraulic couplers pumps and motors hoses and valves Assemble Accessories Fire Extinguisher Prepare 37 If required mount a fire extinguisher near the power unit but away from possible points of ignition The fire extinguisher should always be classified for both oil and electric fires It should meet legal and
10. a strike include power outage smoke e explosion popping noises e arcing electricity If any of these occur assume an electric strike has occurred CMW Safety 16 PR95 Operator s Manual Emergency Procedures If an Electric Line is Damaged If you suspect an electric line has been damaged and you are in pit DO NOT MOVE Remain in pit and take the following actions The order and degree of action will depend upon the situation e Warn people nearby that an electric strike has occurred Instruct them to leave the area and contact utility Contact utility company to shut off power Do not leave pit until given permission by utility company If you suspect an electric line has been damaged and you are out of pit DO NOT TOUCH ANYTHING IN PIT 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 e 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 on other piece of equipment DO NOT MOVE Remain on truck or trailer and take the following actions The order and degree of action will depend on the situation
11. control 9 Rear jaw manual control 5 Rod makeup standby control 10 Ignition switch Item Description Notes 1 Bursting unit engage control To turn on hydraulic flow to bursting unit press 2 Bursting unit standby control To stop hydraulic flow to bursting unit press 3 Emergency stop switch To turn off power unit engine press IMPORTANT All emergency stops must be connected and disengaged for unit to start CMW Controls 26 PR95 Operator s Manual Povver Unit Item Description Notes 4 Rod makeup engage control To turn on hydraulic flow to rod makeup device press 5 Rod makeup standby control To stop hydraulic flow to rod makeup device press 6 Throttle To increase engine speed push up To decrease engine speed pull down 7 Bursting unit manual control In push mode To return carriage to back of unit pull To push rod into pipe push In pull mode To pull new pipe through pipe pull To return carriage to front of unit push Use in sequence with rear jaw manual control to push and pull rods from power unit control station Push sequence push jaw manual control push bursting unit manual control pull jaw control e pull bursting unit control Pull sequence push bursting unit manual control push jaw manual control pull bursting unit control e pull jaw control 8 Rod makeup manual cont
12. measured Due to selected options delivered equipment may not necessarily match that shown CMW PR95 Operator s Manual Support 89 Procedure Support Procedure Notify your dealer immediately of any malfunction or failure of Ditch VVitch equipment Always give model serial number and approximate date of your equipment purchase This information should be recorded and placed on file by the ovvner 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 Warranty 90 PR95 Operator s Manual VVarranty Ditch VVitch 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 CMVV that fail due to a defect in material or workmanship within one 1 year of first commercial use Exception 2 years for all SK attach
13. regulatory requirements CMW Prepare 38 PR95 Operator s Manual Check Supplies and Prepare Equipment CMW PR95 Operator s Manual Transport 39 Transport Chapter Contents Lil soba ERG as AL bai 40 olan 40 Procedure sara da 7 ed ORE RO 40 CMW Transport 40 PR95 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 avvay A Points Lifting points are identified by lifting decals Lifting at other points is unsafe and can damage machinery ic1319a eps Procedure Bursting Unit Use a crane capable of supporting the equipment s size and weight See Specifications on page 85 or measure and weigh equipment before lifting Use lift points as shown J190m005h eps CMW PR95 Operator s Manual Transport Lift 41 Povver Pack Use a crane capable of supporting the equipment s size and weight See Specifications on page 85 or measure and weigh equipment before lifting Use lift points as shown J190m003h eps Rod Box Use a crane capable of supporting the equipment s size and weight J190m088h eps CMW Transport 42 PR95 Operator s Manual Lift Extension Frame Use a crane capable of supporting the equipment s size and weight J190m075h eps Accessory Kit Use a crane capable of supporting the
14. 1 Work button white With mode selector in push mode push and hold to push rod into existing pipe With mode selector in pull mode push and hold to pull new pipe 2 Return button black With mode selector in push mode push and hold to return carriage to back of unit Jaws close when button is released With mode selector in pull mode push and hold to return carriage to front of unit Jaws close when button is released 3 Mode selector To enter pull mode move left To enter push mode move right Decal is marked reverse CMW Controls 22 PR95 Operator s Manual Remote Controller Item Description Notes 4 Emergency stop switch Push to stop power unit engine IMPORTANT All emergency stops must be connected and disengaged for unit to start CMW PR95 Operator s Manual Povver Unit Povver Unit Gauges and Indicators HA O O 7 9 j O j190m077h eps Hourmeter Main cylinders pressure gauge Jaw system pressure gauge Battery charge indicator DN m 5 Engine preheater indicator 6 Engine oil pressure indicator 7 Coolant temperature indicator Controls 23 CMW Controls 24 PR95 Operator s Manual Povver Unit Item Description Notes 1 Hourmeter c00ic369h eps Displays engine operatin
15. 11 Safety Alert Classifications Safety Alert Classifications These classifications and the icons defined on the follovving pages vvork 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 dh DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury AX WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury dh CAUTION 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 Safety 12 PR95 Operator s Manual Safety Alerts Safety Alerts dh DANGER 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 dh DANGER Moving tools will kil
16. 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 which 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 6866 220 2 euwoyemo Aiad 99 xog od Oul SYHOM SUIYICIA soj1eu ay L
17. PR95 Operator s Manual CE ome issue 1 0 MN 053 1102 PR95 Operator s Manual Overvievv 1 Overvievv Chapter Contents Serial Number Location 2 Intended Use 3 Unit Components 3 Operator Orientation 4 About This Manual 4 Bulleted Lists 4 Numbered AA PARO NOE 4 Continued Indicators vrai pA AA KAKANIN 4 CMW Overview 2 PR95 Operator s Manual Serial Number Location Serial Number Location Record serial numbers and date of purchase in spaces provided Povver unit 2 and engine serial numbers 1 are located as shovvn 119om109h eps Date of manufacture Date of purchase Povver unit serial number Engine serial number CMW PR95 Operator s Manual Overview 3 Intended Use Intended Use Ditch VVitch pipe bursters are intended for the replacement of buried pipes and conduits The PR95 produces 187 400 lb 88 t of pullback force A power unit provides hydraulic power to run the pipe burster 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
18. ator s Manual 1000 Hour 1000 Hour Location Task Notes POVVER Change hydraulic fluid UNIT i Change engine coolant Power Unit Change Hydraulic Fluid 21 Change hydraulic fluid and filter every 1000 hours for normal service Drain hydraulic fluid 3 change filter and add THF at hydraulic fluid fill 2 J190m021h eps 1 Change Engine Coolant Drain cooling system at drain 2 every 1000 hours Add coolant at fill 1 NOTICE The use of non approved coolant may lead to engine damage or premature engine failure and will void engine warranty See Approved Coolant on page 63 for list Of approved coolanis m Y J190m022h eps CMW PR95 Operator s Manual Service 77 As Needed As Needed Location Task Notes BURSTING Repair jaw threads UNIT POWER Change air filter UNIT Adjust fan belt tension Bursting Unit Repair Jaw Threads Remove Jaws 1 Remove covers shown 2 Put bursting unit into manual mode and move cylinders until pin bolt hole is aligned with hole 3 Open jaws slightly J190m118h eps CMW Service 78 PR95 Operator s Manual As Needed 4 Remove covers shovvn on sides of bursting unit J190m041h eps 5 Disconnect hose 2 6 Remove support plate 1 from pin bolt J190m042h eps 7 Thread large s
19. d rod into soil at front of pit CMW Burst Pipe 46 PR95 Operator s Manual Push Rods Push Rods IMPORTANT If bursting unit or rod makeup device does not work Ensure all emergency stops are connected and disengaged e Check all hydraulic and electrical connections Start povver unit engine Assemble pilot rod See Pilot Rods on page 52 Disable brake Thread 2 3 rods together Boom IMPORTANT Spray lubricant such as WD 40 on threads of each rod every use 5 Put bursting unit into push mode and push rod string into existing pipe 6 Thread next rod onto rod string loosely 7 Swing rod makeup device into position and place collar onto end of rod 8 Thread onto pipe loosely 9 Turn rotation speed direction control to right 10 Press engage switch until rods thread together completely 11 Move rod makeup device clear of rod 12 Push rod into pipe 13 Continue threading rods together and pushing into pipe until pilot assembly enters exit pit CMW PR95 Operator s Manual Burst Pipe 47 Connect Connect 1 Install towing head 2 onto end of new pipe 1 2 Remove pilot rod assembly 3 Install bursting head 5 over rod 6 and slide forward until threads are visible 4 Thread stop rod assembly 4 on end of rod string 5 Connect stop rod assembly to towing head with a shackle 3 J190m127h eps j190m008h eps CMW Burst Pipe 48 PR95 Operato
20. 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 e f fire is small and fire extinguisher is available attempt to extinguish fire e f fire cannot be extinguished leave area as quickly as possible and contact emergency personnel CMW Safety 18 PR95 Operator s Manual Emergency Procedures CMW PR95 Operator s Manual Controls 19 Controls Chapter Contents Bursting Unit ba a 20 Remote Controller 21 Power Unit onec usb lay e eee 23 Rod Makeup Device 28 CMW fo Controls 20 PR95 Operator s Manual Bursting Unit Bursting Unit J190m031h eps Front jaw control Item Description Notes Front jaw control To enable automatic front jaw IMPORTANT Use in pull mode operation push Enable when bursting pipe 8 Disable when pushing CMW PR95 Operator s Manual Remote Controller Remote Controller Controls 21 J190m129h eps 1 Work button white 2 Return button black 3 Mode switch 4 Emergency stop switch Item Description Notes
21. each job CMW Service 66 PR95 Operator s Manual 10 Hour 10 Hour Location Task Notes POVVER Check engine oil level UNIT Check hydraulic fluid level Check coolant level Check hydraulic hoses and fittings Povver Unit Check Engine Oil Level 2 b Check engine oil at dipstick 1 before operation and every 10 hours thereafter Check vvith unit on level surface and at least 15 minutes after stopping engine Add DEO at fill 2 as necessary to keep oil level at highest line on dipstick J190m026h eps CMW PR95 Operator s Manual 10 Hour Check Engine Coolant Level Check coolant level vvith engine cool every 10 hours Maintain coolant level at 1 25 mm belovv bottom of radiator cap If low add approved coolant IMPORTANT See Approved Coolant on page 83 for information on approved coolants Check Hydraulic Fluid Level Check hydraulic fluid level every 10 hours Maintain fluid level at halfway point on upper sight glass 1 when engine is off and fluid is cool Add THF at hydraulic fluid fill 2 Service 67 J190m013h eps J190m014h eps CMW Service 68 PR95 Operator s Manual 10 Hour heck H lic H Check Hydraulic Hoses vo Check hydraulic hoses for leaks every 10 hours ae a V 1 EZ J190m082h eps AV ARNING CMW PR95 Operator s Manual S
22. equipment s size and weight J190m004h eps CMW PR95 Operator s Manual Burst Pipe 43 Burst Pipe Chapter Contents Prepare System 44 Pus HOUS sea b ma Radara s 46 Connect saa a a m al m Rss 47 Pull Pipe y aaa en a R x 48 CMW Burst Pipe 44 PR95 Operator s Manual Prepare System Prepare System 1 Unload bursting unit power unit and rod boxes next to burster pit 2 Connect hydraulic hoses to power unit x MPORTANT 2 Ensure connectors are clean before threading hoses onto connectors 7 a 4 Each connector is a different size and 6 will only attach to the same sized YO connector o 5 Connect hose 5 first and work up to hose 1 for easy access J190m020h eps Hoses 1 2 3 and 5 are from bursting unit Hoses 4 and 6 are from rod makeup device Tighten hoses fully Lower bursting unit into pit Use boards to ensure rods will be level with existing pipe Place end of rod makeup device arm into hole on end of rear of bursting unit J190m132h eps CMW PR95 Operator s Manual Burst Pipe 45 Prepare System 6 Connect electrical cables Connector 1 is for stationary emergency stop e Connector 2 is for remote emergency stop e Connector 3 is for remote bursting unit control J190m007h eps 7 Connect ground rod to bursting unit 8 Drive groun
23. ervice 69 50 Hour 50 Hour Location Task Notes BURSTING Lube large hydraulic cylinders front MPG l UNIT Lube small front cylinders MPG Lube carriage rollers MPG Lube large hydraulic cylinders rear MPG Lube small front cylinders lower area MPG POWER Check radiator UNIT Change engine oil and filter Initial service Bursting Unit Lube Large Hydraulic Cylinders Front O Lube 2 zerks with MPG every 50 hours G S o Oi 9 3 n J190m039h eps EA CMW Service 70 Lube Small Front Cylinders Lube 2 zerks vvith MPG every 50 hours Lube 4 zerks vvith MPG every 50 hours Lube Carriage Rollers Lube 6 zerks vvith MPG every 50 hours CMW PR95 Operator s Manual 50 Hour J190m034h eps N T 0 J190m040h eps
24. esel engine antifreeze coolant This will lead to engine damage or premature engine failure CMW Service 64 PR95 Operator s Manual Each Use Fach Use Location Task Notes BURSTING Lube front hydraulic pressure system components MPG UNIT Lube rear pin bolts MPG Lube rear pressure axles MPG Clean jaw threads after each job Bursting Unit Lube Front Hydraulic Pressure System Components 1 ol 2 0 Lube 4 zerks with MPG each use 3 IMPORTANT Ensure front jaw is up before 4 lubing al i I IE Ol O 1 Lube Rear Pin Bolts Lube 2 zerks vvith MPG each use CMW J190m038h eps J190m035h eps PR95 Operator s Manual Service 65 Each Use Lube Rear Pressure Axles Lube 2 zerks with MPG each use IMPORTANT Ensure rear jaw is up before lubing o le l e 9 o J190m036h eps Clean Jaw Threads Clean jaw threads with high pressure water after
25. g time Gauge is marked hours Use these times to schedule service 2 Main cylinders pressure gauge c00ic37 1h eps Displays hydraulic pressure at main cylinders Gauge is marked pump pressure main Full load reading should be 3600 psi 248 bar 3 Jaw system pressure gauge c00ic371h eps Displays hydraulic pressure in jaw system Gauge is marked pump pressure jaws Full load reading should be 3600 psi 248 bar 4 Battery charge indicator Lights when battery is not charging Indicator is marked charge 5 Engine preheater indicator Lights when glow plugs are on Indicator is marked glow IMPORTANT Start engine after light goes off 6 Engine oil pressure indicator Lights when engine oil pressure is low Indicator is marked oil pressure 7 Coolant temperature indicator Lights if cooling system fluid overheats ndicator is marked vvater temp Turn off engine and let cool e Check cooling system fluid level CMW PR95 Operator s Manual Power Unit Controls Controls 25 O e O 999 10 1 6d iz X j190m002h eps 1 Bursting unit engage control 6 Throttle 2 Bursting unit standby control 7 Bursting unit manual control 3 Emergency stop switch 8 Rod makeup manual control 4 Rod makeup engage
26. h 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 Foreword 6 PR95 Operator s Manual PR95 Operator s Manual ssue number 1 0 OM 9 06 Part number 053 1102 Copyright 2006 by The Charles Machine VVorks Inc a Eg Ditch ES Witch Ditch Witch CMW AutoCrowd Modularmatic Jet Trac Roto Witch Subsite Fluid Miser Perma Soil Power Pipe Super Witch Super Witch II Pierce Airrow The Underground and The Underground Authority Worldwide are registered trademarks of The Charles Machine Works Inc CMW PR95 Operator s Manual Contents 7 Contents Overvievv 1 machine serial number information about the type of vvork this machine is designed to perform basic machine compone
27. intended use Ditch Witch pipe bursters and power units should be operated serviced and repaired only by persons familiar with their particular characteristics and acquainted with the relevant safety procedures Unit Components j190m001h eps 1 Power unit 3 Bursting unit 2 Accessory kit 4 Rod makeup device CMW Overview 4 PR95 Operator s Manual Operator Orientation Operator Orientation P IMPORTANT Top view of unit is shown 1 Front of unit oo 2 Right side of unit 4 2 3 Rear of unit 4 Left side of unit OO 3 J190m143h eps About This Manual This manual contains information for the proper use of this machine See Operation Overview for basic operating procedures Cross references such as See page 50 will direct you to detailed procedures Bulleted Lists Bulleted lists provide helpful or important information or contain procedures that do not have to be performed in a specific order Numbered Lists Numbered lists contain illustration callouts or list steps that must be performed in order Continued Indicators indicates that a procedure is continued on the next page CMW PR95 Operator s Manual Foreword 5 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 wit
28. ir Jaw Threads 1 Use screwdriver to remove debris from threads Pressure wash threads Use grinder to repair threads as shown IMPORTANT Grind only enough material from jaws to return them to the correct shape J190m050h eps Install Jaws Install lower jaw Install upper jaw Remove jaw extraction tool and bolts Position pressure axle over upper jaw Lower cam onto pressure axle Align one cylinder with pin hole and use small slide hammer to install rod Repeat for other cylinder Install snap rings Remove slide hammer P e N m de Oo qe z 0 Thread large slide hammer into other side of pin bolt 11 Use slide hammer to pull pin bolt into position 12 Install support plate 13 Remove slide hammer 14 Install covers CMW Service 84 PR95 Operator s Manual As Needed Povver Unit Change Air Filter o Change air filter as needed To change 1 Disengage clasps 2 and remove end cup Remove primary element 3 Remove secondary element 4 if dirty VVipe inside of housing and vvash end cup Install new element s r Install end cup and engage clasps B J190m019h eps ND a RF o Reset air filter service indicator 1 Adjust Fan Belt Tension 1 Tum off engine and remove key 2 Apply moderate thumb pressure to belt between pulleys as shown 3 Belt is properly tensioned when deflection is ab
29. l area One Call or similar services and have existing lines located and marked Call any utilities in your area that do not subscribe to One Call Examine Pullback Material Ask for a sample of the material you will be pulling back Check its weight and stifiness Contact the manufacturer for bend radius information Check that you have appropriate pullback devices 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 PR95 Operator s Manual Prepare 31 Inspect Site Inspect Site nspect iobsite before transporting equipment Check for the follovving Inspect jobsite before transporting equipment Check for the following changes in elevation such as hills or open trenches e obstacles such as buildings railroad crossings or streams signs of utilities buried utility notices Utility facilities without overhead lines gas or water meters junction boxes drop boxes light poles manhole covers sunken ground e traffic access soil type and condition depths of existing pipes CMW Prepare 32 PR95 Operator s Manual Inspect Site Identify Hazards e Identify safety hazards Follow U S Department of Labor regulations on excavating and tre
30. l or injure Never use wrenches or tools on moving rods and burster unit components when unit is operating 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 on unit could cut off hand or foot Stay away CMW PR95 Operator s Manual Safety 13 Safety Alerts AX WARNING Incorrect procedures could result in death injury or property damage Learn to use equipment correctly AX WARNING 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 smoking no flame no spark NI AA WARNING Fire or explosion possible Fumes could ignite and cause burns No Moving traffic hazardous situation Death or serious injury could result Avoid moving vehicles wear high visibility clothing post appropriate warning signs AX WARNING Hot pressurized cooling system fluid could cause serious burns Allow to co
31. lide hammer into pin bolt Pull pin bolt clear of cylinders but not all the way out as shown 9 Remove slide hammer J190m043h eps CMW PR95 Operator s Manual Service 79 As Needed 10 Thread small slide hammer 3 into eylinder rod 2 11 Remove snap ring 1 12 Use slide hammer to remove cylinder rod completely 13 Repeat for other cylinder J190m046h eps 14 Support cylinders as shown 15 Remove slide hammer J190m119h eps 16 Install eye and bolt into cam 17 Push cylinder control forward gently 18 Attach lifting device to pin as shown J190m120h eps CMW Service 80 PR95 Operator s Manual As Needed 19 Lift cam slowly until pressure axle shown is accessible J190m121h eps 20 Flip pressure axle clear of jaws to allow access to top jaw J190m0122h eps CMW PR95 Operator s Manual Service 81 As Needed 21 Install bolts into top jaw 22 Engage jaw extraction tool shown on bolts 23 Lift out top jaw J190m0123h eps 24 Press down on side of lower jaw shown and remove by hand J190m0124h eps CMW Service 82 PR95 Operator s Manual As Needed pa J190m0125h eps J190m0126h eps 25 Clean area under lower jaw before reassembly CMW PR95 Operator s Manual Service 83 As Needed Repa
32. ments 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
33. nching Part 1926 Subpart P and other similar regulations Have an experienced locating equipment operator sweep area within 20 6 m to each side of burst path Verify previously marked line and cable locations Mark location of all buried utilities and obstructions 37 CMW PR95 Operator s Manual Prepare 33 Inspect Site Select Exit and Burster Pit Locations Consider the following when selecting pit locations Traffic Vehicle and pedestrian traffic must be a safe distance from bursting equipment Allow at least 10 3 m buffer zone around equipment Space Check that starting and ending points allow enough space for exit and burster pits Check that exit area has enough space for product to be installed Check that there is enough space to work Access Consider shade wind fumes and other site features CMVV Prepare 34 PR95 Operator s Manual Plan Burst Path Plan Burst Path Plan the burst path from entry to end before job begins Locate the entire route of the pipe to be replaced to ensure a straight path Expose all crossing or parallel utilities within 18 500 mm of the pipe being burst Visually verify that bursting head does not damage utility Prepare Jobsite mm 37 Mark Burst Path Mark your planned burst path vvith flags or paint CMW PR95 Operator s Manual Prepare 35 Prepare dobsite Dig Launch and Burster Pits Dimensions poss
34. nis and hovv to use this manual Forevvord 5 part number revision level and publication date of this manual and factory contact information Safety 9 machine safety alerts and emergency procedures Controls 19 machine controls gauges and indicators and hovv to use them Prepare 29 procedures for inspecting and classifying the jobsite planning the installation and preparing the jobsite for work Transport 39 procedures for lifting and hauling Burst Pipe 43 procedures for setting up equipment and performing the burst re Systems and Equipment 51 A SS bursting string accessory kit Complete the Job 57 procedures for restoring the jobsite and storing equipment Service 59 service intervals and instructions for this machine including lubrication replacement of wear items and basic maintenance 1 5 KA KA Specifications 85 machine specifications including weights measurements power ratings and fluid capacities Support 89 1 the vvarranty policy for this machine and procedures for obtaining vvarranty consideration and training CMVV Contents 8 PR95 Operator s Manual CMW PR95 Operator s Manual Chapter Contents Guidelines cesos srta AY AY 10 Safety Alert Classifications 11 Safety Aler S WING R 12 Emergency Procedures 15 Electric Strike eee 15 If an Electric Line i
35. ol before servicing CMW Safety 14 PR95 Operator s Manual Safety Alerts dh CAUTION Flying objects may cause injury Wear hard hat and safety glasses ll dh CAUTION Hot parts may cause burns Do not touch until cool dh CAUTION Exposure to high noise levels may cause hearing loss Wear hearing protection dh CAUTION Fall possible Slips or trips may result in injury Keep area clean TJWNEOR Ww 4k CAUTION Battery acid may cause burns Avoid contact 4k CAUTION 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 PR95 Operator s Manual Safety 15 Emergency Procedures Emergency Procedures Before operating any equipment review emergency procedures and check that all safety precautions have been taken EMERGENCY SHUTDOWN Turn ignition switch to stop position or push remote engine stop button Electric Strike Description When working near electric cables remember the following Electricity follows all paths to ground not just path of least resistance Pipes hoses and cables will conduct electricity back to all equipment Low voltage current can injure or kill Almost one third of work related electrocutions result from contact with less than 440 volts Most electric strikes are not noticeable but indications of
36. out 1 4 3 8 7 9 mm 4 If needed loosen alternator bolts shown and pull alternator out until correct tension is reached 5 Tighten alternator bolts J190m028h eps CMW PR95 Operator s Manual Bursting Unit Specifications 85 Bursting Unit a L V oo ol Na Hie Q On Q wv H 9 e 9 O j190m067h eps Dimensions U S Metric L length 71 in 1 8m W width 27 6 in 700 mm H height 43 3 in 1 4m Weight mass 7050 Ib 3200 kg Operational U S Metric Pullback force 187 400 Ib 85t Rod U S Metric Length 39 4 in 1m Diameter 1 97 in 50 mm Weight mass 33 Ib 15 kg CMW Specifications 86 PR95 Operator s Manual Povver Unit Povver Unit j190m066h eps Dimensions U S Metric L length 83in 2 1m W wid
37. r s Manual Pull Pipe Pull Pipe mn j190m009h eps 1 Push bursting unit away from pit wall slightly pi O O ES Slide pulling brace shown into position Ensure brace is flush with pit wall Put bursting unit into pull mode Enable brake Pull back rod Unthread and place in rod box oco Continue pulling back rods until towing assembly reaches burster pit J190m131h eps CMW PR95 Operator s Manual Burst Pipe 49 Pull Pipe 119om011h eps 8 Thread one rod onto rod in bursting unit 9 Remove rod makeup device 10 Push bursting unit back slightly to remove pulling brace 11 Move burster back in pit and position extension frame between between pipe burster and existing pipe 12 Put bursting unit in pull mode and pull towing system into extension frame 13 Remove extension frame 14 Disconnect and remove towing system 15 Remove bursting unit from pit 16 Connect both ends of new pipe to existing pipe to complete job 119om012h eps CMVV Burst Pipe 50 PR95 Operator s Manual Pull Pipe CMW PR95 Operator s Manual Systems and Equipment 51 Systems and Equipment Chapter Contents Bursting String ix Aha AE 52 P lotbodse mah KE l AA a ad e pna 52 Bursting Heads esanaia eee enda aa aa KK eR Eo des A 53 TOWING es as Riese Sex t os C er Roca RC 54 Extension Frame 55 Accessory K L n ase RAE 55 NY e
38. rol To engage hydraulics to rod makeup device pull and hold To disengage hydraulics release 9 Rear jaw manual control In push mode To close jaws pull To open jaws push In pull mode To close jaws push To open jaws pull Use in sequence with bursting unit manual control to push and pull rods See Bursting unit manual control for sequence CMW PR95 Operator s Manual Power Unit Controls 27 Item Description Notes 10 Ignition switch To start engine insert key and turn clockwise To stop engine turn key counterclockwise IMPORTANT If unit won t start ensure all emergency stop switches are disengaged CMW fe Controls 28 Rod Makeup Device j190m145h eps 1 Engage switch PR95 Operator s Manual Rod Makeup Device 7 Md NG 2 Rotation speed direction control Item Description Notes 1 Engage switch Press switch to engage rod makeup device IMPORTANT Jaws must be closed before unthreading rod in rod device to prevent unthreading downhole 2 Rotation speed direction control To thread rods faster move handle to right To thread unthread rods slower move handle toward center To unthread rods faster move handle to left IMPORTANT Direction is determined from standing behind engage handle CMW PR95 Operator s Manual Chapter Contents Gather Information
39. s Damaged 16 Ifa Gas Line is Damaged 17 If a Fiber Optic Cable is Damaged 17 If Machine Catches on Fire 17 Safety 9 Safety CMW Safety 10 PR95 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 One Call 888 258 0808 and any utility companies which do not subscribe to One Call Have all underground pipes and cables located and marked before operating equipment If you damage a utility contact utility company 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 is present Contact your Ditch Witch dealer if you have any question about operation maintenance or equipment use CMW PR95 Operator s Manual Safety
40. th 51 2 in 13m H height 49 2 in 1 25m Weight mass 3200 lb 1450 kg CMW PR95 Operator s Manual Specifications 87 Povver Unit Povver U S Metric Engine Kubota V3300E Fuel diesel Cooling medium liquid niection indirect Aspiration natural Cylinders 4 Displacement 202 in3 3 3L Bore 3 86 in 98 mm Stroke 4 33 in 110 mm Power manufacturer s gross power rating per SAE J1995 63 hp 47 kVV manufacturer s net power rating per SAE 41349 59 hp 44 kVV rated speed 2200 rpm 2200 rpm Hydraulic System U S Metric Main pump Maximum flovv 42 gpm 161 L min Maximum pressure 3600 psi 250 bar Jaw pump Maximum flow 17 gpm 64 L min Maximum pressure 3600 psi 250 bar CMW Specifications 88 PR95 Operator s Manual Povver Unit Fluid Capacities U S Metric Fuel tank 10 6 gal 40L Hydraulic reservoir 53 gal 200L Engine oil including filter 14 qt 13L Engine cooling sytem 5 4 gal 5 1L Battery 12V negative ground SAE cold crank rating OF 18 C 670 amps Noise Levels Exterior 100 dBA sound power per ISO 6395 Operator 79 dBA sound pressure per ISO 6394 Specifications are called out according to SAE recommended practices where indicated Specifications are general and subject to change without notice If exact measurements are required equipment should be weighed and
41. ual Service 73 200 Hour 200 Hour Location Task Notes POVVER Change engine oil DEO UNIT Power Unit Change Engine Oil Change engine oil after 50 hours Drain oil 4 and add 14 qt 13 L of DEO at fill 2 IMPORTANT If operating in extremely dusty conditions change oil more frequently Use oil specified in temperature chart found in Recommended Lubricants Service Key on page 62 J190m027h eps CMW Service 74 400 Hour PR95 Operator s Manual 400 Hour Location Task Notes POVVER Change engine oil filter UNIT Change fuel filter Drilling Unit Change Engine Oil Filter Change engine oil filter 3 every 400 hours for normal service Change Fuel Filter Replace fuel filter every 400 hours If you refuel from cans replace filter more often See parts manual or contact your Ditch Witch dealer for correct replacement filter CMW J190m027h eps J190m030h eps PR95 Operator s Manual Service 75 500 Hour 500 Hour Location Task Notes POVVER Clean hydraulic strainer UNIT Change hydraulic filter Povver Unit Clean Hydraulic Strainer Clean hydraulic strainer every 500 hours Replace if damaged J190m117h eps Change Hydraulic Filters Change hydraulic filters every 500 hours J190m017h eps CMW Service 76 PR95 Oper
42. uipment 54 Types and Uses PR95 Operator s Manual Bursting String Type Uses 1 standard cutting ductile iron steel head cast iron reinforced concrete 2 standard cracking head concrete clay fragile pipe 3 standard plastic PVC PE head plastic PVC PE Towing Heads IMPORTANT Ensure towing head is sized to match new pipe Standard towing head attaches to new PE pipe allowing it to be pulled through existing pipe after bursting CMW PE 2 X oL J190m073h eps J190m072h eps PR95 Operator s Manual Extension Frame Extension Frame The extension frame allovvs room to remove the tovving assembly from the nevv pipe after it enters the bursting unit pit Accessory Kit 7 chain set for power unit bursting unit 3 chain set for smaller items grease gun and grease cartridges ground rod hand tools slide hammers remote control module remote emergency stop modules rod makeup device Systems and Equipment 55 J190m074h eps CMW Systems and Equipment 56 PR95 Operator s Manual Accessory Kit CMW PR95 Operator s Manual Complete the Job 57 Complete the Job ng Chapter Contents Stow Components 58 Restore Jobsite 58 CMW Complete the Job 58 PR95 Operator s Manual
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