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PR95

Operator’s

Manual

053- 1102

Issue 1.0

CMW

Summary of Contents for PR95

Page 1: ...PR95 Operator s Manual 053 1102 Issue 1 0 CMW...

Page 2: ...or s Manual Overview 1 CMW Overview Chapter Contents Serial Number Location 2 Intended Use 3 Unit Components 3 Operator Orientation 4 About This Manual 4 Bulleted Lists 4 Numbered Lists 4 Continued In...

Page 3: ...er Location CMW Serial Number Location Record serial numbers and date of purchase in spaces provided Power unit 2 and engine serial numbers 1 are located as shown Date of manufacture Date of purchase...

Page 4: ...res 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 consi...

Page 5: ...sic 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 d...

Page 6: ...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...

Page 7: ...Copyright 2006 by The Charles Machine Works Inc Ditch Witch CMW AutoCrowd Modularmatic Jet Trac Roto Witch Subsite Fluid Miser Perma Soil Power Pipe Super Witch Super Witch II Pierce Airrow The Under...

Page 8: ...the jobsite planning the installation and preparing the jobsite for work 29 Transport procedures for lifting and hauling 39 Burst Pipe procedures for setting up equipment and performing the burst 43 S...

Page 9: ...Contents 8 PR95 Operator s Manual CMW Service Record a record of major service performed on the machine 93...

Page 10: ...ntents Guidelines 10 Safety Alert Classifications 11 Safety Alerts 12 Emergency Procedures 15 Electric Strike Description 15 If an Electric Line is Damaged 16 If a Gas Line is Damaged 17 If a Fiber Op...

Page 11: ...s 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 e...

Page 12: ...evels DANGER WARNING and CAUTION Learn what each level means indicates an imminently hazardous situation which if not avoided will result in death or serious injury indicates a potentially hazardous s...

Page 13: ...r death Provide ventilation Moving tools will kill 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...

Page 14: ...c 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 Fire or explos...

Page 15: ...until cool Exposure to high noise levels may cause hearing loss Wear hearing protection Fall possible Slips or trips may result in injury Keep area clean Battery acid may cause burns Avoid contact Im...

Page 16: ...ust 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 co...

Page 17: ...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 utilit...

Page 18: ...r 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 If a Fiber Optic Cabl...

Page 19: ...Safety 18 PR95 Operator s Manual Emergency Procedures CMW...

Page 20: ...PR95 Operator s Manual Controls 19 CMW Controls Chapter Contents Bursting Unit 20 Remote Controller 21 Power Unit 23 Rod Makeup Device 28...

Page 21: ...nual Bursting Unit CMW Bursting Unit Front jaw control Item Description Notes Front jaw control To enable automatic front jaw operation push To disable pull IMPORTANT Use in pull mode Enable when burs...

Page 22: ...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...

Page 23: ...22 PR95 Operator s Manual Remote Controller CMW 4 Emergency stop switch Push to stop power unit engine IMPORTANT All emergency stops must be connected and disengaged for unit to start Item Descriptio...

Page 24: ...wer Unit CMW Power Unit Gauges and Indicators 1 Hourmeter 2 Main cylinders pressure gauge 3 Jaw system pressure gauge 4 Battery charge indicator 5 Engine preheater indicator 6 Engine oil pressure indi...

Page 25: ...re 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 preh...

Page 26: ...ting unit manual control 8 Rod makeup manual control 9 Rear jaw manual control 10 Ignition switch Item Description Notes 1 Bursting unit engage control To turn on hydraulic flow to bursting unit press...

Page 27: ...nce 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 pull bursting unit contr...

Page 28: ...ls 27 Power Unit CMW 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 dise...

Page 29: ...h 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...

Page 30: ...ullback Material 30 Arrange for Traffic Control 30 Plan for Emergency Services 30 Inspect Site 31 Identify Hazards 32 Select Exit and Burster Pit Locations 33 Plan Bore Path 34 Prepare Jobsite 34 Mark...

Page 31: ...Call Services Call 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 s...

Page 32: ...pment Check for the following changes in elevation such as hills or open trenches obstacles such as buildings railroad crossings or streams signs of utilities buried utility notices utility facilities...

Page 33: ...k location of all buried utilities and obstructions Jobsite hazards could cause death or serious injury Use correct equipment and work methods Use and maintain proper safety equipment NOTICE Wear pers...

Page 34: ...trian 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 pit...

Page 35: ...ify that bursting head does not damage utility Prepare Jobsite Mark Burst Path Mark your planned burst path with flags or paint Jobsite hazards could cause death or serious injury Use correct equipmen...

Page 36: ...pipe Sloped back end aids new pipe entry Burster Pit 2 Must be in line with existing pipe Must allow burster to be level with existing pipe Unit Burster Pit Exit Pit Length A Width B Length C Width D...

Page 37: ...e Equipment CMW Check Supplies and Prepare Equipment Check Supplies marking flags or paint fuel keys cutting heads clevis barrier cones and tape spray lubricant such as WD 40 personal protective equip...

Page 38: ...il Condition and Function filters air oil hydraulic couplers pumps and motors hoses and valves Assemble Accessories Fire Extinguisher If required mount a fire extinguisher near the power unit but away...

Page 39: ...Prepare 38 PR95 Operator s Manual Check Supplies and Prepare Equipment CMW...

Page 40: ...PR95 Operator s Manual Transport 39 CMW Transport Chapter Contents Lift 40 Points 40 Procedure 40...

Page 41: ...afe and can damage machinery 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 l...

Page 42: ...er 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 Rod Box Use a crane capab...

Page 43: ...nsport 42 PR95 Operator s Manual Lift CMW Extension Frame Use a crane capable of supporting the equipment s size and weight Accessory Kit Use a crane capable of supporting the equipment s size and wei...

Page 44: ...PR95 Operator s Manual Burst Pipe 43 CMW Burst Pipe Chapter Contents Prepare System 44 Push Rods 46 Connect 47 Pull Pipe 48...

Page 45: ...e from rod makeup device 3 Tighten hoses fully 4 Lower bursting unit into pit Use boards to ensure rods will be level with existing pipe 5 Place end of rod makeup device arm into hole on end of rear o...

Page 46: ...m CMW 6 Connect electrical cables Connector 1 is for stationary emergency stop Connector 2 is for remote emergency stop Connector 3 is for remote bursting unit control 7 Connect ground rod to bursting...

Page 47: ...r 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 Pus...

Page 48: ...stall 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 strin...

Page 49: ...nit away from pit wall slightly 2 Slide pulling brace shown into position Ensure brace is flush with pit wall 3 Put bursting unit into pull mode 4 Enable brake 5 Pull back rod 6 Unthread and place in...

Page 50: ...nsion 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 syste...

Page 51: ...Burst Pipe 50 PR95 Operator s Manual Pull Pipe CMW...

Page 52: ...PR95 Operator s Manual Systems and Equipment 51 CMW Systems and Equipment Chapter Contents Bursting String 52 Pilot Rods 52 Bursting Heads 53 Towing Heads 54 Extension Frame 55 Accessory Kit 55...

Page 53: ...g String CMW Bursting String Pilot Rods Type Uses 1 fiber pilot rod used in pipes with considerable joint misalignment 2 flexible pilot rod used in pipes with curves also used in failing pipes 3 stand...

Page 54: ...o prevent shackle and new pipe damage during installation Components IMPORTANT Ensure identification numbers on stop rod system and bursting head match IMPORTANT Standard cutting head is shown Compone...

Page 55: ...aches to new PE pipe allowing it to be pulled through existing pipe after bursting Type Uses 1 standard cutting head ductile iron steel cast iron reinforced concrete 2 standard cracking head concrete...

Page 56: ...om to remove the towing assembly from the new 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 cart...

Page 57: ...Systems and Equipment 56 PR95 Operator s Manual Accessory Kit CMW...

Page 58: ...PR95 Operator s Manual Complete the Job 57 CMW Complete the Job Chapter Contents Stow Components 58 Restore Jobsite 58...

Page 59: ...e the Job 58 PR95 Operator s Manual Stow Components CMW Stow Components 1 Install all covers 2 Load components onto trailer 3 Secure all components on trailer Restore Jobsite Fill in entry and burstin...

Page 60: ...tor s Manual Service 59 CMW Service Chapter Contents Service Precautions 60 Recommended Lubricants Service Key 62 Each Use 64 10 Hour 66 50 Hour 69 200 Hour 73 250 Hour 75 400 Hour 74 1000 Hour 76 As...

Page 61: ...can damage electronics Disconnect battery 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 w...

Page 62: ...61 Service Precautions CMW Opening Closing Power Unit Hood To open 1 Remove pins 2 Lift hood 3 Engage prop rod 2 into holder 1 as shown To close 1 Disengage prop rod from holder 2 Stow prop rod 3 Care...

Page 63: ...ile Manufacturer s Association ACEA and SAE viscosity recommended by engine manufacturer MPG Multipurpose grease meeting ASTM D217 and NLGI 5 THF Tractor hydraulic fluid similar to Phillips 66 HG Mobi...

Page 64: ...r more information on engine lubrication and maintenance see your Kubota engine manual Engine Oil Temperature Chart Approved Coolant Add only only automotive type antifreeze coolant meeting ASTM D3306...

Page 65: ...mponents Lube 4 zerks with MPG each use Lube Rear Pin Bolts Lube 2 zerks with MPG each use Location Task Notes BURSTING UNIT Lube front hydraulic pressure system components MPG Lube rear pin bolts MPG...

Page 66: ...r s Manual Service 65 Each Use CMW Lube Rear Pressure Axles Lube 2 zerks with MPG each use Clean Jaw Threads Clean jaw threads with high pressure water after each job IMPORTANT Ensure rear jaw is up b...

Page 67: ...ration and every 10 hours thereafter Check with 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 Locatio...

Page 68: ...t 1 25 mm below bottom of radiator cap If low add approved coolant Check Hydraulic Fluid Level Check hydraulic fluid level every 10 hours Maintain fluid level at halfway point on upper sight glass 1 w...

Page 69: ...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 containe...

Page 70: ...erks with MPG every 50 hours Location Task Notes BURSTING UNIT Lube large hydraulic cylinders front MPG Lube small front cylinders MPG Lube carriage rollers MPG Lube large hydraulic cylinders rear MPG...

Page 71: ...vice 70 PR95 Operator s Manual 50 Hour CMW Lube Small Front Cylinders Lube 2 zerks with MPG every 50 hours Lube 4 zerks with MPG every 50 hours Lube Carriage Rollers Lube 6 zerks with MPG every 50 hou...

Page 72: ...PR95 Operator s Manual Service 71 50 Hour CMW Lube Large Hydraulic Cylinders Rear Lube 2 zerks with MPG every 50 hours Lube Small Front Cylinders Lower Area Lube 2 zerks with MPG every 50 hours...

Page 73: ...h radiator toward engine If grease and oil are present on radiator spray with solvent and allow to soak overnight Change Engine Oil Filter Initial Service Change engine oil and filter after 50 hours D...

Page 74: ...ne oil after 50 hours Drain oil 4 and add 14 qt 13 L of DEO at fill 2 Location Task Notes POWER UNIT Change engine oil DEO IMPORTANT If operating in extremely dusty conditions change oil more frequent...

Page 75: ...il 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 dea...

Page 76: ...0 Hour Power Unit Clean Hydraulic Strainer Clean hydraulic strainer every 500 hours Replace if damaged Change Hydraulic Filters Change hydraulic filters every 500 hours Location Task Notes POWER UNIT...

Page 77: ...ter and add THF at hydraulic fluid fill 2 Change Engine Coolant Drain cooling system at drain 2 every 1000 hours Add coolant at fill 1 Location Task Notes POWER UNIT Change hydraulic fluid Change engi...

Page 78: ...pair 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 Location Task Notes BURSTING UN...

Page 79: ...CMW 4 Remove covers shown on sides of bursting unit 5 Disconnect hose 2 6 Remove support plate 1 from pin bolt 7 Thread large slide hammer into pin bolt 8 Pull pin bolt clear of cylinders but not all...

Page 80: ...ylinder rod 2 11 Remove snap ring 1 12 Use slide hammer to remove cylinder rod completely 13 Repeat for other cylinder 14 Support cylinders as shown 15 Remove slide hammer 16 Install eye and bolt into...

Page 81: ...Service 80 PR95 Operator s Manual As Needed CMW 19 Lift cam slowly until pressure axle shown is accessible 20 Flip pressure axle clear of jaws to allow access to top jaw...

Page 82: ...R95 Operator s Manual Service 81 As Needed CMW 21 Install bolts into top jaw 22 Engage jaw extraction tool shown on bolts 23 Lift out top jaw 24 Press down on side of lower jaw shown and remove by han...

Page 83: ...n area under lower jaw before reassembly NOTICE If lower rear jaw will not move use 24 mm socket to turn bolt shown under jaw If lower front jaw will not move unbolt access cover turn unit on its side...

Page 84: ...Position pressure axle over upper jaw 5 Lower cam onto pressure axle 6 Align one cylinder with pin hole and use small slide hammer to install rod 7 Repeat for other cylinder 8 Install snap rings 9 Rem...

Page 85: ...using and wash end cup 5 Install new element s 6 Install end cup and engage clasps 7 Reset air filter service indicator 1 Adjust Fan Belt Tension 1 Turn off engine and remove key 2 Apply moderate thum...

Page 86: ...ons Bursting Unit Dimensions U S Metric L length 71 in 1 8 m W width 27 6 in 700 mm H height 43 3 in 1 1 m Weight mass 7050 lb 3200 kg Operational U S Metric Pullback force 187 400 lb 85 t Rod U S Met...

Page 87: ...Specifications 86 PR95 Operator s Manual Power Unit CMW Power Unit Dimensions U S Metric L length 83 in 2 1 m W width 51 2 in 1 3 m H height 49 2 in 1 25 m Weight mass 3200 lb 1450 kg...

Page 88: ...ent 202 in3 3 3 L Bore 3 86 in 98 mm Stroke 4 33 in 110 mm Power manufacturer s gross power rating per SAE J1995 63 hp 47 kW manufacturer s net power rating per SAE J1349 59 hp 44 kW rated speed 2200...

Page 89: ...pment should be weighed and measured Due to selected options delivered equipment may not necessarily match that shown Fluid Capacities U S Metric Fuel tank 10 6 gal 40 L Hydraulic reservoir 53 gal 200...

Page 90: ...hase 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 Us...

Page 91: ...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 H...

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Page 94: ...PR95 Operator s Manual Service Record 93 CMW Service Record Service Performed Date Hours...

Page 95: ...Service Record 94 PR95 Operator s Manual CMW Service Performed Date Hours...

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