PR95 Operator’s Manual CMW® Issue 1.
PR95 Operator’s Manual Overview - 1 Overview Chapter Contents Serial Number Location . . . . . . . . . . . . . . . . . . . . . . 2 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Operator Orientation. . . . . . . . . . . . . . . . . . . . . . . . . 4 About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 4 • Bulleted Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PR95 Operator’s Manual Overview - 2 Serial Number Location 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.
PR95 Operator’s Manual Overview - 3 Intended Use Intended Use Ditch Witch 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.
Overview - 4 PR95 Operator’s Manual Operator Orientation Operator Orientation IMPORTANT: Top view of unit is shown. 1. Front of unit 2. Right side of unit 3. Rear of unit 4. Left side of unit 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.
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 with the equipment at all times for future reference. If you sell your equipment, be sure to give this manual to the new owner. If you need a replacement copy, contact your Ditch Witch dealer.
PR95 Operator’s Manual Foreword - 6 PR95 Operator’s Manual Issue number 1.0/OM-9/06 Part number 053-1102 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 Underground, and The Underground Authority Worldwide are registered trademarks of The Charles Machine Works, Inc.
PR95 Operator’s Manual Contents - 7 Contents Overview 1 machine serial number, information about the type of work this machine is designed to perform, basic machine components, and how to use this manual Foreword 5 part number, revision level, and publication date of this manual, and factory contact information Safety 9 machine safety alerts and emergency procedures Controls 19 machine controls, gauges, and indicators and how to use them Prepare 29 procedures for inspecting and classifying t
Contents - 8 Service Record a record of major service performed on the machine CMW PR95 Operator’s Manual 93
PR95 Operator’s Manual Safety - 9 Safety Chapter Contents Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Safety Alert Classifications . . . . . . . . . . . . . . . . . . 11 Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Emergency Procedures . . . . . . . . . . . . . . . . . . . . . 15 • Electric Strike Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 • If an Electric Line is Damaged . . . . . . . . . . . .
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.
PR95 Operator’s Manual Safety - 11 Safety Alert Classifications Safety Alert Classifications These classifications and the icons defined on the following pages work together to alert you to situations which could be harmful to you, jobsite bystanders or your equipment. When you see these words and icons in the book or on the machine, carefully read and follow all instructions. YOUR SAFETY IS AT STAKE. Watch for the three safety alert levels: DANGER, WARNING and CAUTION. Learn what each level means.
PR95 Operator’s Manual Safety - 12 Safety Alerts Safety Alerts 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. 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 injury. Use correct equipment and work methods.
PR95 Operator’s Manual Safety - 13 Safety Alerts Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly. 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.
PR95 Operator’s Manual Safety - 14 Safety Alerts Flying objects may cause injury. Wear hard hat and safety glasses. Hot parts may cause burns. Do not touch 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. Improper handling or use of chemicals may result in illness, injury, or equipment damage.
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.
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. • 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.
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. • 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.
Safety - 18 PR95 Operator’s Manual Emergency Procedures CMW
PR95 Operator’s Manual Controls - 19 Controls Chapter Contents Bursting Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Remote Controller . . . . . . . . . . . . . . . . . . . . . . . . . 21 Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Rod Makeup Device . . . . . . . . . . . . . . . . . . . . . . . .
PR95 Operator’s Manual Controls - 20 Bursting Unit Bursting Unit Front jaw control Item Description Notes Front jaw control To enable automatic front jaw operation, push. IMPORTANT: Use in pull mode. To disable, pull. CMW • Enable when bursting pipe. • Disable when pushing.
PR95 Operator’s Manual Controls - 21 Remote Controller Remote Controller 1. Work button (white) 3. Mode switch 2. Return button (black) 4. Emergency stop switch Item Description 1. Work button (white) With mode selector in push mode, push and hold to push rod into existing pipe. Notes 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.
PR95 Operator’s Manual Controls - 22 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.
PR95 Operator’s Manual Controls - 23 Power Unit Power Unit Gauges and Indicators 1. Hourmeter 5. Engine preheater indicator 2. Main cylinders pressure gauge 6. Engine oil pressure indicator 3. Jaw system pressure gauge 7. Coolant temperature indicator 4.
PR95 Operator’s Manual Controls - 24 Power Unit Item Description Notes 1. Hourmeter Displays engine operating time. Gauge is marked “hours.” Use these times to schedule service. 2. Main cylinders pressure gauge 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 Displays hydraulic pressure in jaw system. Gauge is marked “pump pressure jaws.
PR95 Operator’s Manual Controls - 25 Power Unit Controls 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 control 9. Rear jaw manual control 5. Rod makeup standby control 10. Ignition switch Item Description 1. Bursting unit engage control To turn on hydraulic flow to bursting unit, press. 2.
PR95 Operator’s Manual Controls - 26 Power Unit Item Description 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. Notes To decrease engine speed, pull down. 7. Bursting unit manual control In push mode: To return carriage to back of unit, pull.
PR95 Operator’s Manual Controls - 27 Power Unit Item Description Notes 10. Ignition switch To start engine, insert key and turn clockwise. IMPORTANT: If unit won’t start, ensure all emergency stop switches are disengaged. To stop engine, turn key counterclockwise.
PR95 Operator’s Manual Controls - 28 Rod Makeup Device Rod Makeup Device 1. Engage switch 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. IMPORTANT: Direction is determined from standing behind engage handle.
PR95 Operator’s Manual Prepare - 29 Prepare Chapter Contents Gather Information . . . . . . . . . . . . . . . . . . . . . . . . . 30 • Review Job Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 • Notify One-Call Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 • Examine Pullback Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 • Arrange for Traffic Control. . . . . . . . . . . . . . . .
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.
PR95 Operator’s Manual Prepare - 31 Inspect Site Inspect Site Inspect jobsite before transporting equipment. Check for the following: Inspect jobsite before transporting equipment.
PR95 Operator’s Manual Prepare - 32 Inspect Site Identify Hazards • Identify safety hazards. Follow U.S. Department of Labor regulations on excavating and trenching (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. Jobsite hazards could cause death or serious injury.
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.
PR95 Operator’s Manual Prepare - 34 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 Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment.
PR95 Operator’s Manual Prepare - 35 Prepare Jobsite Dig Launch and Burster Pits Dimensions Unit PR95 Burster Pit Exit Pit * Length (A) Width (B) Length (C) Width (D) U.S. (metric) U.S. (metric) U.S. (metric) U.S. (metric) 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 Exit Pit (1) • Must be in line with existing pipe. • Sloped back end aids new pipe entry.
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 WD-40) • personal protective equipment, such as hard hat and safety glasses • notepad and pencil CMW
PR95 Operator’s Manual Prepare - 37 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 If required, mount a fire extinguisher near the power unit but away from possible points of ignition.
Prepare - 38 PR95 Operator’s Manual Check Supplies and Prepare Equipment CMW
PR95 Operator’s Manual Transport - 39 Transport Chapter Contents Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 • Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 • Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PR95 Operator’s Manual Transport - 40 Lift Lift Crushing weight. If load falls or moves it could kill or crush you. Use proper procedures and equipment or stay away. Points Lifting points are identified by lifting decals. Lifting at other points is unsafe 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 lift points as shown.
PR95 Operator’s Manual Transport - 41 Lift Power 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 capable of supporting the equipment's size and weight.
Transport - 42 PR95 Operator’s Manual Lift 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 weight.
PR95 Operator’s Manual Burst Pipe - 43 Burst Pipe Chapter Contents Prepare System . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Push Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Pull Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. IMPORTANT: • Ensure connectors are clean before threading hoses onto connectors. • Each connector is a different size and will only attach to the same-sized connector. • Connect hose 5 first and work up to hose 1 for easy access. • Hoses 1, 2, 3 and 5 are from bursting unit. • Hoses 4 and 6 are from rod makeup device.
PR95 Operator’s Manual Burst Pipe - 45 Prepare System 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 unit. 8. Drive ground rod into soil at front of pit.
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. • Check all hydraulic and electrical connections. 1. Start power unit engine. 2. Assemble pilot rod. See “Pilot Rods” on page 52. 3. Disable brake. 4. Thread 2-3 rods together. IMPORTANT: Spray lubricant (such as WD-40) on threads of each rod every use. 5.
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).
Burst Pipe - 48 PR95 Operator’s Manual Pull Pipe Pull Pipe 1. Push bursting unit 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 rod box. 7. Continue pulling back rods until towing assembly reaches burster pit.
PR95 Operator’s Manual Burst Pipe - 49 Pull Pipe 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. IMPORTANT: Ensure extension frame is level and centered. Pull bursting unit forward until it is firmly against extension frame. 12. Put bursting unit in pull mode and pull towing system into extension frame. 13.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 • Pilot Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 • Bursting Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 • Towing Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Systems and Equipment - 52 PR95 Operator’s Manual Bursting String 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.
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 shackle and new pipe damage during installation. Components IMPORTANT: Standard cutting head is shown. Component Description 1.
Systems and Equipment - 54 PR95 Operator’s Manual Bursting String Types and Uses Type Uses 1. standard cutting head ductile iron, steel, 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.
PR95 Operator’s Manual Systems and Equipment - 55 Extension Frame Extension Frame The extension frame allows room to remove the towing assembly from the new pipe after it enters the bursting unit pit.
Systems and Equipment - 56 PR95 Operator’s Manual Accessory Kit CMW
PR95 Operator’s Manual Complete the Job - 57 Complete the Job Chapter Contents Stow Components . . . . . . . . . . . . . . . . . . . . . . . . . 58 Restore Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . .
Complete the Job - 58 PR95 Operator’s Manual 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.
PR95 Operator’s Manual Service - 59 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 .
PR95 Operator’s Manual Service - 60 Service Precautions Service Precautions Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly. NOTICES: • Unless otherwise instructed, all service should be performed with engine off. • Refer to engine manufacturer’s manual for engine maintenance instructions. Welding Precaution NOTICE: Welding can damage electronics. • Disconnect battery to prevent damage to battery.
PR95 Operator’s Manual Service - 61 Service Precautions 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. Carefully close hood. 4. Install pins.
PR95 Operator’s Manual Service - 62 Recommended Lubricants/Service Key Recommended Lubricants/Service Key Item Description 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 MPG Multipurpose grease meeting ASTM D217 and NLGI 5 THF Tractor hydraulic fluid, similar to Phillips 66 HG, Mobilfluid 423, Chevron Tractor Hydraulic Fluid, Texaco TDH Oil, Shel
PR95 Operator’s Manual Service - 63 Recommended Lubricants/Service Key Proper lubrication and maintenance protects Ditch Witch equipment from damage and failure. Service intervals listed are for minimum requirements. In extreme conditions, service machine more frequently. Use only recommended lubricants. Fill to capacities listed in “Fluid Capacities” on page 88. For more information on engine lubrication and maintenance, see your Kubota® engine manual.
PR95 Operator’s Manual Service - 64 Each Use Each Use Location Task Notes BURSTING UNIT Lube front hydraulic pressure system components MPG Lube rear pin bolts MPG Lube rear pressure axles MPG Clean jaw threads after each job Bursting Unit Lube Front Hydraulic Pressure System Components Lube 4 zerks with MPG each use. IMPORTANT: Ensure front jaw is up before lubing. Lube Rear Pin Bolts Lube 2 zerks with MPG each use.
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. Clean Jaw Threads Clean jaw threads with high-pressure water after each job.
PR95 Operator’s Manual Service - 66 10 Hour 10 Hour Location Task POWER UNIT Check engine oil level Check hydraulic fluid level Check coolant level Check hydraulic hoses and fittings Power Unit Check Engine Oil Level Check engine oil at dipstick (1) before operation 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.
PR95 Operator’s Manual Service - 67 10 Hour Check Engine Coolant Level Check coolant level, with engine cool, every 10 hours. Maintain coolant level at 1” (25 mm) below bottom of radiator cap. If low, add approved coolant. IMPORTANT: See “Approved Coolant” on page 63 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.
PR95 Operator’s Manual Service - 68 10 Hour Check Hydraulic Hoses Check hydraulic hoses for leaks every 10 hours. Pressurized fluid or air could pierce skin and cause injury or death. Stay away. NOTICE: Escaping pressurized fluid can cause injury or pierce skin and poison. • Before disconnecting a hydraulic line, turn engine off and operate all controls to relieve pressure. Lower, block, or support any raised component with a hoist.
PR95 Operator’s Manual Service - 69 50 Hour 50 Hour 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 Lube small front cylinders - lower area MPG POWER UNIT Check radiator Change engine oil and filter Initial service Bursting Unit Lube Large Hydraulic Cylinders - Front Lube 2 zerks with MPG every 50 hours.
Service - 70 PR95 Operator’s Manual 50 Hour 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 hours.
PR95 Operator’s Manual Service - 71 50 Hour 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.
Service - 72 PR95 Operator’s Manual 50 Hour Power 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 Service - 73 200 Hour 200 Hour Location Task Notes POWER UNIT Change engine oil DEO 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.
PR95 Operator’s Manual Service - 74 400 Hour 400 Hour Location Task POWER UNIT Change engine oil filter 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.
PR95 Operator’s Manual Service - 75 500 Hour 500 Hour Location Task POWER UNIT Clean hydraulic strainer Notes Change hydraulic filter Power Unit Clean Hydraulic Strainer Clean hydraulic strainer every 500 hours. Replace if damaged. Change Hydraulic Filters Change hydraulic filters every 500 hours.
PR95 Operator’s Manual Service - 76 1000 Hour 1000 Hour Location Task POWER UNIT Change hydraulic fluid Change engine coolant Power Unit Change Hydraulic Fluid 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). Change Engine Coolant Drain cooling system at drain (2) every 1000 hours. Add coolant at fill (1).
PR95 Operator’s Manual Service - 77 As Needed As Needed Location Task BURSTING UNIT Repair jaw threads POWER UNIT Change air filter Notes 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.
Service - 78 PR95 Operator’s Manual As Needed 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 the way out, as shown. 9. Remove slide hammer.
PR95 Operator’s Manual Service - 79 As Needed 10. Thread small slide hammer (3) into cylinder 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 cam. 17. Push cylinder control forward gently. 18. Attach lifting device to pin as shown.
Service - 80 PR95 Operator’s Manual As Needed 19. Lift cam slowly until pressure axle (shown) is accessible. 20. Flip pressure axle clear of jaws to allow access to top jaw.
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. 24. Press down on side of lower jaw (shown) and remove by hand.
Service - 82 PR95 Operator’s Manual As Needed 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, and use 14-mm hex wrench to turn bolt (shown) under jaw. 25. Clean area under lower jaw before reassembly.
PR95 Operator’s Manual Service - 83 As Needed Repair Jaw Threads 1. Use screwdriver to remove debris from threads. 2. Pressure wash threads. 3. Use grinder to repair threads as shown. IMPORTANT: Grind only enough material from jaws to return them to the correct shape. Install Jaws 1. Install lower jaw. 2. Install upper jaw. 3. Remove jaw extraction tool and bolts. 4. Position pressure axle over upper jaw. 5. Lower cam onto pressure axle. 6.
Service - 84 PR95 Operator’s Manual As Needed Power Unit Change Air Filter Change air filter as needed. To change 1. Disengage clasps (2) and remove end cup. 2. Remove primary element (3). 3. Remove secondary element (4), if dirty. 4. Wipe inside of housing 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.
PR95 Operator’s Manual Specifications - 85 Bursting Unit Specifications 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. Metric Length 39.4 in 1m Diameter 1.
Specifications - 86 PR95 Operator’s Manual Power Unit 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.
PR95 Operator’s Manual Specifications - 87 Power Unit Power U.S. Metric Displacement 202 in3 3.3 L Bore 3.86 in 98 mm Stroke 4.33 in 110 mm 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 rpm 2200 rpm Engine: Kubota V3300E Fuel: diesel Cooling medium: liquid Injection: indirect Aspiration: natural Cylinders: 4 Power Hydraulic System U.S.
Specifications - 88 PR95 Operator’s Manual Power Unit Fluid Capacities U.S. Metric Fuel tank 10.6 gal 40 L Hydraulic reservoir 53 gal 200 L Engine oil, including filter 14 qt 13 L Engine cooling sytem 5.4 gal 5.1 L Battery 12V, negative ground, SAE cold crank rating @ 0°F (-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.
PR95 Operator’s Manual Support - 89 Procedure Support Procedure Notify your dealer immediately of any malfunction or failure of Ditch Witch equipment. Always give model, serial number, and approximate date of your equipment purchase. This information should be recorded and placed on file by the owner at the time of purchase. Return damaged parts to dealer for inspection and warranty consideration if in warranty time frame.
PR95 Operator’s Manual Warranty - 90 Warranty Ditch Witch Equipment and Replacement Parts Limited Warranty Policy Subject to the limitation and exclusions herein, free replacement parts will be provided at any authorized Ditch Witch dealership for any Ditch Witch equipment or parts manufactured by The Charles Machine Works, Inc. (CMW) that fail due to a defect in material or workmanship within one (1) year of first commercial use (Exception: 2 years for all SK attachments).
PR95 Operator’s Manual Service Record - 93 Service Record Service Performed Date Hours CMW
Service Record - 94 Service Performed CMW PR95 Operator’s Manual Date Hours
