Ditch Witch PR95 User Manual
PR95
Operator’s
Manual
CMW
®
Issue 1.0
053- 1102
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
• Numbered Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
• “Continued” Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
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Overview - 2 PR95 Operator’s Manual
Serial Number Location
Serial Number Location
Record serial numbers and date of purchase in spaces prov ided. Power unit (2) and eng ine serial numbers
(1) are located as shown.
CMW
Date of manufacture
Date of purchase
Power unit serial number
Engine serial number
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.
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.
Use in any other way is considered contrary to the intended use.
Unit Components
1. Power unit
2. Accessory kit
3. Bursting unit
4. Rod makeup device
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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.
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.
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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 equipmen t 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 publishe d. For the latest information on Ditch Witch equipment, see your
Ditch Witch dealer.
Thank you for buying and using Ditch Witch equipment.
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Foreword - 6 PR95 Operator’s Manual
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 r egistered trademarks of The Charles Machine Works, Inc.
CMW
PR95 Operator’s Manual Contents - 7
Contents
Overview
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
part number, revision level, and publication date of this manual, and factory contact
information
Safety
machine safety alerts and emergency procedures
Controls
machine controls, gauges, and indicators and how to use them
Prepare
procedures for inspecting and classifying the jobsite, planning the installation, and
preparing the jobsite for work
Transport
procedures for lifting and hauling
Burst Pipe
procedures for setting up equipment and performing the burst
1
5
9
19
29
39
43
Systems and Equipment
bursting string, accessory kit
Complete the Job
procedures for restoring the jobsite and storing equipment
Service
service intervals and instructions for this machine including lubrication, replacement
of wear items, and basic maintenance
Specifications
machine specifications including weights, measurements, power ratings, and fluid
capacities
Support
the warranty policy for this machine, and procedures for obtaining warranty
consideration and training
51
57
59
85
89
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Contents - 8 PR95 Operator’s Manual
Service Record
a record of major service performed on the machine
93
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
• If a Gas Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
• If a Fiber Optic Cable is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
• If Machine Catches on Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
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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 marke d before operating equipment. If you damage a
utility, contact utility company.
• Classify jobsite based on its hazards and use correct tools and machin ery, 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, ma intenance, or equipmen t
use.
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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.
indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
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.
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Safety - 12 PR95 Operator’s Manual
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. Use and maintain proper safety
equipment.
Crushing weight could cause death or seriou s injur y. Use
proper procedures and equipment or stay away.
Moving parts on unit could cut off hand or foot. Stay away.
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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.
Pressurized fluid or air could pierce skin a nd cause injur y or
death. Stay away.
Fire or explosion possible. Fumes could ignite and cause burns. No
smoking, no flame, no spark.
Moving traffic - hazardous situation. Death or serious injury could result.
Avoid moving vehicles, wear high visibility clothing, post appropriate warning signs.
Hot pressurized cooling system fluid could cause serious burns. Allow to
cool before servicing.
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Safety - 14 PR95 Operator’s Manual
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. Follow instructions on labels and in material safety da ta sheets
(MSDS).
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PR95 Operator’s Manual Safety - 15
Emergency Procedures
Emergency Procedures
Before operating any equipment, review emergency proc edures and check that all safety precau tions 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 a strike include:
• power outage
•smoke
•explosion
• popping noises
• arcing electricity
If any of these occur, assume an electric strike has occurred.
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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.
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.
• 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.
• 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 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.
• Contact utility company to shut off power.
• Do not return to area or allow anyone into area until given permission by utility company.
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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 cu t and that they sh ould leave the area.
• Leave jobsite as quickly as possible.
• Immediately call your local emergency phone number and utility company.
• If jobsite is along street, stop traffic from driving near jobsite .
• Do not return to jobsite until given permission by emergency personnel and utility company.
If a Fiber Optic Cable is Damaged
Do not look into cut ends of fiber optic or unidentified cable. Vision damage can occur.
If Machine Catches on Fire
Perform emergency shutdown procedure and then take the following actions. The order and degree of
action will depend on the situation.
• Immediately move battery disconnect switch (if equipped) to disconnect position.
• If fire is small and fire extinguisher is available, attempt to extinguish fire.
• If fire cannot be extinguished, leave area as quickly as possible and contact emergency personnel.
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Safety - 18 PR95 Operator’s Manual
Emergency Procedures
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PR95 Operator’s Manual Controls - 19
Controls
Chapter Contents
Bursting Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Remote Controller . . . . . . . . . . . . . . . . . . . . . . . . . 21
Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Rod Makeup Device . . . . . . . . . . . . . . . . . . . . . . . . 28
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Controls - 20 PR95 Operator’s Manual
Bursting Unit
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 bursting pipe.
• Disable when pushing.
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PR95 Operator’s Manual Controls - 21
Remote Controller
Remote Controller
1. Work button (white)
2. Return button (black)
Item Description Notes
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 switch
4. Emergency stop switch
3. Mode selector To enter pull mode, move left.
To enter push mode, move
right.
Decal is marked “reverse.”
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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.
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PR95 Operator’s Manual Controls - 23
Power Unit
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 indicator
7. Coolant temperature indicator
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Controls - 24 PR95 Operator’s Manual
Power Unit
Item Description Notes
1. Hourmeter Displays engine operating
time.
2. Main cylinders pressure
gauge
3. Jaw system pressure
gauge
Displays hydraulic pressure
at main cylinders.
Displays hydraulic pressure in
jaw system.
Gauge is marked “hours.”
Use these times to schedule service.
Gauge is marked “pump pressure
main.”
Full load reading should be 3600 psi
(248 bar).
Gauge is marked “pump pressure
jaws.”
Full load reading should be 3600 psi
(248 bar).
4. Battery charge
indicator
5. Engine preheater
indicator
6. Engine oil pressure
indicator
7. Coolant temperature
indicator
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Lights when battery is not
charging.
Lights when glow plugs are
on.
Lights when engine oil
pressure is low.
Lights if cooling system fluid
overheats.
Indicator is marked “charge.”
Indicator is marked “glow.”
IMPORTANT: Start engine after light
goes off.
Indicator is marked “oil pressure.”
Indicator is marked “water temp.”
• Turn off engine and let cool.
• Check cooling system fluid level.
PR95 Operator’s Manual Controls - 25
Power Unit
Controls
1. Bursting unit engage control
2. Bursting unit standby control
3. Emergency stop switch
4. Rod makeup engage control
5. Rod makeup standby control
Item Description Notes
1. Bursting unit engage
control
2. Bursting unit standby
control
3. Emergency stop switch To turn off power unit engine,
To turn on hydraulic flow to
bursting unit, press.
To stop hydraulic flow to
bursting unit, press.
press.
6. Throttle
7. Bursting unit manual control
8. Rod makeup manual control
9. Rear jaw manual control
10. Ignition switch
IMPORTANT: All emergency stops
must be connected and disengaged
for unit to start.
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Controls - 26 PR95 Operator’s Manual
Power Unit
Item Description Notes
4. Rod makeup engage
control
5. Rod makeup standby
control
6. Throttle To increase engine speed,
7. Bursting unit manual
control
To turn on hydraulic flow to
rod makeup device, press.
To stop hydraulic flow to rod
makeup device, press.
push up.
To decrease engine speed,
pull down.
In push mode:
To return carriage to back of
unit, pull.
To push rod into pipe, push.
In pull mode:
T o 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
• pull bursting unit control
Pull sequence:
8. Rod makeup manual
control
9. Rear jaw manual
control
To engage hydraulics to rod
makeup device, pull and hold.
To disengage hydraulics,
release.
In push mode:
To close jaws, pull.
To open jaws, push.
In pull mode:
To close jaws, push.
To open jaws, pull.
• push bursting unit manual control
• push jaw manual control
• pull bursting unit control
• pull jaw control
Use in sequence with bursting unit
manual control to push and pull rods.
See “Bursting unit manual control” for
sequence.
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PR95 Operator’s Manual Controls - 27
Power Unit
Item Description Notes
10. Ig n ition switch To st art 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.
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Controls - 28 PR95 Operator’s Manual
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.
2. Rotation speed/
direction control
To thread rods faster, move
handle to right.
To thread/unthread rods
slower, move handle toward
center.
T o unthre ad rods faster , move
handle to left.
IMPORTANT: Jaws must be closed
before unthreading rod in rod device
to prevent unthreading downhole.
IMPORTANT: Direction is determined
from standing behind engage handle.
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