Ditch Witch PR100 Operator's Manual
  1. Manuals
  2. Brands
  3. Ditch Witch Manuals
  4. Construction Equipment
  5. PR100
  6. Operator's manual
Ditch Witch PR100 Operator's Manual

Ditch Witch PR100 Operator's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
PR100
Operator's
Manual
®
Issue 1.0
CMW
053-1392

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the PR100 and is the answer not in the manual?

Questions and answers

Related Manuals for Ditch Witch PR100

Summary of Contents for Ditch Witch PR100

  • Page 1 PR100 Operator’s Manual ® Issue 1.0 053-1392...

  • Page 2: Table Of Contents

    PR100 Operator’s Manual Overview - 1 Overview Chapter Contents Serial Number Location ..... . 2 Intended Use ....... 3 Equipment Modification .

  • Page 3: Serial Number Location

    PR100 Operator’s Manual Overview - 2 Serial Number Location Serial Number Location Record serial numbers and date of purchase in spaces provided. Power pack (2) and engine serial numbers (1) are located as shown. Date of manufacture Date of purchase...

  • Page 4: Intended Use

    Intended Use Intended Use Ditch Witch pipe bursters are intended for the replacement of buried pipes and conduits. The PR100 produces 200,000 lb (91 t) of pullback force. A power pack provides hydraulic power to run the pipe bursting unit.

  • Page 5: Unit Components

    PR100 Operator’s Manual Overview - 4 Unit Components Unit Components 1. Power pack 4. Assisted makeup device (AMD) 2. Tool kit 5. Rod box 3. Bursting unit 6. Work light...

  • Page 6: Operator Orientation

    PR100 Operator’s Manual Overview - 5 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.
  • Page 7 PR100 Operator’s Manual Overview - 6 About This Manual...

  • Page 8: Foreword

    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.
  • Page 9 Copyright 2009 by The Charles Machine Works, Inc. , Ditch Witch, CMW, AutoCrowd, Jet Trac, Roto Witch, Subsite, Fluid Miser, Power Pipe, Super Witch, Pierce Airrow, The Underground, The Underground Authority Worldwide, and Zahn are registered trademarks of The Charles Machine Works, Inc.
  • Page 10 PR100 Operator’s Manual Contents - 9 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...
  • Page 11 PR100 Operator’s Manual Contents - 10 Service Record a record of major service performed on the machine...

  • Page 12: Safety

    PR100 Operator’s Manual Safety - 11 Safety Chapter Contents Guidelines ....... . 12 Safety Alert Classifications .

  • Page 13: Guidelines

    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.

  • Page 14: Safety Alert Classifications

    PR100 Operator’s Manual Safety - 13 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.

  • Page 15: Safety Alerts

    PR100 Operator’s Manual Safety - 14 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.
  • Page 16 PR100 Operator’s Manual Safety - 15 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.
  • Page 17 PR100 Operator’s Manual Safety - 16 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.

  • Page 18: Emergency Procedures

    PR100 Operator’s Manual Safety - 17 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.

  • Page 19: If An Electric Line Is Damaged

    PR100 Operator’s Manual Safety - 18 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 and DO NOT TOUCH ANYTHING. Remain in pit and take the following actions. The order and degree of action will depend upon the situation.

  • Page 20: If A Gas Line Is Damaged

    PR100 Operator’s Manual Safety - 19 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.
  • Page 21 PR100 Operator’s Manual Safety - 20 Emergency Procedures...

  • Page 22: Controls

    PR100 Operator’s Manual Controls - 21 Controls Chapter Contents Bursting Unit ......22 Remote Controller .

  • Page 23: Bursting Unit

    PR100 Operator’s Manual Controls - 22 Bursting Unit Bursting Unit Automatic front clamp control Item Description Notes Automatic front clamp To enable automatic front IMPORTANT: Use in pull mode. control clamp operation, push. • Enable when pulling pipe. To disable, pull.

  • Page 24: Remote Controller

    PR100 Operator’s Manual Controls - 23 Remote Controller Remote Controller 1. Work button (white) 3. Mode selector switch 2. Return button (black) 4. Remote stop switch Item Description Notes 1. Work button (white) With mode selector in push mode, push and hold to push rod into existing pipe.
  • Page 25 PR100 Operator’s Manual Controls - 24 Remote Controller Item Description Notes 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.

  • Page 26: Power Pack

    PR100 Operator’s Manual Controls - 25 Power Pack Power Pack Gauges and Indicators 1. Engine oil pressure indicator 5. Pull/push pressure gauge 2. Engine coolant temperature indicator 6. Clamp pressure gauge 3. Hydraulic fluid temperature indicator 7. Hourmeter 4. Hydraulic filter restriction indicator...
  • Page 27 PR100 Operator’s Manual Controls - 26 Power Pack Item Description Notes 1. Engine oil pressure Lights briefly when engine is Engine will stop. indicator started. Remains on when engine oil pressure is low. 1. Check oil level. 2. Check for leaks before starting engine.
  • Page 28 PR100 Operator’s Manual Controls - 27 Power Pack Item Description Notes 5. Push/pull pressure Displays hydraulic pressure Full load reading should be 3700 psi gauge at horizontal cylinders. (255 bar). 6. Clamp pressure gauge Displays hydraulic pressure Full load reading should be 2200 psi for clamp cylinders.
  • Page 29 PR100 Operator’s Manual Controls - 28 Power Pack Controls 1. Work light switch 5. Hydraulic flow control (for AMD) 2. Cold start switch 6. Bursting unit manual control 3. Remote enable switch 7. Clamp control 4. Throttle control 8. Ignition switch...
  • Page 30 PR100 Operator’s Manual Controls - 29 Power Pack Item Description Notes 2. Cold start switch To start cold engine when NOTICE: temperature is between 32°F (0°C) and 50°F (10°C): • Do not press and hold cold start switch for more than 25 seconds.
  • Page 31 PR100 Operator’s Manual Controls - 30 Power Pack Item Description Notes 5. Hydraulic flow control To increase hydraulic flow to Maximum output is 7.2 gpm (27.2 L/ (for AMD) assisted makeup device min) at 2500 psi (172 bar). (AMD), move handle toward horizontal position.
  • Page 32 PR100 Operator’s Manual Controls - 31 Power Pack Item Description Notes 8. Ignition switch To start engine, insert key and IMPORTANT: If unit won’t start, turn clockwise. ensure all emergency stop switches are disengaged. To stop engine, turn key counterclockwise.
  • Page 33 PR100 Operator’s Manual Controls - 32 Power Pack Miscellaneous 1. Battery disconnect switch 3. Auxiliary electrical outlets 2. Pan drain Item Description Notes 1. Battery disconnect To disconnect battery, turn IMPORTANT: Use battery disconnect switch counterclockwise. switch when servicing, welding, and during long-term storage.
  • Page 34 PR100 Operator’s Manual Controls - 33 Power Pack Item Description Notes 2. Pan drain To drain spilled fluid from power pack: • Remove plug. • Replace plug when drain pan is empty. 3. Auxiliary electrical To operate work lights or...
  • Page 35 PR100 Operator’s Manual Controls - 34 Power Pack Connector Panel 1. Electrical connector for remote controller 5. Rear clamp closed connector 2. Hydraulic return connector 6. Push pressure connector 3. Hydraulic supply connector 7. Pull pressure connector 4. Front clamp closed connector...
  • Page 36 PR100 Operator’s Manual Controls - 35 Power Pack Item Description Notes 2. Hydraulic return To operate hydraulic power IMPORTANT: Connect return hose connector tools with power pack before connecting supply hose. hydraulic system, connect hydraulic return hose to connector. 3. Hydraulic supply...
  • Page 37 PR100 Operator’s Manual Controls - 36 Power Pack Item Description Notes 6. Push pressure Pressure on this hose connector extends horizontal cylinder. 7. Pull pressure connector Pressure on this hose retracts horizontal cylinder.

  • Page 38: Assisted Makeup Device (Amd)

    PR100 Operator’s Manual Controls - 37 Assisted Makeup Device (AMD) Assisted Makeup Device (AMD) Rotation speed/direction control Item Description Notes Rotation speed/direction To thread rods faster, push IMPORTANT: control handle forward. • Direction is determined from To unthread rods faster, pull standing behind AMD.
  • Page 39 PR100 Operator’s Manual Controls - 38 Assisted Makeup Device (AMD)

  • Page 40: Prepare

    PR100 Operator’s Manual Prepare - 39 Prepare Chapter Contents Gather Information ......40 • Review Job Plan ......... . .40 •...

  • Page 41: Gather Information

    PR100 Operator’s Manual Prepare - 40 Gather Information Gather Information A successful job begins before the pull. 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.

  • Page 42: Inspect Site

    PR100 Operator’s Manual Prepare - 41 Inspect Site Inspect Site Inspect jobsite before transporting equipment. Check for the following: • changes in elevation such as hills or open trenches • obstacles such as buildings, railroad crossings, or streams • signs of utilities –...

  • Page 43: Identify Hazards

    PR100 Operator’s Manual Prepare - 42 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.

  • Page 44: Select Installation And Bursting Pit Locations

    PR100 Operator’s Manual Prepare - 43 Inspect Site Select Installation and Bursting Pit Locations Consider the following when selecting pit locations: Traffic Vehicle and pedestrian traffic must be a safe distance from pulling equipment. Allow at least 10’ (3 m) buffer zone around equipment.

  • Page 45: Plan Bore Path

    PR100 Operator’s Manual Prepare - 44 Plan Pull Path Plan Pull Path Plan the pull 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.

  • Page 46: Prepare Installation Point

    PR100 Operator’s Manual Prepare - 45 Prepare Jobsite Dig Installation and Bursting Pits Dimensions Unit Bursting Pit Installation Pit * Length (A) Width (B) Length (C) Width (D) U.S. (metric) U.S. (metric) U.S. (metric) U.S. (metric) PR100 12’ (3.6 m) 5’...
  • Page 47 PR100 Operator’s Manual Prepare - 46 Prepare Jobsite Bursting Pit (2) • Must be level to align bursting unit properly with existing pipe. • Cover pit floor with gravel for drainage and to allow bursting unit to be level with existing pipe.

  • Page 48: Check Supplies And Prepare Equipment

    PR100 Operator’s Manual Prepare - 47 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 and penetrating oil (p/n 255-1010) •...

  • Page 49: Prepare Equipment

    PR100 Operator’s Manual Prepare - 48 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 •...

  • Page 50: Transport

    PR100 Operator’s Manual Transport - 49 Transport Chapter Contents Lift Points and Procedure ....50 • Power Pack ..........50 •...

  • Page 51: Lift Points And Procedure

    PR100 Operator’s Manual Transport - 50 Lift Points and Procedure Lift Points and Procedure Crushing weight. If load falls or moves it could kill or crush you. Use proper procedures and equipment or stay away. Lifting points are identified by lifting decals. Lifting at other points is unsafe and can damage machinery.

  • Page 52: Bursting Unit

    PR100 Operator’s Manual Transport - 51 Lift Points and Procedure Bursting Unit Use equipment capable of supporting the unit's size and weight. See “Specifications” on page 97 or measure and weigh equipment before lifting. Use supplied lift chains at lift points as shown.

  • Page 53: Extension Cage

    PR100 Operator’s Manual Transport - 52 Lift Points and Procedure Extension Cage Use equipment capable of supporting the extension cage's size and weight. Tool Kit Use equipment capable of supporting the tool kit size and weight.

  • Page 54: Tie Down Points And Procedure

    PR100 Operator’s Manual Transport - 53 Tie Down Points and Procedure Tie Down Points and Procedure Power Pack 1. To tie down power pack, use D-rings shown. 2. Ensure that drip pan (1) is installed and door (2) is closed and secure.

  • Page 55: Bursting Unit

    PR100 Operator’s Manual Transport - 54 Tie Down Points and Procedure Bursting Unit To tie down bursting unit, use D-rings shown. NOTICE: Do not attempt to transport rod box with bursting unit. Remove rod box before transporting. Rod Box To tie down rod box, use chain or strap as shown.

  • Page 56: Burst Pipe

    PR100 Operator’s Manual Burst Pipe - 55 Burst Pipe Chapter Contents Prepare Equipment ......56 Setup and Configuration ....59 Emergency Stop Procedure .

  • Page 57: Prepare Equipment

    PR100 Operator’s Manual Burst Pipe - 56 Prepare Equipment Prepare Equipment 1. Use equipment capable of safely lifting and unloading bursting unit and related equipment next to bursting pit. 2. Place gravel as a pit floor liner to establish slip-...
  • Page 58 PR100 Operator’s Manual Burst Pipe - 57 Prepare Equipment 6. Connect electrical cable from remote controller to power pack. NOTICE: Ensure that remote enable switch on power pack is in OFF position to prevent bursting unit movement when starting power pack engine.
  • Page 59 PR100 Operator’s Manual Burst Pipe - 58 Prepare Equipment Moving tools will kill or injure. Never use wrenches or tools on moving rods and bursting unit components when unit is operating. Turning shaft will kill you or crush arm or leg. Stay away.

  • Page 60: Setup And Configuration

    PR100 Operator’s Manual Burst Pipe - 59 Setup and Configuration Setup and Configuration Proper setup includes: • bursting unit (1) placed in gravel-lined bursting pit with steel plate in position • power pack (5) is positioned outside of bursting pit •...

  • Page 61: Emergency Stop Procedure

    PR100 Operator’s Manual Burst Pipe - 60 Emergency Stop Procedure Emergency Stop Procedure To shutdown power pack engine under normal conditions, use key switch on power pack. To shutdown power pack using remote controller, press the remote stop switch on the end of remote controller.
  • Page 62 PR100 Operator’s Manual Burst Pipe - 61 10. Select pilot rod and apply spray lube to rod threads. 11. Lubricate rod threads with spray lube and connect two rods to pilot rod and tighten. IMPORTANT: Spray threads of each rod with spray lubricant (p/n 255-1010) at every use.

  • Page 63: Connect Bursting/Splitting Head

    PR100 Operator’s Manual Burst Pipe - 62 Connect Bursting/Splitting Head Connect Bursting/Splitting Head 1. Install bursting/splitting head (2) onto end of new product (1). 2. Remove pilot rod assembly. 3. Install bursting/splitting head (5) over rod (6) and slide forward until threads are visible.

  • Page 64: Pull New Product

    PR100 Operator’s Manual Burst Pipe - 63 Pull New Product Pull New Product Incorrect procedures could result in death, injury, or property damage. Learn to use equipment correctly. NOTICE: • Maintain 2-way communication between bursting pit and all other personnel.
  • Page 65 PR100 Operator’s Manual Burst Pipe - 64 6. Remove assisted makeup device (AMD). 7. Connect one rod onto rod in bursting unit. 8. Push bursting unit back slightly to remove steel plate. 9. Move bursting unit back in pit and position extension cage between between bursting unit and existing pipe and pit wall.

  • Page 66: Systems And Equipment

    PR100 Operator’s Manual Systems and Equipment - 65 Systems and Equipment Chapter Contents Bursting String ......66 •...

  • Page 67: Bursting String

    PR100 Operator’s Manual Systems and Equipment - 66 Bursting String Bursting String Pilot Rods Type Uses standard pilot rod used in pipes without joint misalignment female-to-female used for double- adapter bursting fiber ball pilot rod used in pipes with considerable joint...

  • Page 68: Bursting/Splitting Heads

    PR100 Operator’s Manual Systems and Equipment - 67 Bursting String Bursting/Splitting Heads Identification and Uses Stop rods and bursting/splitting heads are each marked with an identification number, as shown. IMPORTANT: Ensure identification numbers on stop rod system and bursting/splitting heads match.

  • Page 69: Extension Cage

    • 7’ chain set (for power pack, bursting unit) • 3’ chain set (for smaller items) • grease gun and grease cartridges • hand tools • slide hammers Note: Accessories and tools are available separately. Contact your Ditch Witch dealer.

  • Page 70: Complete The Job

    PR100 Operator’s Manual Complete the Job - 69 Complete the Job Chapter Contents Stow Components ......70 Restore Jobsite .
  • Page 71 PR100 Operator’s Manual Complete the Job - 70 Stow Components Stow Components 1. Install all covers. 2. Load components onto trailer. 3. Secure all components on trailer. Restore Jobsite Fill in installation, bursting and service connection pits. Stow Tools Make sure all components, accessories and tools are loaded and properly secured on trailer.

  • Page 72: Service

    PR100 Operator’s Manual Service - 71 Service Chapter Contents Service Precautions ......72 Recommended Lubricants/Service Key ..73 Approved Coolant.

  • Page 73: Service Precautions

    PR100 Operator’s Manual Service - 72 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.

  • Page 74: Recommended Lubricants/Service Key

    For more information on engine lubrication and maintenance, see your 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 105 to record all required service to your machine.

  • Page 75: Approved Coolant

    PR100 Operator’s Manual Service - 74 Recommended Lubricants/Service Key Engine Oil Temperature Chart Temperature range anticipated before next oil change See engine manual for more information about oil viscosity and operation in arctic conditions. Approved Fuel This engine is designed to run on diesel fuel. Use only high quality fuel meeting ASTM D975 No. 2D or equivalent.

  • Page 76: Each Use

    PR100 Operator’s Manual Service - 75 Each Use Each Use Location Task Notes BURSTING Lube rear clamp pivot MPGM UNIT Lube front clamp MPGM Clean rod/pipe threads before each use Clean jaw threads after each use POWER Check drip pan...
  • Page 77 PR100 Operator’s Manual Service - 76 Each Use Lube Front Clamp Lube zerks (1, 2) with special MPGM before each use or every 10 hours. IMPORTANT: Ensure jaw is up before lubing. Clean Rod/Pipe Threads Clean rod/pipe threads before each use. Brush threads with wire brush to remove debris and lube with spray lubricant and penetrating oil.
  • Page 78 PR100 Operator’s Manual Service - 77 Each Use Power Pack Check Drip Pan Check drip pan under couplers after each use. Drain as needed.

  • Page 79: 10 Hour

    PR100 Operator’s Manual Service - 78 10 Hour 10 Hour Location Task Notes POWER Check engine oil level PACK Drain fuel/water separator Check engine coolant level DEAC Check engine air filter service indicator Check hydraulic fluid level Check hydraulic hoses and fittings...
  • Page 80 PR100 Operator’s Manual Service - 79 10 Hour Check Engine Coolant Level Check coolant level, with engine cool, every 10 hours. Maintain coolant level to mark on reservoir. If low, add approved coolant. IMPORTANT: See “Approved Coolant” on page 74 for information on approved coolants.
  • Page 81 PR100 Operator’s Manual Service - 80 10 Hour Check Hydraulic Fluid Level Check hydraulic fluid level every 10 hours. Maintain fluid level two-thirds point up sight glass (2), when engine is off, fluid is cool, and thrust cylinders are retracted (if connected to pull box).

  • Page 82: 50 Hour

    PR100 Operator’s Manual Service - 81 50 Hour 50 Hour Location Task Notes BURSTING Lube push/pull cylinder rear pins MPGM UNIT Lube push/pull cylinder front pins MPGM Lube front clamp cylinder pins MPGM Lube rear clamp cylinder pins MPGM POWER...
  • Page 83 PR100 Operator’s Manual Service - 82 50 Hour Lube Push/Pull Cylinder Front Pins Lube zerks (3, 4) with MPG every 50 hours. Lube Front Clamp Cylinder Pins Lube zerks (5, 6, 7, 8) with special MPGM every 50 hours. Lube Rear Clamp Cylinder Pins Lube zerks with special MPGM before every 50 hours.
  • Page 84 PR100 Operator’s Manual Service - 83 50 Hour Power Pack 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. IMPORTANT: Be careful not to damage fins with high pressure air or water.

  • Page 85: 500 Hour

    PR100 Operator’s Manual Service - 84 500 Hour 500 Hour Location Task Notes POWER Change engine oil and filter PACK Change fuel filter Change hydraulic filters Power Pack Change Engine Oil and Filter Change oil and filter after first 50 hours of operation and every 500 hours thereafter.
  • Page 86 PR100 Operator’s Manual Service - 85 500 Hour Change Hydraulic Filters Change hydraulic filters every 500 hours or when filter restriction indicator is on.

  • Page 87: 1000 Hour

    PR100 Operator’s Manual Service - 86 1000 Hour 1000 Hour Location Task Notes POWER Change hydraulic fluid PACK Power Pack 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 (1). Fill until level is two-thirds up sight glass (2) with thrust cylinders retracted (if connected to pull box).

  • Page 88: 2000 Hour

    PR100 Operator’s Manual Service - 87 2000 Hour 2000 Hour Location Task Notes POWER Change engine coolant DEAC PACK Power Pack Change Engine Coolant Drain cooling system at drain (3) every two years or 2000 hours. Add coolant at fill (1). Fill to mark on reservoir (2.) Capacity is approximately 3.7 gal...

  • Page 89: As Needed

    PR100 Operator’s Manual Service - 88 As Needed As Needed Location Task Notes BURSTING Repair jaw threads UNIT POWER Change air filter PACK Adjust fan belt tension Bursting Unit Repair Jaw Threads Maintenance and service procedures will extend the life of jaws.
  • Page 90 PR100 Operator’s Manual Service - 89 As Needed 5. Attach extension arm (1) to jaw service tool (2). 6. Position jaw service tool over clamp arm and secure with screw (3). 7. Remove large pivot pin retaining strap. For rear jaw set, remove retaining bar on right side of unit.
  • Page 91 PR100 Operator’s Manual Service - 90 As Needed 8. Thread large slide hammer into pivot pin bolt hole. 9. Pull pin clear of bore about 9-3/4” (248 mm) but not all the way out, as shown. 10. Remove slide hammer.
  • Page 92 PR100 Operator’s Manual Service - 91 As Needed 18. Ensure that pin is at end of travel in guide plate slot, as shown. 19. Rotate jaw service lever (1) upward. 20. Install prop rod (2) into pin hole and through jaw service lever, as shown.
  • Page 93 PR100 Operator’s Manual Service - 92 As Needed 22. Clean grease from bolt holes and install bolts into top jaw, three to four turns. 23. Engage jaw extraction tool (shown) on bolts. 24. Lift out top jaw. IMPORTANT: Be careful to not lose springs between jaws.
  • Page 94 PR100 Operator’s Manual Service - 93 As Needed Grinding Jaw Threads Use a standard die grinder and the abrasive disk supplied to restore threads. NOTICE: The following procedure must be done by someone familiar with proper die grinding techniques. Wear protective clothing to protect against metal debris created by the grinder.
  • Page 95 PR100 Operator’s Manual Service - 94 As Needed 5. Apply tape to jaw springs (as shown) to hold springs in upper jaw bores during installation. 6. Install upper jaw. 7. Remove jaw extraction tool and bolts. Fill bolt holes with grease to prevent debris from clogging threads.
  • Page 96 PR100 Operator’s Manual Service - 95 As Needed 5. Install large pivot pin retaining strap, shown. 6. Remove slide hammer. 7. Check and tighten any hydraulic hoses that may have loosened. 8. Install hose tie to secure hoses to unit frame.
  • Page 97 PR100 Operator’s Manual Service - 96 As Needed Power Pack Change Air Filter Change air filter element when red band on filter minder (1) is visible. Push button to re-set indicator. To replace air filter: 1. Disengage latches (2) and remove cover (3).

  • Page 98: Specifications

    PR100 Operator’s Manual Specifications - 97 Bursting Unit Specifications Bursting Unit Dimensions U.S. Metric L, length 74 in 1.88 m W, width 29 in 737 mm H, height 45 in 1.14 m Weight, mass 6800 lb 3084 kg Operational U.S.
  • Page 99 PR100 Operator’s Manual Specifications - 98 Power Pack Power Pack Dimensions U.S. Metric L, length 80 in 2.03 m W, width 38.5 in 980 mm H, height 62.5 in 1.6 m Weight, mass (dry weight, without fluids) 2600 lb 1180 kg...
  • Page 100 PR100 Operator’s Manual Specifications - 99 Power Pack Power U.S. Metric Engine: Cummins B3.3NA Fuel: diesel Cooling medium: liquid Injection: indirect Aspiration: natural Cylinders: 4 Displacement 3.3 L 199 in Bore 3.74 in 95 mm Stroke 4.53 in 115 mm Power manufacturer’s gross power rating (per SAE J1995)
  • Page 101 PR100 Operator’s Manual Specifications - 100 Power Pack Fluid Capacities U.S. Metric Fuel tank 19 gal 72 L Hydraulic reservoir 30 gal 114 L Engine oil, including filter 9 qt 8.5 L Engine cooling sytem 3.7 gal 14.0 L Battery 12V, negative ground, SAE cold crank rating @ 0°F (-18°C), 800 amps.

  • Page 102: Support

    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.
  • Page 103 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 SK5 attachments).
  • Page 106 PR100 Operator’s Manual Service Record - 123 Service Record Service Performed Date Hours...
  • Page 107 PR100 Operator’s Manual Service Record - 124 Service Performed Date Hours...

Table of Contents