p80/pp25 - ditch witch operator’s manual overview - 1 ... electric hydraulic control (optional) 8....

P80/PP25

Operator’sManual

053-2296Issue 1.2

P80/PP25 Operator’s Manual Overview - 1

Overview

Chapter Contents

Serial Number Location . . . . . . . . . . . . . . . . . . . . . . 2

Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Equipment Modification . . . . . . . . . . . . . . . . . . . . . . 5

Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Operator Orientation. . . . . . . . . . . . . . . . . . . . . . . . . 6

About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 6

• Bulleted Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

• Numbered Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Overview - 2 P80/PP25 Operator’s ManualSerial Number Location

Serial Number Location

Record serial numbers and date of purchase in spaces provided.

Date of manufacture

Date of purchase

Rod pusher serial number (shown)

Power pack serial number

Engine serial number


Unit Components

Unit Components

1. Drill rod

2. Jaw lever

3. Rotation device

4. hydraulic hoses

5. Cylinder

6. Mechanical hydraulic control (optional)

7. Electric Hydraulic Control (Optional)

8. Power unit

Overview - 4 P80/PP25 Operator’s ManualUnit Components

Trench Box Back Brace

T-bar


Intended Use

Intended Use

The Ditch Witch® P80 rod pusher offers a way to bore under sidewalks, roads, or other obstructions without making open cuts. The rod-through-centerline design produces a true, straight bore. Beacon housings, heads, and other options make the unit directional. The P80 Rod pusher is compact and easy to use with either a trench box, back brace, or T-bar set-up configuration.

The Ditch Witch PP25 power pack is designed to provide hydraulic power to a a variety of equipment, including the P80 rod pusher.

Ditch Witch P80 rod pusher and PP25 power pack should be operated, serviced, and repaired only by persons familiar with their particular characteristics and acquainted with the relevant safety procedures.

Equipment Modification

This equipment was designed and built in accordance with applicable standards and regulations. Modification of equipment could mean that it will no longer meet regulations and may not function properly or in accordance with the operating instructions.

Modification of equipment should only be made by competent personnel possessing knowledge of applicable standards, regulations, equipment design functionality/requirements and any required specialized testing.

Overview - 6 P80/PP25 Operator’s ManualOperator Orientation

Operator Orientation

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.

IMPORTANT: Top view of unit is shown.

P80/PP25 Operator’s Manual Foreword - 7

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. 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 DepartmentPO Box 66Perry, OK 73077-0066 USA

The descriptions and specifications in this manual are subject to change without notice. The Charles Machine Works, Inc. reserves the right to improve equipment. Some product improvements may have taken place after this manual was published. For the latest information on Ditch Witch equipment, see your Ditch Witch dealer.

Thank you for buying and using Ditch Witch equipment.

Foreword - 8 P80/PP25 Operator’s Manual

P80/PP25Operator’s Manual

Issue number 1.2/OM-08/15 Part number 053-2296

Copyright 2010, 2014, 2015

by The Charles Machine Works, Inc.

, Ditch Witch, and The Underground Authority Worldwide are registered trademarks of The Charles Machine Works, Inc.

P80/PP25 Operator’s Manual Contents - 9

Contents

Overviewmachine serial number, information about the type of work this machine is designed to perform, basic machine components, and how to use this manual

1

Forewordpart number, revision level, and publication date of this manual, and factory contact information

7

Safetymachine safety alerts and emergency procedures

11

Controlsmachine controls, gauges, and indicators and how to use them

21

Prepareprocedures for inspecting and classifying the jobsite, planning the installation, and preparing the jobsite for work

27

Transportprocedures for lifting and hauling

35

Push Rodprocedures for setting up equipment and pushing rod

41

Complete the Jobprocedures for restoring the jobsite and storing equipment

57

Specificationsmachine specifications including weights, measurements, power ratings, and fluid capacities

59

Supportthe warranty policy for this machine, and procedures for obtaining warranty consideration and training

65

Service Recorda record of major service performed on the machine

69

Contents - 10 P80/PP25 Operator’s Manual

P80/PP25 Operator’s Manual Safety - 11

Safety

Chapter Contents

Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Califronia Proposition 65 Warning . . . . . . . . . . . . 12

Safety Alert Classifications . . . . . . . . . . . . . . . . . . 13

Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Emergency Procedures . . . . . . . . . . . . . . . . . . . . . 17

• Electric Strike Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

• If an Electric Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

• If a Gas Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

• If a Fiber Optic Cable is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

• If Machine Catches on Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Safety - 12 P80/PP25 Operator’s ManualGuidelines

Guidelines

Follow these guidelines before operating any jobsite equipment:

• Complete proper training and read operator’s manual before using equipment.

• Contact your local One-Call (811 in USA) or the One-Call referral number (888-258-0808 in USA and Canada) to have underground utilities located before digging. Also contact any utilities that do not participate in the One-Call service.

• Classify jobsite based on its hazards and use correct tools and machinery, safety equipment, and work methods for jobsite.

• Mark jobsite clearly and keep spectators away.

• Wear personal protective equipment.

• Review jobsite hazards, safety and emergency procedures, and individual responsibilities with all

personnel before work begins. Safety videos are available from your Ditch Witch® dealer.

• Replace missing or damaged safety shields and safety signs.

• Use equipment carefully. Stop operation and investigate anything that does not look or feel right.

• Do not operate unit where flammable gas is present.

• Contact your Ditch Witch dealer if you have any question about operation, maintenance, or equipment use.

California Proposition 65 Warning

This product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

• battery posts, terminals and related accessories

• engine exhaust

• ethylene glycol


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.

Safety - 14 P80/PP25 Operator’s ManualSafety 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 bursting unit components when unit is operating.

Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment.

Crushing weight could cause death or serious injury. Use proper procedures and equipment or stay away.

Moving parts on unit could cut off hand or foot. Stay away.

Read operator’s manual. Know how to use all controls before operating

machine. When you see this sign on the machine or in the manual, read it and use caution. Your safety is at stake.

Improper control function could cause death or serious injury. If control does not work as described in instructions, stop machine and have it serviced.


Safety Alerts

Looking into fiber optic cable could result in permanent vision damage. Do not look into ends of fiber optic or unidentified cable.

Fluid or air pressure could pierce skin and cause injury 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.

Explosion possible. Serious injury or equipment damage could occur. Follow directions carefully.

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.

Safety - 16 P80/PP25 Operator’s ManualSafety Alerts

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 data sheets (MSDS).


Emergency Procedures


Before operating any equipment, review emergency procedures and check that all safety precautions have been taken.

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. Many 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.

EMERGENCY SHUTDOWN - Turn ignition switch to stop position or push remote engine stop button.

Safety - 18 P80/PP25 Operator’s ManualEmergency 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.

• 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. 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.


• 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.


• 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.


• Do not return to area or allow anyone into area until given permission by utility company.



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.

• 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.

Safety - 20 P80/PP25 Operator’s ManualEmergency Procedures

P80/PP25 Operator’s Manual Controls - 21

Controls

Chapter Contents

P80 Rod Pusher . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

PP25 Power Pack . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Controls - 22 P80/PP25 Operator’s ManualP80 Rod Pusher

P80 Rod Pusher

1. Jaw lever

2. Rotation device (optional)

3. Level adjusting screw

4. Mechanical hyraulic control valve (optional)

5. Electric hydraulic control (optional)

Item Description Notes

1. Jaw lever Push lever to move to pull rod.

Pull lever to push rod.


P80 Rod Pusher

2. Rotation Device This control rotates rod as it is pushed or pulled.

Disengage device to steer rod.

3. Level Adjusting Screw This control allows the unit to be adjusted to match grade of bore.

• Loosen wing nut.

• Adjust unit.

• Tighten wing nut.

IMPORTANT: Trench box mounted rod pushers do not have level adjusting screws. Entire trench box must be adjusted to set grade of bore.

4. Mechanical Hydraulic Control (Optional)

This lever operates the hydraulic cylinder.

• Engage hydraulic control.

• Move jaw lever to push or pull rod.

5. Electric Hydraulic Control (Optional)

This lever operates the hydraulic cylinder.

• Engage hydraulic control.

• Move jaw lever to push or pull rod.


Controls - 24 P80/PP25 Operator’s ManualPP25

PP25

1. Ignition switch

2. Choke control

3. Fuel gauge

4. Battery voltmeter

5. Hourmeter

6. Throttle control

7. Battery compartment

8. Case drain hydraulic connector

9. Return hydraulic connector

10. Pressure hydraulic connector


1. Ignition switch To start engine, insert key and turn clockwise.

To stop engine, turn key counterclockwise.

IMPORTANT: If unit won’t start, ensure all emergency stop switches are disengaged.


PP25

2. Choke control To close choke valve, pull. Close this valve to enrich air/fuel mixture and help start cold engine.

Open choke valve after engine runs for a few seconds.

3. Fuel gauge Displays fuel level in tank.

4. Battery voltmeter Displays system voltage. Should show 12-14V with engine running during normal operation.

5. Hourmeter Displays engine operating time.

Use these times to schedule service.

6. Throttle control To increase engine speed, push up.

To decrease engine speed, pull down.


Controls - 26 P80/PP25 Operator’s ManualPP25

7. Battery compartment To access battery, turn ring and remove door.

To disconnect battery, remove negative (black) cable from battery post.

8. Hydraulic coupler, case drain

To power hydraulic equipment, connect hydraulic line to connector.

NOTICE: Couplers do not connect under pressure. Do not attempt to connect hydraulic lines while unit is operating. Stop PP25 engine before connecting hydraulic lines.

9. Hydraulic coupler, return

10. Hydraulic coupler, pressure


P80/PP25 Operator’s Manual Prepare - 27

Prepare

Chapter Contents

Gather Information . . . . . . . . . . . . . . . . . . . . . . . . . 28

• Review Job Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

• Notify One-Call Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

• Arrange for Traffic Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

• Plan for Emergency Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Inspect Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

• Identify Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Classify Jobsite. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

• Inspect Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

• Select a Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

• Apply Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Check Supplies and Prepare Equipment . . . . . . . 34

• Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

• Fluid Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

• Condition and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

• Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Prepare - 28 P80/PP25 Operator’s ManualGather Information

Gather Information

A successful job begins before you dig. The first step in planning is reviewing information already available about the job and jobsite.

Review Job Plan

Review blueprints or other plans. Check for information about existing or planned structures, elevations, or proposed work that may be taking place at the same time.

Notify One-Call Services

Contact your local One-Call (811 in USA) or the One-Call referral number (888-258-0808 in USA and Canada) to have underground utilities located before digging. Also contact any utilities that do not participate in the One-Call service.

Examine Pullback Material

Ask for a sample of the material you will be pulling back. Check its weight and stiffness. Contact the manufacturer for bend radius information. Check that you have appropriate devices to attach pullback material.

Arrange for Traffic Control

If working near a road or other traffic area, contact local authorities about safety procedures and regulations.

Plan for Emergency Services

Have the telephone numbers for local emergency and medical facilities on hand. Check that you will have access to a telephone.


Inspect Site

Inspect Site

Inspect jobsite before transporting equipment. Check for the following:

• changes in elevation such as hills or other open trenches

• obstacles such as buildings, railroad crossings, or streams

• signs of utilities (See “Inspect Jobsite” on page 30.)

• traffic

• access

• soil type and condition

Identify Hazards

Identify safety hazards and classify jobsite. See “Classify Jobsite” on page 30.


NOTICE:

• Wear personal protective equipment including hard hat, safety eye wear, and hearing protection.

• Do not wear jewelry or loose clothing.

• Notify One-Call and companies which do not subscribe to One-Call.

• Comply with all utility notification regulations before digging or drilling.

• Verify location of previously marked underground hazards.

• Mark jobsite clearly and keep spectators away.

Remember, jobsite is classified by hazards in place -- not by line being installed.

Prepare - 30 P80/PP25 Operator’s ManualClassify Jobsite

Classify Jobsite

Inspect Jobsite

• Follow U.S. Department of Labor regulations on excavating and trenching (Part 1926, Subpart P) and other similar regulations.

• Contact your local One-Call (811 in USA) or the One-Call referral number (888-258-0808 in USA and Canada) to have underground utilities located before digging. Also contact any utilities that do not participate in the One-Call service.

• Inspect jobsite and perimeter for evidence of underground hazards, such as:

– “buried utility” notices

– utility facilities without overhead lines

– gas or water meters

– junction boxes

– drop boxes

– light poles

– manhole covers

– sunken ground

• Have an experienced locating equipment operator sweep area within 20 feet (6 m) to each side of trench path. Verify previously marked line and cable locations.

• Mark location of all buried utilities and obstructions.

• Classify jobsite.

Select a Classification

Jobsites are classified according to underground hazards present.

If working . . . then classify jobsite as . . .

within 10’ (3 m) of a buried electric line electric

within 10’ (3 m) of a natural gas line natural gas

in sand, granite, or concrete which is capable of producing crystalline silica (quartz) dust

crystalline silica (quartz) dust

within 10’ (3 m) of any other hazard other

NOTICE: If you have any doubt about jobsite classification, or if jobsite might contain unmarked hazards, take steps outlined previously to identify hazards and classify jobsite before working.


Classify Jobsite

Apply Precautions

Once classified, precautions appropriate for jobsite must be taken.

Electric Jobsite Precautions

Use one or both of these methods.

• Expose line by careful hand digging or soft excavation.

• Have service shut down while work is in progress. Have electric company test lines before returning them to service.

Natural Gas Jobsite Precautions

In addition to positioning equipment upwind from gas lines, use one or both of these methods.

• Expose lines by careful hand digging or soft excavation.

• Have gas shut off while work is in progress. Have gas company test lines before returning them to service.

Crystalline Silica (Quartz) Dust Precautions

Follow OSHA or other guidelines for exposure to crystalline silica when trenching, sawing or drilling through material that might produce dust containing crystalline silica (quartz).

Other Jobsite Precautions

You may need to use different methods to safely avoid other underground hazards. Talk with those knowledgeable about hazards present at each site to determine which precautions should be taken or if job should be attempted.

Prepare - 32 P80/PP25 Operator’s ManualPlan Bore Path

Plan Bore Path

Plan the bore path, from entry to end, before job begins. Locate the entire route of the material to be installed to ensure a straight path. For complicated bores, consult an engineer. Have jobsite surveyed and bore path calculated. Expose all crossing or parallel utilities within 18” (500 mm) of the material being installed.

Mark Bore Path

Mark your planned bore path with flags or paint.

Select Start and End Points

Select one end of the jobsite to use as a starting point. If trench box is used, it can be placed in middle of bore path and rod can be pushed or pulled both directions, then joined.

Consider the following when selecting a starting point:

• Slope. consider how slope will affect boring unit set-up and bending rod.

• Traffic. Vehicle and pedestrian traffic must be at a safe distance from equipment. Allow at least 10 ft (3 m) buffer zone around equipment.

• Space. Check that starting and eding points allow enough space for gradual rod bending.

• Comfort. Consider shade, wind, fumes, and other site features.


Prepare Jobsite

Prepare Jobsite

Dig Installation Pit

Launch rod deep enough to prevent soil mounding. As a general rule, allow one foot of depth for every inch of rod diameter.

If a trench box is used, depth is limited by soil type according to the US Department of Labor Regulations, Part 1926, Subpart P. This document is available from the US Government Printing Office, 202-783-3238.

Installation Pit:

• Must be in line with bore path. For bore to be successful, first rod must be straight.

• Sloped back end aids new product installation. Consider new product bend radius.

• To prevent bending or straining rod, position rod pusher for straight entry.


NOTICE:

• Cutting high voltage cable can cause electrocution. Expose lines by hand before digging.

• All vegetation near operator’s station must be removed. Contact with trees, shrubs, or weeds during electrical strike could result in electrocution.

Soil Type Maximum Depth

A 18 ft (5.5 m)

B 10 ft (3.0 m)

C 5 ft (1.7 m)

Prepare - 34 P80/PP25 Operator’s ManualCheck Supplies and Prepare Equipment

Check Supplies and Prepare Equipment

Supplies

• fuel

• keys

• personal protective equipment, such as hard hat and safety glasses

Fluid Levels

• fuel

• hydraulic fluid

• battery charge

• engine oil

Condition and Function

• fan belts

• filters (air, oil, hydraulic)

• pumps and motors

• hoses and valves

• signs, guards, and shields

Accessories

Fire Extinguisher

If required, mount a fire extinguisher near the power unit but away from possible points of ignition. The fire extinguisher should always be classified for both oil and electric fires. It should meet legal and regulatory requirements.

P80/PP25 Operator’s Manual Transport - 35

Transport

Chapter Contents

Lift Points and Procedure . . . . . . . . . . . . . . . . . . . 36

• Power Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

• Rod Pusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

• Rod Pusher with T-Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

• Rod Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

• Trench Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

• Trench Box with Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

• Back Brace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Tie Down Points and Procedure . . . . . . . . . . . . . . 39

Transport - 36 P80/PP25 Operator’s ManualLift Points and Procedure

Lift Points and Procedure

Lifting points are identified by lifting decals. Lifting at other points is unsafe and can damage machinery.

Use equipment capable of supporting the size and weight of the unit being lifted. See “Specifications” on page 99 or measure and weigh equipment before lifting.

Power Pack

Use equipment capable of supporting the power pack's size and weight. Use lift chains at lift points as shown.

Crushing weight. If load falls or moves it could kill or crush you. Use proper procedures and equipment or stay away.


Lift Points and Procedure

Rod Pusher

Use equipment capable of supporting the unit's size and weight. See “Specifications” on page 99 or measure and weigh equipment before lifting. Lift rod pusher by connecting chain to lift ring.

Rod Pusher with T-Bar

Attach chain to front lift point.

Rod Box

Use equipment capable of supporting the rod box's size and weight. Attach chains to lift rings.

Transport - 38 P80/PP25 Operator’s ManualLift Points and Procedure

Trench Box

Lift trench box by attaching four chains to lift points and to a common lift ring. Chains must be:

• at least 80 in (2030 mm) from lift points to lift ring,

• of equal length,

• strong enough to bear 10,000 lb (44,500 N) lifting force.

Maximum allowable lifting force is 20,000 lb (89,000 N).

Trench Box with Extensions

Lift trench box with extensions by installing extensions then connecting chains to trench box lift points, as above.

Do not assemble or disassemble trench box and extension when trench box is in trench.


Tie Down Points and Procedure

Back Brace

Lift unit with back brace by attaching chain to lift rings at front and back of back brace.

Lift back brace support by lift ring at top of support.

Tie Down Points and Procedure

Rod pusher, rod box, back brace, and trench box may be carried on any truck or trailer able to transport the equipment gross weight.

• Install all pins to hold rod pusher in place.

• Use tie-downs to anchor equipment.

Transport - 40 P80/PP25 Operator’s Manual

P80/PP25 Operator’s Manual Push Rods - 41

Push Rods

Chapter Contents

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

• Trench Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

• Back Brace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

• T-Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Assemble Strike System . . . . . . . . . . . . . . . . . . . . 48

• Arrange Grid Mats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

• Assemble Bonding Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

• Install Control Box and Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

• Install Strobe Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

• Connect to Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

• Test Strike System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Push Rods - 42 P80/PP25 Operator’s ManualSetup

Setup

Proper set-up and bracing is necessary for efficient rod pushing and pulling. Rod pushers can be used with three configurations: trench box, back brace, and T-bar. Set-up and bracing procedures depend on configuration used. Follow set-up instruction for configuration you are using.

Trench Box

1. Dig starting trench at least 3’ (1 m) wide, at least 9’ (3 m) long, and as deep as desired bore. Maximum trench depth depends on job type. For information on soil typing, read US Department of Labor Regulations on Excavating and Trenching, Part 1926, Subpart P.

2. Level and compact trench floor.

IMPORTANT: In muddy or unstable soils, place boards across trench floor to support trench box. Level boards before installing trench box.

3. Dig target trench deep enough to meet bore and long enough to remove rod. Keep spoil on one side of trench and at least 4’ (1.2 m) away.

4. If trench is deeper than 4’ (1.2 m), install trench box extensions.

5. Fasten chains to lift points, lower trench box into starting trench, and position it.

6. Lower rod pusher into trench.



Crushing weight could cause death or serious injury. Use proper procedures and equipment or stay away.

NOTICE: Cave-in possible. Read, understand, and follow US Department of Labor Regulations on Excavating and Trenching, Part 1926, Subpart P.

Soil Type Maximum depth

A 18’ (5.5 m)

B 10’ (3.0 m)

C 5’ (1.7 m)


Setup

7. Install pins, as shown.

8. Slide a rod through cylinder and install pilot head, as shown.

9. Fasten chain and lift rod pusher in level position. Lower unit into trench.

10. Backfill and compact soil around trench box. Top 2’ (600 mm) of soil must be well compacted.


11. Attach hydraulic control hose to power unit and rod pusher.

12. Set up Electric Strike System. See instructions later in this chapter.


Setup

Back Brace

1. Dig starting trench 18” (460 mm) wide and 72-99” (1830-2500 mm) long.

2. Level and compact trench floors.

3. Dig target trench deep enough to meet bore path and long enough to remove rod.

4. Slide a rod through cylinder and install pilot head.


6. Attach hydraulic control hoses to power unit hydraulic manifold. Connect other hoses from hydraulic control valve block to rod pusher.

7. Align unit with intended bore path.

8. Place a level on push rod at rear of unit. Adjust angle to match grade of bore.


T-Bar

1. Dig T-Bar trench a minimum of 6” (150 mm) wide.

2. Dig rod pusher trench a minimum of 9” (230 mm) wide. Do not break edges or corners of T-Bar trench.

3. Dig rod trench, as shown. Trench should be slightly longer than rod being used. Level and compact trench floors.

4. Dig target trench deep enough to meet bore path and long enough to remove rod.

5. Set T-bar on cylinder and install clip pins.


Setup

6. Slide a rod through cylinder and install pilot head.


8. Attach hydraulic control hoses to power unit hydraulic manifold. Connect other hoses from hydraulic control valve block to rod pusher.

9. Align Unit with intended bore path.

10. Place a level on push rod at rear of unit. Adjust angle to match grade of bore.

NOTICE: Hydraulic hoses DO NOT connect under pressure. Stop unit before connecting hydraulic hoses.

Push Rods - 48 P80/PP25 Operator’s ManualAssemble Strike System

Assemble Strike System

Anytime rod pusher with trench box is used in an electric jobsite, a trench box with electric strike system and directional boring system must be properly set up, tested, and used.

In addition to control box, electric strike system includes grid mats, bonding cables, barriers, and protective boots and gloves meeting the following standards:

• Wear high-top boots with legs of pants tucked completely inside. Boots must meet the electric hazard protection requirements of ANSI Z-41, 1991, when tested at 14,000 volts.

• Gloves must have 17,000 AC maximum use voltage, according to ASTM specification D120-87.

• If working around higher voltage, use gloves and boots with appropriately higher ratings.

NOTICE: The electric strike system does not prevent electric strikes or detect strikes before they occur. If alarms are activated, a strike has already occurred and equipment is electrified.



Arrange Grid Mats

A. Bore Path B. Trench Box C. Trailer D. Strike System Control Box E. Power unit

1. Arrange grid mats around trench box.

2. Arrange grid mats between trench box and trailer.

3. Stake grid mats.

4. Place floor grids on rail on trench box floor. Position grids at end opposite rod pusher and with bonding cables on same side as welded tab.


Assemble Bonding Equipment

1. Drive voltage stake into ground at least 6 ft (2 m) from starting trench.

2. Clip voltage limiter to voltage stake.

3. Connect cable from voltage limiter to back of control box and lock with 1/4 turn.

4. Connect bonding cables to grid mats.

5. Drive ground rod into soil near grid mats.

6. Move cords and cables under grid mats.



Install Control Box and Cables

1. Attach control box to mounting bracket with wing nuts.

2. Attach current coil cable to top of current coil assembly

• Attach blue or green connector at (A).

• Attach black connector at (B).

• Attach brown or white connector at (C).

3. Plug current coil into back of control box.

4. Plug power cable into back of control box.

5. Attach bonding cable to top of rod pusher.

6. Connect grids on trench box floor and rod pusher bonding cable at welded tabs.

7. Connect grid mats by attaching bonding cables to control box bracket.

Install Strobe Lights

1. Plug other end of power cable into first strobe light.

2. Place light on grid mat near trench box.

3. Plug strobe light bonding cable into grid mat.

4. Plug electric cable into strobe light. Plug other end of cable into second strobe light.

5. Place second strobe light on trailer.

6. Connect strobe light bonding cable to trailer or power unit.


Connect to Power

1. Connect 50 ft (15.3 m) cable to trailer and to control box.

2. Plug power harness with alligator clips to strobe light on trailer.

3. Connect alligator clips to power unit on battery.



NOTICES:

• Low main battery power will shut off control box. Backup battery only signals loss of main power. Restore main power before continuing.

• The electric strike system will work with low backup batteries but might not warn of main battery system failure.



Test Strike System

If system fails any part of this test, see “Troubleshooting the Strike System” in MAINTENANCE. Do not bore until test is completed successfully.

1. Turn power switch on. Light above switch should come on.

2. Check that Lo Main and Lo Backup lights are off.

3. Press test button.

• Horns on boring unit and power unit will sound.

• Strobe lights on both units will flash.

• Voltage and current hazard lights on alarm panel will light.

4. Press reset button.

• Strobes will stop flashing.

• Green system lights will come on.

Push Rods - 54 P80/PP25 Operator’s ManualOperate

Operate

Crushing weight. If load falls or moves, it could kill or crush you. Use proper procedures or stay away.

NOTICE: Cave-in possible. Read, understand, and follow US Department of Labor Regulations on Excavating and Trenching, Part 1926, Subpart P.


Fluid or air pressure could pierce skin and cause injury or death. Stay away.

NOTICE: Escaping pressurized fluid can cause injury or pierce skin and poison. Before disconnecting lines, turn engine off and operate system controls to relieve pressure. Before using system, check that all connections are tight and all lines are undamaged. Fluid leaks can be hard to detect. Use a piece of cardboard or wood, rather than hands, to search for leaks. Wear protective clothing and eye protection. If you are injured, seek immediate medical attention.

Moving parts on unit could cut off hand or foot. Stay away.

NOTICE: Stand and work only in operator’s position (shown large square).


Operate

Pushing Straight

1. Start power pack.

2. Push pilot head against front wall of trench.

3. Activate hydraulic control.

4. Pull jaw lever back gently. Rod will enter soil.

5. Push jaw lever forward, then gently pull it back again.

6. As needed, connect new rod, tighten with pipe wrench, and continue pushing.

Changing Direction

1. Select directional head and attach to beacon housing.

P80 has three directional heads:

• (A) Less aggressive head for tight, clay soil

• (B) Standard head for normal soil

• (C) Aggressive head for soft soil

2. Attach beacon housing assembly to rod.

3. Slide rod through cylinder.

4. Engage rotation control and pull jaw lever back gently. Rod will enter soil.

5. Pull jaw lever forward, then gently pull it back again. Do not clamp jaws over threaded joint. Bore first 10 ft (3 m) and confirm location with detection equipment.

6. Compare location to bore plan. If no steering is needed, continue to bore, checking beacon readings regularly.

7. To steer:

• Rotate rod until detection equipment clockface indicates direction rod should turn.

• Push rod a short distance without rotation.

• Complete pushing rod with rotation.

• Check beacon location and repeat as necessary.

8. As needed, connect new rod, tighten with pipe wrench, and continue pushing.

NOTICE: Do not clamp jaws on rod threads.

IMPORTANT: Steering is a skill operators gain with experience. These instructions only cover basic procedures. For information about specific equipment or jobsites, contact your Ditch Witch® dealer.

Push Rods - 56 P80/PP25 Operator’s ManualOperate

Expanding and Pullback

Expanding

A. Rod B. Bell Stop C. Expander D. Clevis

1. When rod reaches target trench, attach bell stop, expander, and another bell stop. Use clevis to attach material to drill string.

2. Pull expander back through bore. If bore will be expanded further, add rod sections behind expander to keep drill string in bore.

3. When expander is in set-up trench, remove expander and both expander stops.

4. To expand bore further:

• Remove expander and replace with larger expander.

• Repeat procedure going reverse direction.

• Pull progressively larger expanders followed by rods until bore is correct diameter for material.

• continue to use strike system when working in electric jobsite.

Pullback1. Attach expander stop, expander and clevis to rod end.

Expander should be larger than pullback material.

2. Attach rod pulling grips or threaded rod adapter to clevis.

3. Pull rod or cable through bore.

Optional Rod Wiper

Before pulling back or expanding, spearate rods in front of unit. Slide rod wiper on rod and reconnect.

P80/PP25 Operator’s Manual Complete the Job - 57

Complete the Job

Chapter Contents

Stow Components . . . . . . . . . . . . . . . . . . . . . . . . . 58

Restore Jobsite . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Stow Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Complete the Job - 58 P80/PP25 Operator’s ManualStow 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.

P80/PP25 Operator’s Manual Specifications - 59

P80 w/Trench Box

Specifications

P80 w/Trench Box

Dimensions U.S. Metric

P80 Basic weight 253 lb 115 kg

Trench Box

L, length 108 in 2750 mm

W, width 36 in 920 mm

H1, height 48 in 1220 mm

H2, Height from base to centerline of bore 8.4 in 213 mm

Weight, trench box 930 lb 420 kg

Operating weight w/P80 installed 1240 lb 560 kg

Operating weight w/P80 and 42 4-ft rods 2700 lb 1225 kg

Operational U.S. Metric

Stroke, each cycle 9 in 229 mm

Bore diameter, max. 13 in 325 mm

Hydraulic flow, min to max 5-20 gpm 20-75 L/min

Hydraulic pressure, max 2500 psi 1723.8 bar

Cylinder force at 2500 psi 81,360 lb 362 025 N

Specifications - 60 P80/PP25 Operator’s ManualP80 w/Trench Box

P80 w/Back Brace



Back Brace

L2, Length, min to max 72-100 in 1800-2500 mm

A, Width 17 in 430 mm

H3, Height 18 in 450 mm

D, Height from base to centerline of bore 7.6 in 190 mm

Level adjustment height 6 in 150 mm

Weight, back brace 440 lb 200 kg

Operating weight w/P80 installed 704 lb 320 kg





Hydraulic pressure, max 2500 psi 1723.8 bar



P80 w/Trench Box

P80 w/T-Bar



T-Bar

A, Cylinder diameter 8 in 200 mm

B, T-Bar width 5.8 in 145 mm

C, T-Bar height 12 in 203 mm

D, Base to cylinder centerline 7.2 in 183 mm

H3, Height without handle 16 in 400 mm

L3, Length, T-bar installed with cylinder retracted 42 in 1050 mm

W2, Width, T-bar 72 in 1800 mm

Push rod diameter 1.75 in 44 mm

Weight of T-bar 204 lb 93 kg

Weight w/P80 installed 462 lb 210 kg

Specifications - 62 P80/PP25 Operator’s ManualP80 w/Trench Box





Hydraulic pressure, max 2500 psi 172 bar



PP25

PP25


L, length 48.5 in 1.23 m

W, width 27.5 in 700 mm

H, height 30 in 760 mm

Weight, mass (dry weight, without fluids) 685 lb 310 kg

Specifications - 64 P80/PP25 Operator’s ManualPP25

Specifications are called out according to SAE recommended practices where indicated. Specifications are general and subject to change without notice. If exact measurements are required, equipment should be weighed and measured. Due to selected options, delivered equipment may not necessarily match that shown.

Power U.S. Metric

Engine: Honda® GX690, EPA Phase III

Fuel: gasoline

Cooling medium: air

Cylinders: 2

Displacement 42 in3 688 cm3

Bore 3.03 in 77 mm

Stroke 2.83 in 72 mm

Power

manufacturer’s gross power rating (per SAE J1995) 22.2 hp 16.6 kW

rated speed 3600 rpm 3600 rpm

Hydraulic System U.S. Metric

Pump

Flow capacity @ 3200 rpm 11.7 gpm 44.3 L/min

Maximum pressure 2500 psi 172 bar

Filtration (nominal) 10 micron 10 micron

Fluid Capacities U.S. Metric

Fuel tank 9.5 gal 36 L

Hydraulic reservoir 20 gal 76 L

Engine oil, including filter 2.1 qt 1.9 L

Battery

12V, negative ground, SAE cold crank rating @ 0°F (-18°C), 525 amps.

SAE reserve capacity rating, 85 min

Noise Levels

Exterior sound power per ISO 6394 is < or = to 108 dBA per ISO 6394.

P80/PP25 Operator’s Manual Support - 65

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.

Order genuine Ditch Witch replacement or repair parts from your authorized Ditch Witch dealer. Use of another manufacturer's parts may void warranty consideration.

Resources

Publications

Contact your Ditch Witch dealer for publications and videos covering safety, operation, service, and repair of your equipment.

Ditch Witch Training

For information about on-site, individualized training, contact your Ditch Witch dealer.

Warranty - 66 P80/PP25 Operator’s Manual

Warranty

Ditch Witch® Equipment and Replacement PartsLimited 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. Free labor will be provided at any authorized Ditch Witch dealership for installation of parts under this warranty during the first year following “initial commercial” use of the serial-numbered Ditch Witch equipment on which it is installed. The customer is responsible for transporting their equipment to an authorized Ditch Witch dealership for all warranty work.

Exclusions from Product Warranty• All incidental or consequential damages.

• All defects, damages, or injuries caused by misuse, abuse, improper installation, alteration, neglect, or uses other than those for which products were intended.

• All defects, damages, or injuries caused by improper training, operation, or servicing of products in a manner inconsistent with manufacturer’s recommendations.

• All engines and engine accessories (these are covered by original manufacturer’s warranty).

• Tires, belts, and other parts which may be subject to another manufacturer’s warranty (such warranty will be available to purchaser).

• ALL IMPLIED WARRANTIES NOT EXPRESSLY STATED HEREIN, INCLUDING ANY WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY.

IF THE PRODUCTS ARE PURCHASED FOR COMMERCIAL PURPOSES, AS DEFINED BY THE UNIFORM COMMERCIAL CODE, THEN THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE FACE HEREOF AND THERE ARE NO IMPLIED WARRANTIES OF ANY KIND WHICH EXTEND TO A COMMERCIAL BUYER. ALL OTHER PROVISIONS OF THIS LIMITED WARRANTY APPLY INCLUDING THE DUTIES IMPOSED.

products have been tested to deliver acceptable performance in most conditions. This does not imply they will deliver acceptable performance in all conditions. Therefore, to assure suitability, products should be operated under anticipated working conditions prior to purchase.

Defects will be determined by an inspection within thirty (30) days of the date of failure of the product or part by CMW or its authorized dealer. CMW will provide the location of its inspection facilities or its nearest authorized dealer upon inquiry. CMW reserves the right to supply remanufactured replacements parts under this warranty as it deems appropriate.

Extended warranties are available upon request from your local Ditch Witch dealer or CMW.

Some states do not allow exclusion or limitation of incidental or consequential damages, so above limitation of exclusion may not apply. Further, some states do not allow exclusion of or limitation of how long an implied warranty lasts, so the above limitation may not apply. This limited warranty gives product owner specific legal rights and the product owner may also have other rights which vary from state to state.

For information regarding this limited warranty, contact CMW’s Product Support department, P.O. Box 66, Perry, OK 73077-0066, or contact your local dealer.

First version: 1/91; Latest version: 11/11

P80/PP25 Operator’s Manual Service Record - 69

Service Record

Service Performed Date Hours

Service Record - 70 P80/PP25 Operator’s Manual

Service Performed Date Hours

p80/pp25 - ditch witch operator’s manual overview - 1 ... electric hydraulic control (optional) 8....

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