N/A Ditch Witch Welder PR95 P80 Parts Manual 050 684

User Manual: Ditch Witch Welder PR95

Open the PDF directly: View PDF .
Page Count: 105 [warning: Documents this large are best viewed by clicking the View PDF Link!]

Title
Contents
DECALS
FRAME COMPONENTS
HYDRAULICS
ELECTRICAL
ACCESSORIES
MISCELLANEOUS

P40/P80

(Rod Pusher)

Parts

Manual

CMW®

Issue 15

050-684

ID0040642

P40/P80

(Rod Pusher)

ISSUE NO. 15PL-08/11

For Replacement Copy Order P/N 050-684

This manual contains information concerning the following models:

P40/P80 (Rod Pusher)

, Ditch Witch, CMW, AutoCrowd, Modularmatic, Jet Trac, Roto Witch, Subsite, Fluid

Miser, Perma-Soil, Power Pipe, Super Witch, Super Witch II, Pierce Arrow, The Underground, and The

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

FOREWORD___________

8/6/2010, Rev-B 800-001

This manual contains illustrated parts lists to help you select quality ProTech ®

Replacement parts for your Ditch Witch ® equipment. Using other replacement parts will

lessen the productivity of your equipment.

Part numbers enclosed in a box are no longer available from The Charles Machine

Works, Inc. Your local Ditch Witch dealer may be able to locate the part for you.

Footnotes provide more information to help you identify parts shown in the manual.

Assembly instructions and Tech Bits articles referenced in footnotes are available

through your local Ditch Witch dealer.

Description and specifications in this book were current at publication. However,

The Charles Machine Works, Inc. reserves the right to improve equipment, so this

manual might not reflect the most current improvements.

Instructions on recommended equipment use and maintenance are in the Operator’s

Manual that was shipped with your equipment.

Keep the following in mind when ordering ProTech replacement parts:

Specify parts you need by part number and description, not by illustration reference

numbers.

Have equipment model and serial number on hand to help ensure you get the right

parts for your machine whether it’s old or new.

Thank you for buying and using Ditch Witch equipment and ProTech replacement parts.

WARRANTY__________________________

Ver. 03 ID0134872

DW WARRANTY Policy

July, 2005

POLICY 1: DITCH WITCH® EQUIPMENT AND REPLACEMENT PARTS

LIMITED WARRANTY POLICY

Subject to the limitation and exclusions herein, free replacement parts will be provided at any authorized Ditch

Witch dealership for any Ditch Witch equipment or parts manufactured by The Charles Machine Works, Inc.

(CMW) that fail due to a defect in material or workmanship within one (1) year of first commercial use

(Exception: 2 years for all SK500 Attachments). 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 are 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.

Ditch Witch 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 it’s nearest

authorized dealer upon inquiry. CMW reserves the right to supply remanufactured replacement 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 the above

limitation or 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 Ditch Witch dealer.

CONTENTS______________________

ID0040643

Decals

Decal Location - P40/P80 ................................... 8

Frame Components

Back Brace ..................................................... 12

Drive Rod Pusher - P40/P80 ............................... 22

Drive Rod Pusher - Trench Box ......................... 20

Power Pack Support ....................................... 36

Rod Rack ........................................................ 38

Storage Box - Early Style .................................... 34

Storage Box - S2A/S5A ..................................... 32

T-Bar .............................................................. 14

Tool Box - Early Style ......................................... 30

Trailer Mount .................................................... 26

Trailer Mount - Early Style .................................. 24

Trench Box ..................................................... 16

Trench Box Extension .................................... 18

Trench Box Trailer Mounts ............................. 28

Hydraulics

Cylinder Drive Rod - P40 ................................. 52

Cylinder Drive Rod - P80 - Begins ....................... 54

Cylinder Drive Rod - P80 - Ends .......................... 56

Drive Hydraulics - Early Style .............................. 46

Drive Hydraulics - P40/P80 ................................. 48

Drive Hydraulics - Present ................................. 44

Hydraulic Control Valve .................................. 50

Hydraulic Schematic ....................................... 42

Solenoid Control ............................................. 58

Electrical

Coil Bracket - Early Style .................................... 72

Current Transformer........................................ 68

Electric Diagram - Present ................................. 70

Grid System Hardware - Present ........................ 62

Strobe Light .................................................... 66

Boring Components

Pilot Heads - Beacon/Sondes - P80 - Old ............... 80

Pilot Heads - P40 - New Style ............................... 78

Pilot Heads - P40 - Old Style ............................... 76

Pilot Heads - P80 - New Style ............................... 82

Pulling Tools .................................................... 88

Pulling Tools Accessories .............................. 90

Push Rods - P40 ............................................. 84

Push Rods - P80 .............................................. 86

Rod Grabber - P40/P80 ..................................... 92

Miscellaneous

Bolt/Nut Torque Chart ..................................... 96

Optional Kits .................................................. 100

Parts Manual Change Request ..................... 101

Related Publications ...................................... 100

Replacement O-Ring Chart ............................. 99

Warranty Registration ................................... 104

ID0135069

DECALS

DECAL LOCATION

P40 - P80

801-851

2.25”

5.50”

5.00”

2.78”

3.38”

23.08”

2.00”

FOOTNOTES

REF

NO.

PART

NUMBER QTY DESCRIPTION REMARKS

275-573

274-012

274-013

274-049

274-050

274-079

275-048

275-306

275-310

275-326

275-341

275-430

275-446

275-447

274-724

273-009

USE 39”

DECAL KIT - P40 - P80

TP2 MODEL-ID

TP5 MODEL-ID

DANGER ELECTROCUTION

WARNING JOBSITE HAZARD

OPERATION INSTRUCTIONS

IMPORATANT SAFETY RULES

DITCH WITCH EMBLEM

WARNING CRUSHING WEIGHT

WARNING SLIDING PARTS

ACCENT STRIPE (1-7/16”)

P40 MODEL-ID

P80 MDEL-ID

ONE CALL NOTIFICATION

P40-P80 PATENT(S)

DECAL LOCATION

P40 - P80

801-851

ID0134963

NOTES:

ID0135068

FRAME

COMPONENTS

05 ID0125652

DRIVE ROD PUSHER

P40 AND P80

NOTE:

FOOTNOTES:

REF

NO. PART

NUMBER QTY DESCRIPTION REMARKS

05 ID0125652

NOT SHOWN:

DRIVE ROD PUSHER

P40 AND P80

SEE FOOTNOTE 1

SEE FOOTNOTE 2

P40

P80

SEE FOOTNOTE 1

SEE FOOTNOTE 2

P40

P80

P40

P80

P40

P80

P40

P80; ENDS WITH S/N CMWP80_90000223.

SEE FOOTNOTE 1

SEE FOOTNOTE 2

SEE FOOTNOTE 1

SEE FOOTNOTE 2

INCL REF NO.'S 2, 4, 7, 9-10, 13 & 17 SEE FOOTNOTE 3

INCL REF NO.'S 1, 5, 14-15 & 19 SEE FOOTNOTE 2

P40

P80

1. END W/ SN 2H1335 ON P40 AND ENDS W/ SN 2H1308 ON P80.

2. BEGINS W/ SN 2H1336 ON P40 AND BEGINS W/ SN 2H1309 ON P80. TO UPGRADE UNITS PRIOR

TO THESE SERIAL NUMBERS ORDER ESID JAWS CONVERSION KIT AND REFER TO INSTALLATION

INSTRUCTIONS 050-210.

3. REFER TO INSTALLATION INSTRUCTIONS 050-218.

P80

P40

2. 105-339 1 BOLT (3/4-NC X 2-3/4")

3. 183-517 2 PIN

183-502 2 PIN

4. 184-024 1 LINKAGE PIN

354-223 1 JAW CONNECTOR STRAP

6. 354-021 2 JAW

354-078 2 JAW

7. 354-130 1 LINKAGE

8. 361-991 1 HANDLE

9. 354-171 1 TRUSS FRAME

354-172 1 TRUSS FRAME

10. 183-676 2 HITCH PIN

12. 105-831 5 FLG LK BOLT (1/2-NC X 1-1/2")

105-337 5 FLG BOLT (5/8-NC X 2")

13. 110-228 1 LYNCH PIN (7/16" X 2")

106-216 2 BOLT (3/8-NC X 1", SIL BRZ)

15. 105-071 2 WASHER (1/2")

16. 110-013 1 GRIP (1", BLK)

17. 105-340 1 FLG LOCKNUT (3/4-NC)

18. 110-417 2 SPRING CLIP PIN (.187" X 1")

19. 184-187 2 BUSHING

21. 181-906 1 BUSHING

181-910 1 BUSHING

190-468 P80 TRENCH BOX ADPTR KIT

190-469 P40 TRENCH BOX ADPTR KIT

190-479 ESS JAW CONVERSION KIT

354-133 EAR EXTENSION

354-134 EAR EXTENSION

1. 116-283 1 WASHER (.531", RUBBER)

116-443 1 WASHER (1.25", RUBBER)

5. 354-027 1 STRAP

11. 115-499 4 CLIP RING (1")

115-483 4 CLIP RING (1-1/4")

14. 106-070 2 SHLD BOLT (1/2" X 3/8", 3/8-NC)

105-069 2 WASHER (.406")

20. 105-702 2 SET SCREW (3/8-NC X 3/8", CUP)

106-012 5 FLG BOLT (5/8-NC X 3") SEE FOOTNOTE 4 - BEGINS WITH S/N CMWP80P90000225.

4. USE WITH 150-3036 CYL., USE LOCTITE 277 OR EQUIVALENT.

04 ID0125651

DRIVE ROD PUSHER

P40 AND P80

NOTE:

FOOTNOTES:

REF

NO. PART

NUMBER QTY DESCRIPTION REMARKS

04 ID0125651

NOT SHOWN:

DRIVE ROD PUSHER

P40 AND P80

SEE FOOTNOTE 1

SEE FOOTNOTE 2

P40

P80

SEE FOOTNOTE 1

SEE FOOTNOTE 2

P40

P80

SEE FOOTNOTE 1

SEE FOOTNOTE 2

P40

P80

P40

P80

SEE FOOTNOTE 1

SEE FOOTNOTE 2

P40

P80

P40

P80

INCLUDES REF NO.'S 1, 5, 9 & 12. SEE FOOTNOTE 2

1. ENDS W/ SN 2H1335 ON P40 AND ENDS W/ SN 2H1308 ON P80.

2. BEGINS W/ SN 2H1336 ON P40 AND BEGINS W/ SN 2H1309 ON P80. TO UPGRADE UNITS PRIOR

TO THESE SERIAL NUMBERS ORDER ESID JAWS CONVERSION KIT AND REFER TO INSTALLATION

INSTRUCTIONS 050-210.

1. 105-071 2 WASHER (1/2")

2. 361-991 1 HANDLE

3. 105-831 5 FLG LK BOLT (1/2-NC X 1-1/2")

106-012 5 FLG BOLT (5/8-NC X 3")

106-216 2 BOLT (3/8-NC X 1", SIL BRZ)

6. 110-013 1 GRIP (1", BLK)

7. 110-417 2 SPRING CLIP PIN (.187" X 1")

10. 181-906 1 BUSHING

181-910 1 BUSHING

11. 183-517 2 PIN

183-502 2 PIN

354-223 1 JAW CONNECTOR STRAP

13. 354-018 1 PIVOT

354-073 1 PIVOT

14. 354-021 2 JAW

354-078 2 JAW

15. 110-055 2 MACH BUSHING (1-1/4" X 14GA)

110-220 2 MACH BUSHING (1-1/2" X 14GA)

16. 184-187 2 BUSHING

190-479 ESS JAW CONVERSION KIT

105-069 2 WASHER (.406")

4. 105-702 2 SET SCREW (3/8-NC X 3/8", CUP)

5. 106-070 2 SHLD BOLT (1/2" X 3/8", 3/8-NC)

8. 115-499 4 CLIP RING (1")

115-483 4 CLIP RING (1-1/4")

9. 116-283 1 WASHER (.531", RUBBER)

116-443 1 WASHER (1.25", RUBBER)

12. 354-027 1 STRAP

09 ID0051826

STORAGE BOX - S2A, S5A

13 12

23 27

2524

NOTE:

FOOTNOTES:

REF

NO. PART

NUMBER QTY DESCRIPTION REMARKS

09 ID0051826

NOT SHOWN:

STORAGE BOX - S2A, S5A

S2A

S5A

S5A, SEE FOOTNOTE 1

(8) S2A / (7) S5A

S2A

(10) S2A / (7) S5A

OBSOLETE (2) S2A / (5) S5A

(2) S2A / (5) S5A

S2A USE 12"

S2A, USE 12"

S2A, SEE FOOTNOTE 1

S2A, USE 75"

(4) S2A / (2) S5A

USE 24", SEE FOOTNOTE 1

S5A, SEE FOOTNOTE 1

S2A

S5A

S5A, REAR STORAGE BRACE, SEE FOOTNOTE 1

S2A, SEE FOOTNOTE 1

190-426 STORAGE BOX CONVERSION KIT

18. 110-449 6 POP RIVET (3/16" X .690")

115-968 AR BUTTON PLUG (3/8"-3)

050-192 INSTALLATION DIAGRAM

1. 105-069 1 WASHER (.406")

2. 105-825 AR FLG LK BOLT (3/8-NC X 3/4")

4. 105-845 AR FLG LOCKNUT (3/8-NC)

5. 106-070 2 SHLD BLT (1/2" X 3/8", 3/8-NC)

6. 110-219 AR HOLE PLUG (3/8")

7. 110-366 AR VELCRO STRIP (1", SOLD PER 1")

8. 110-431 AR VELCRO STRIP (1", SOLD PER 1")

9. 115-349 1 GROMMET (1/2")

10. 115-399 AR BULK STRIP (3/4", SOLD PER 1")

11. 215-478 AR BUTT CONNECTOR (14-16GA)

12. 215-488 AR FLEX GUARD (3/8", SOLD PER 1")

17. 360-124 1 S2 S4 T6 T12BW TAG BRACKET

19. 105-814 3 FLG LOCKNUT (3/8-NC)

20. 303-330 1 HASP

1. PARTS NOT INCLUDED WITH KIT AND SHOULD BE ORDERED SEPARATELY.

326-987 1 STORAGE BOX BODY

14. 326-983 1 STORAGE BOX BODY

15. 326-985 1 STORAGE BOX TOP ASS'Y (S2A)

326-982 1 STORAGE BOX TOP

190-425 STORAGE BOX KIT

3. 105-826 2 FLG LK BOLT (3/8-NC X 1")

274-012 1 TP 2 MODEL-ID

274-013 1 TPAC 5 MODEL-ID DECAL

275-306 1 DITCH WITCH EMBLEM

275-089 1 STEERING WHEEL PLAQUE

13. 215-496 AR 1- WIRE (14 GA, BRN) SOLD PER FT

16. 326-188 1 "NS" REAR BRACKET

21. 300-5317 1 HASP

22. 110-223 1 LATCH BRACKET

23. 110-222 1 HOOD LATCH

24. 110-224 1 ANCHOR BRACKET

25. 105-823 1 FLG LK BOLT (5/16-NC X 3/4")

26. 105-003 1 FLG LOCKNUT (5/16-NC)

27. 105-818 1 BOLT (1/4-NC X 1-1/2")

28. 105-085 1 LOCKNUT (1/4-NC)

ID0134963

NOTES:

ID0135071

HYDRAULICS

02 ID0125634

DRIVE HYDRAULICS

P40 & P80 WITH SOLENOID CONTROL VALVE

18 25

FOOTNOTE (3)

PORT A

PORT B

PRESSURE

RETURN

FOOTNOTE (3)

SOL A

SOL B

NOTE:

FOOTNOTES:

REF

NO. PART

NUMBER QTY DESCRIPTION REMARKS

02 ID0125634

NOT SHOWN:

DRIVE HYDRAULICS

P40 & P80 WITH SOLENOID CONTROL VALVE

1. REFER TO INSTALLATION DIAGRAM 050-190.

2. TO PROVIDE GREATER HOSE LENGTH, ORDER SETS OF HOSE (REF. NO. 8 OR 9)

AND CONNECTOR (08 O/08 S) LISTED UNDER NOT SHOWN.

3. SEE PAGE ENTITLED "ELECTRICAL DIAGRAM, P40/P80, PRESENT PRODUCTION".

100-714 SOLENOID CONTROL VALVE KIT

1. 105-053 4 NUT

2. 105-156 4 BOLT (3/8-NC X 1-1/2")

3. 105-261 4 BOLT (1/4-NC X 1-1/2", GD 8)

4. 115-686 AR GROMMET EDGING

5. 154-233 4 CONNECTOR (08 O/08 S)

155-778 O-RING (014 D70, VITON)

155-706 O-RING (908 D90)

6. 154-234 2 CONNECTOR (08 O/12 S)

155-778 O-RING (014 D70, VITON)

155-709 O-RING (912 D90)

155-778 O-RING (014 D70, VITON)

155-706 O-RING (908 D90)

8. 154-662 2 HOSE (98", 3000 PSI)

9. 154-663 2 HOSE (170", 3000 PSI)

10. 155-935 1 DUST CAP

11. 155-936 1 DUST PLUG

12. 158-583 1 SOLENOID CONTROL VALVE

13. 159-004 1 QUICK BODY

14. 159-007 1 QUICK ADAPTER

15. 159-029 2 QUICK BODY

16. 159-030 2 QUICK ADAPTER

17. 159-059 1 SUBPLATE

18. 105-820 4 FLANGE LOCK BOLT (1/4-NC X 3/4")

19. 105-832 4 FLANGE LOCKNUT (1/4-NC)

20. 362-746 2 RECEPTACLE BRACKET

21. 363-019 1 BRACKET

22. 151-024 1 CYLINDER (5.0" X 2.25" X 9.0")

151-025 1 CYLINDER (7.0" X 2.75" X 9.0")

23. 154-005 2 CONNECTOR (08 S)

155-706 O-RING (908 D90)

24. 155-706 2 O-RING (908 D90)

25. 501-325 2 FLANGE LOCK BOLT (5/16-NC X 5/8")

26. 105-003 2 FLANGE LOCKNUT (5/16-NC)

154-274 2 ADAPTER CONNECTOR

(13/16-ORS M X 13/16-ORS M,STR)

155-778 ORS O-RING (-014)

INCL. REF. NO.'S 1 THRU 26, SEE FOOTNOTE 1

USE 16"

SEE FOOTNOTE 2

2 PER UNIT

5" - P40

SEE FOOTNOTE 4; ENDS WITH S/N CMWP80_90000223.

SEE FOOTNOTE 2

7. 154-235 2 CONNECTOR (08 0/08,90)

217-737 SOLENOID REPAIR KIT

500-690 SEAL KIT

150-3036 1 P80 CYLINDER ASSEMBLY

SEE FOOTNOTE 4; BEGINS WITH S/N CMWP80P90000225

5X 106-012 (5/8-NC X 3") MOUNTING BOLTS REQ'D.

02 ID0139814

DRIVE HYDRAULICS

P40 / P80

EARLY STYLE

PORT A

PORT B

SOL A

SOL B

PRESS. RETURN

FOOTNOTE 1

NOTE:

FOOTNOTES:

REF

NO. PART

NUMBER QTY DESCRIPTION REMARKS

02 ID0139814

NOT SHOWN:

DRIVE HYDRAULICS

P40 / P80

EARLY STYLE

1. THESE PARTS PROVIDE FOR PRESSURE GUAGE OPTION. SEE FOOTNOTE 3.

2. TO PROVIDE GREATER HOSE LENGTH, ORDER SETS OF HOSE (REF. NO.'S 8 OR 9) AND 154-274 CONNECTOR.

3. REFER TO INSTALLATION DIAGRAM 050-190.

4. 5X 106-012 (5/8-NC X 3") MOUNTING BOLTS REQ'D.

REFER TO O-RING CHART IN THE MISCELLANIEOUS SECTION FOR REPLACEMENT OF SAE AND ORS CONNECTOR O-RINGS

100-714 SOLENOID CONTROL VALVE

1. 105-053 4 NUT (3/8-NC)

2. 105-156 4 BOLT (1/4-NC X 1-1/2")

3. 105-261 4 BOLT (1/4-NC X 1-1/2", ALN HD)

4. 115-686 AR GROMMET EDGING

5. 154-233 4 CONNECTOR (08S-08O)

6. 154-234 2 CONNECTOR (12S-08O)

7. 154-235 2 CONNECTOR (08o-08s 90)

8. 154-662 2 HOSE (08O-98"-3000)

9. 154-663 2 HOSE (08O-170"-3000)

10. 155-935 1 DUST CAP

11. 155-936 1 DUST PLUG

12. 158-583 1 SOLENOID CONTROL VALVE

158-583 1 SOLENOID CONTROL VALVE

13. 159-004 1 QUICK BODY (1-1/16 SAE, JIC)

14. 159-007 1 QUICK ADAPTER (1-1/16 SAE,JIC)

15. 159-029 2 QUICK BODY (1/2 X 3/4-SAE)

16. 159-030 2 QUICK ADAPTER (1/2 X 3/4-SAE)

17. 159-059 1 SUBPLATE

18. 215-691 4 CORD GRIP CONNECTOR

19. 215-732 1 PENDENT CABLE

215-079 TOGGLE SWITCH

20. 215-733 1 POWER CABLE

215-737 ALLIGATOR CLIPS (PAIR)

21. 363-019 1 VALVE BRACHET

22. 151-024 1 DRIVE ROD CYLINDER (5")

151-025 1 DRIVE ROD CYLINDER (7")

23. 154-005 2 CONNECTOR (08S-08J)

24. 155-706 2 O-RING (908 D90)

25. 155-226 2 CONNECTOR (08S-08O, 04NF)

26. 217-528 2 PRESSURE GUAGE (3000 PSI)

154-274 2 CONNECTOR (08O-08O)

INCL REF NO.'S 1 THRU 22. SEE FOOTNOTE 3

USE 16"

SEE FOOTNOTE 2

WITHOUT MANUAL OVERRIDE

WITH MANUAL OVERRIDE

P40

P80 - ENDS WITH S/N CMWP80_90000223.

SEE FOOTNOTE 1

150-3036 1 P80 CYLINDER ASSEMBLY SEE FOOTNOTE 4; BEGINS WITH S/N CMWP80P90000225.

02 ID0125780

DRIVE HYDRAULICS

P40 / P80

10 5

NOTE:

FOOTNOTES:

REF

NO. PART

NUMBER QTY DESCRIPTION REMARKS

02 ID0125780

NOT SHOWN:

DRIVE HYDRAULICS

P40 / P80

REFER TO O-RING CHART IN THE MISCELLANEOUS SECTION FOR REPLACEMENT OF SAE AND ORS

CONNECTOR O-RINGS.

1 - REFER TO INSTALLATION DIAGRAM 050-144.

2 - TO PROVIDE GREATER HOSE LENGTH, ORDER SETS OF HOSE (REF NO.'S 7 OR 8)

AND 154-274 CONNECTOR.

100-702 CONTROL VALVE KIT

1. 501-153 4 FLG LOCK BOLT (3/8-NC X 5/8")

105-181 4 BOLT (3/8-NC X 1/2")

2. 115-686 AR BULK EDGE (5/32", SOLD PER 1")

3. 154-233 2 CONNECTOR (08S-08O)

4. 154-234 2 CONNECTOR (12S-08O)

5. 154-235 2 CONNECTOR (08O-08S 90)

6. 154-236 2 CONNECTOR (12S-08O 90)

7. 154-662 2 HOSE (08O-98"-3000)

8. 154-663 2 HOSE (08O-170"-3000)

9. 155-621 1 HYDRAULIC CONTROL VALVE

10. 155-935 1 DUST CAP

11. 155-936 1 DUST PLUG

12. 159-004 1 QUICK BODY (1-1/16 SAE, JIC)

13. 159-007 1 QUICK ADAPTER (1-1/16 SAE, JIC)

14. 159-029 2 QUICK BODY (1/2 X 3/4-SAE)

15. 159-030 2 QUICK ADAPTER (1/2 X 3/4-SAE)

16. 363-019 1 VALVE BRACKET

17. 151-024 1 CYLINDER (5.0" X 2.250" X 9.000")

151-025 1 CYLINDER (7.0" X 2.750" X 9.000")

18. 154-005 2 CONNECTOR (08S-08J)

19. 155-706 2 O-RING (908 D90)

154-274 2 CONNECTOR (08O-08O)

INCL REF NO.'S 1 THRU 16. SEE FOOTNOTE 1

USE 16"

SEE FOOTNOTE 2

P40

P80-ENDS WITH S/N CMWP80_90000223.

SEE FOOTNOTE 2

150-3036 1 P80 CYLINDER ASSEMBLY SEE FOOTNOTE 3; BEGINS WITH S/N CMWP80P90000225.

3 - 5X 106-012 (5/8-NC X 3") MOUNTING BOLTS REQ'D.

02 ID0127379

HYDRAULIC CONTROL VALVE

SINGLE SPOOL

13 15

NOTE:

FOOTNOTES:

REF

NO. PART

NUMBER QTY DESCRIPTION REMARKS

02 ID0127379

NOT SHOWN:

HYDRAULIC CONTROL VALVE

SINGLE SPOOL

155-621 HYDRAULIC CONTROL VALVE

500-186 1 RELIEF BALL

500-185 1 O-RING (110, D70)

3. 105-079 1 LOCK WASHER (1/4)

4. 105-226 1 WASHER (5/16)

5. 105-512 1 COTTER PIN (3/32 X 3/4")

6. 115-178 1 PLUG (06N, SQ FM HD)

7. 500-054 1 LEVER BRACKET

8. 500-055 2 LOCK WASHER (1/4")

9. 500-056 2 BOLT (1/4-NC X 5/8", SLOT HD)

10. 500-057 2 CUP SEAL

11. 500-058 1 CONTROL VALVE LEVER

12. 500-059 1 LEVER PIN

13. 500-060 4 BOLT

14. 500-061 1 DETENT BONNET

15. 501-179 1 SCREW (1/4 X 1/2)

16. 500-065 1 COMPRESSION SPRING

17. 500-066 1 SPOOL COLLER

18. 500-182 1 COMPRESSION SPRING

19. 500-184 1 RELIEF SEAT

20.

500-374 NEUTRAL RETURN CONVERSION KIT

INCL REF NO.'S 1 THRU 20. SEE FOOTNOTE 2

SEE FOOTNOTE 1

INCL REF NO.'S 3, 4 AND 13 THRU 17

1 - IF REPLACEMENT OF THESE PARTS IS NECESSARY, ORDER RETURN KIT (REF NO. 20) AND REFER

TO INSTALLATION DIAGRAM 050-088.

2 - REFER TO INSTALLATION DIAGRAM 052-141 FOR ADJUSTMENT OF PRESSURE RELIEF.

03 ID0242510

DRIVE ROD CYLINDER

P80

BEGINS WITH S/N CMWP80P90000225

810 14

NOTE:

FOOTNOTES:

REF

NO. PART

NUMBER QTY DESCRIPTION REMARKS

03 ID0242510

NOT SHOWN:

DRIVE ROD CYLINDER

P80

BEGINS WITH S/N CMWP80P90000225

USE LOCTITE 277 OR EQUIVALENT.

1. REPLACEMENT FOR 151-025. 5X 106-012 (5/8-NC X 3") MOUNTING BOLTS REQ'D.

259-136 PISTON RING COMPRESSOR

259-137 PISTON RING GUIDE

150-3060 - P80 CYLINDER ASSEMBLY INCLUDES REF #'S 1 THRU 18

1 150-413 1 ROD ASSEMBLY

2 150-3037 1 BARREL ASSEMBLY

3 150-3039 2 CYLINDER HEAD

4 149-305 1 PISTON

5 149-306 1 RETAINER RING

6 106-096 8 FLG BOLT (1/2-NC X 1-3/4",GD8)

7 125-766 2 WEAR RING

8 157-013 3 O-RING (438 D90)

9 157-529 1 BACKUP RING (438 D90)

10 157-531 2 U-SEAL SEAL

11 157-530 2 WIPER SEAL (2.750")

12 125-767 2 WEAR RING

13 157-015 1 O-RING (232 D70)

14 157-014 2 BACKUP RING (439 D90)

15 155-764 2 O-RING (240 D70)

16 150-3040 2 3-PIECE HEAD RETAINER

17 106-125 8 BOLT (5/16-NC X 1 1/4", SOC)

18 105-437 5 BOLT (5/8-NC X 2-1/2" GR. 5)

02 ID0125779

DRIVE ROD CYLINDER

P80

ENDS WITH S/N CMWP80_90000223

NOTE:

FOOTNOTES:

REF

NO. PART

NUMBER QTY DESCRIPTION REMARKS

02 ID0125779

NOT SHOWN:

DRIVE ROD CYLINDER

P80

ENDS WITH S/N CMWP80_90000223

1 - REFER TO INSTALLATION DIAGRAM 050-115.

SEE FOOTNOTES 2 & 3.

SEE FOOTNOTE 1

151-025 CYL (7.0" X 2.750" X 9.000")

1. 115-534 1 INTERNAL SNAP RING

106-096 8 FLG BOLT (1/2-NC X 1-3/4",GD8)

2. 150-281 1 CYLINDER BARREL

3. 150-413 1 CYLINDER ROD

4. 150-788 2 CYLINDER HEAD

5. 150-972 2 LOCK RING

6. 150-973 1 PISTON

149-305 1 PISTON

7. 150-974 1 RETAINER RING

149-306 1 RETAINER RING

8. 190-164 1 SEAL REPAIR KIT

259-136 PISTON RING COMPRESSOR

259-137 PISTON RING GUIDE

259-135 HEAD SPANNER

3 - SUPERSEDED BY 150-3036; BEGINS WITH S/N CMWP80P90000225.

2 - INCLUDES REFERENCE NUMBERS 1 THRU 8.

ID0134963

NOTES:

ID0135070

ELECTRICAL

01 ID0140488

GRID SYSTEM HARDWARE

ELECTRICAL STRIKE INDICATOR

PRESENT PRODUCTION

FROM GROUND CABLE

TO TRAILER

22 17

413

ON STROBE

FROM GROUND

TO MATS

TO GND

TO POWER

SOURCE

01 ID0140488

GRID SYSTEM HARDWARE

ELECTRICAL STRIKE INDICATOR

PRESENT PRODUCTION

231

36 38

NOTE:

REF

NO. PART

NUMBER QTY DESCRIPTION REMARKS

01 ID0140488

GRID SYSTEM HARDWARE

ELECTRICAL STRIKE INDICATOR

PRESENT PRODUCTION

FOOTNOTES:

1. REPLACEMENT BULB FOR STROBE LIGHT 217-041

2. REPLACEMENT BULB FOR STROBE LIGHT 217-310.

3. REPLACEMENT LENS FOR STROBE LIGHT 217-310

INCL REF NO.'S 1 THRU 32

W/T-HANDLE CLAMP

YELLOW

100-741 ELECTRICAL STRIKE INDICATOR

ADAPTION KIT

1. 106-217 21 BOLT (1/4-NC X 1", SIL BRZ)

2. 106-455 21 NUT (1/4-NC, SIL BRZ)

3. 106-462 1 BOLT (3/8-NC X 1-1/4", SIL BRZ)

4. 215-769 1 GROUND CLAMP

5. 215-771 11 GROUNDING RECEPTACLE

6. 215-775 1 GROUNDING ROD (72" LG)

7. 215-776 1 SLIDE DRIVER

106-053 WING BOLT

8. 215-777 2 GRID (20')

9. 215-790 4 GROUND CABLE (20')

10. 215-791 1 GROUND CABLE (50')

11. 215-793 1 GROUND CABLE (200')

12. 215-795 1 UMBILICAL CABLE (50')

13. 215-799 1 VOLTAGE STAKE (23.5")

14. 216-011 1 STRIKE INDICATOR BOX

15. 259-210 8 TRAFFIC CONE

16. 259-234 8 BARRIER TAPE CLIP

17. 354-168 2 STROBE LIGHT PARTS ASSEMBLY

217-270 1 BULB (12V DC)

217-311 1 BULB (12V DC)

121-055 1 LENS (AMBER)

18. 354-208 1 COIL BRACKET

19. 215-826 1 UMBILICAL CABLE (25')

20. 215-813 1 GROUND CABLE (25')

21. 215-824 2 GRID (6')

22. 215-825 1 POWER WIRE HARNESS

23. 216-012 1 GROUND VOLTAGE LIMITER

24. 183-658 12 MAT STAKE (15")

25. 354-216 2 GRID (3')

26. 106-454 1 NUT (3/8-NC, SIL BRZ)

27. 195-339 2 WING NUT (1/4-NC)

28. 215-828 1 GROUND CABLE (6', M TO M)

29. 215-827 2 GROUND CABLE (6', M TO EYE)

30. 106-221 21 LOCK WASHER (1/4", SIL BRZ)

31. 106-220 1 LOCK WASHER (3/8", SIL BRZ)

32. 260-223 1 BARRIER TAPE ROLL (3" X 1000')

33. 215-771 1 GROUND RECEPTACLE

34. 215-770 1 GROUND PLUG

35. 215-899 1 CABLE (6GA X 4' M-EYE)

36. 215-894 2 CABLE (6GA X 8.5" W/.375 EYE)

37. 106-220 3 WASHER (3/8", SIL BRZ)

38. 106-216 3 BOLT (3/8-NC X 1", SIL BRZ)

39. 105-069 2 WASHER (3/8")

40. 354-223 1 JAW CONNECTOR STRAP

41. 116-443 1 RUBBER WASHER

42. 184-187 2 BUSHING

FOOTNOTE 2

FOOTNOTE 1

FOOTNOTE 3

OBSOLETE

01 ID0153991

CURRENT TRANSFORMER

X 1

X 2

X 3

NOTE:

FOOTNOTES:

REF

NO. PART

NUMBER QTY DESCRIPTION REMARKS

01 ID0153991

NOT SHOWN:

CURRENT TRANSFORMER

354-238 CURRENT TRANSFORMER ASSEMBLY

1. 105-826 4 SCREW (3/8-NC X 1")

2. 362-790 1 BRACKET

3. 105-832 4 FLANGE LOCKNUT (1/4-NC)

4. 362-623 1 COIL COVER BACK

5. 216-023 1 CURRENT TRANSFORMER

6. 362-718 1 COIL COVER FRONT

7. 105-845 4 FLANGE LOCKNUT (3/8-NC)

8. 116-376 4 SPACER

9. 116-283 4 RUBBER WASHER

10. 106-176 1 CONDUIT LOCKNUT (1/2-NPT)

11. 215-853 1 CORD GRIP CONNECTOR

12. 105-297 4 BOLT (1/4-NC X 3-1/4")

13. 215-784 1 CABLE

14. 215-843 3 RING TERMINAL (#10)

1. D - GREEN OR BLUE (TEST), E - BLACK OR SHIELD (COMMON), F - WHITE OR BROWN

2. BRACKET IS USED FOR BOTH P40 AND P80, DIFFERENT MOUNTING

HOLES ARE USED FOR EACH ASSEMBLY.

INCL REF NO.'S 1-14

SEE FOOTNOTE 2

ID0134963

NOTES:

ACCESSORIES

04 ID0134699

P80 PILOT HEADS

NOTE:

FOOTNOTES:

REF

NO. PART

NUMBER QTY DESCRIPTION REMARKS

04 ID0134699

NOT SHOWN:

P80 PILOT HEADS

USE WITH 88B ONLY

1. USE EPOXY (250-023 OR EQUIVALENT) TO SEAL WINDOWS. (250-025 CAULKING GUN ADAPTER REQUIRED).

1. 400-901 AR P80 86B BEACON HOUSING ASSY

2. 105-548 AR ROLL PIN (1/2" X 2-1/4" LG)

3. 102-152 1 BEACON, 86B

4. 400-897 1 86 STANDARD PILOT HEAD

5. 400-898 1 86 AGGRESSIVE PILOT HEAD

6. 400-899 1 86 LESS AGGRESSIVE PILOT HEAD

7. 105-510 1 ROLL PIN (1/4" X 1-1/2")

250-023 AR EPOXY

SEE FOOTNOTE 1

INCL REF NO. 7

SEE FOOTNOTE 1

8. 400-902 1 SLEEVE ASSEMBLY

05 ID0088522

PUSH RODS

P80

NOTE:

FOOTNOTES:

REF

NO. PART

NUMBER QTY DESCRIPTION REMARKS

05 ID0088522

NOT SHOWN:

PUSH RODS

P80

1. 110-142 AR PLASTIC CAP (1-3/4")

2. 356-207 AR THD PROTECTION CAP (1.41" BOX)

3. 110-422 AR PLASTIC CAP (1-3/8" X 2-13/32")

4. 356-206 AR THD PROTECTION CAP (1.41" PIN)

5. 259-131 AR TORPEDO LEVEL

6. 354-146 AR 24" PUSH ROD

354-231 AR 24" PUSH ROD

7. 354-149 AR 48" PUSH ROD

8. 354-150 AR PUSH ROD ADAPTER

354-147 AR PUSH ROD ADAPTER

354-148 AR PUSH ROD ADAPTER

9. 354-033 AR PUSH ROD PILOT

354-157 AR PUSH ROD PILOT

10. 157-550 AR U-SEAL (1.75" ID)

1. API #V-0.040 MALE THREAD (P80) CAN BE IDENTIFIED BY LENGTH, SHOULDER TO END OF PIN = 1.375".

2. API #V-0.055 MALE THREAD (P80) CAN BE IDENTIFIED BY LENGTH, SHOULDER TO END OF PIN = 2.00".

3. API #V-0.040 FEMALE THREADS (P80) CAN BE IDENTIFIED BY THE I.D. AT THE FACE, I.D. = 1.532 DIA.

4. API #V-0.055 FEMALE THREADS (P80) CAN BE IDENTIFIED BY THE I.D. AT THE FACE, I.D. = 1.427".

354-232 AR 48" PUSH ROD

ID0134963

NOTES:

ID0135063

MISCELLANEOUS

SAE Bolt and Nut Torque Value Chart

Grade 5: UNC or UNF Thread

Grade 8: UNC or UNF Thread

*drilled and tapped

Size Hex nut, or bolt tapped into hex

nut, or d&t hole Hex top deformed locknut Flange nut, locknut, or bolt tapped

into flange nut or d&t* hole

ft•lb N•m ft•lb N•m ft•lb N•m

1/4 12 16 8 11 20 27

5/16 25 34 15 20 45 60

3/84054253475100

7/16 65 90 40 55 125 170

1/2 100 135 60 80 190 260

9/16 150 200 90 125 270 370

5/8 200 270 120 165 370 500

3/4 350 475 210 285 650 880

7/8 560 760 340 460 1250 1425

1 840 1140 500 680 1580 2145

1-1/8 1030 1400 320 840 1950 3645

1-1/4 1460 1980 880 1195 2760 3475

Size Hex nut, or bolt tapped into hex

nut, or d&t hole Hex top deformed locknut Flange nut, locknut, or bolt tapped

into flange nut or d&t* hole

ft•lb N•m ft•lb N•m ft•lb N•m

1/4141910142433

5/16 30 40 18 25 50 70

3/85573355090125

7/16 85 115 50 70 140 190

1/2 130 175 80 110 220 300

9/16 190 260 110 150 310 420

5/8 260 355 160 245 430 585

3/4 450 610 270 365 750 1015

7/8 730 990 440 600 1210 1640

1 1090 1480 650 880 1320 2465

1-1/8 1550 2100 930 1260 2580 3500

1-1/4 2180 2955 1310 1780 3640 4935

VS02 ID0053384

Metric Bolt and Cap Screw Torque Values

Do not use these values if a different torque value or tightening procedure is given for specific application.

Torque values listed are for general use only. Check tightness of fasteners periodically.

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical

property class fasteners.

Fasteners should be replaced with the same or higher property class. If higher property class fasteners are

used, these should only be tightened to strength of original.

Make sure fastener threads are clean and that the threads are properly started. This will prevent them from

cross threading or galling when tightened.

Tighten plastic insert or crimped type steel locknuts to approximately 50% of dry torque indicated on chart.

Apply torque to the nut - not the bolt head. Tighten toothed or serrated type locknuts to full torque value.

LUBRICATED means coated with lubricant. DRY means plain or zinc plated without any type of lubricant.

Size Class 4.8 Class 8.8 and 9.8 Class 10.9 Class 12.9

Lubricated Dry Lubricated Dry Lubricated Dry Lubricated Dry

N•m ft•lb N•m ft•lb N•m ft•lb N•m ft•lb N•m ft•lb N•m ft•lb N•m ft•lb N•m ft•lb

M6 4.8 3.5 6 4.5 9 6.5 11 8.5 13 9.5 17 12 15 11.5 19 14.5

M8 128.51511221628203224403037284735

M10 23172921433255406347806075559570

M12 40 29 50 37 75 55 95 70 110 80 140 105 130 95 165 120

M14 63 47 80 60 120 88 150 110 175 130 225 165 205 150 260 190

M16 100 73 125 92 190 140 240 175 275 200 350 225 320 240 400 300

M18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410

M20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580

M22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800

M24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000

M27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1500

M30 675 490 850 625 1600 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000

M33 900 675 1150 850 1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750

M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500

Hydraulic Cylinder Bolt Torque Chart

As a general rule:

• 1/2-inch bolts are used in cylinders with 1-inch rods

• 5/8-inch bolts are used in cylinders with 1 1/4-inch rods

• 3/4-inch bolts are used in cylinders with 1 1/2-inch rods

• 7/8-inch bolts are used in cylinders with 1 3/4-inch rods

• 1-inch bolts are used in cylinders with 2-inch rods (one with 1 3/4-inch)

• 1-1/8-inch bolts are used in cylinders with 2-1/4-inch rods

IMPORTANT: Do not reuse cylinder piston bolts when rebuilding a hydraulic cylinder. Each cylinder repair

kit contains a new bolt. Use it. Lubricate lightly and torque to value shown on chart.

Bolt Size

(inch) Bolt

Part No. Cylinder Repair Kit

Part No. Torque (ft•lb) Torque (N•m)

1/2 106-096 190-165 90-100 120-135

5/8 106-097 190-166 & 190-169 180-200 245-270

3/4 106-098 190-167 & 190-170 290-325 395-440

7/8 106-122 190-172 & 190-174 410-640 550-625

1 106-145 190-175 & 190-189 630-700 855-950

1-1/8 106-146 190-177 770-850 1045-1170

VS02 ID0053384

SAE & ORS Hydraulic Fitting Replacement O-Ring

Chart

Thread size indicates the diameter of the threaded area in fractions of an inch and number of threads per

inch.

NA = not a current CMW part numbered o-ring, or dash size does not occur in current CMW applications

SAE = straight thread fitting that seals by sandwiching a hard o-ring between a shoulder on the male part

and an angular surface at the mouth of the female port.

ORS = o-ring face seal; a type of fitting that seals by compressing a hard, captive o-ring between two flat

parallel faces, one grooved for the o-ring and the other plain to act as the sealing surface

Fraction

Size Dash

Size SAE

(Port Seal O-Ring) ORS

(Face Seal O-Ring)

Thread Size O-Ring P/N Thread Size O-Ring P/N

1/16 1 NA NA NA NA

1/8 2 5/16 - 24 NA NA NA

3/16 3 3/8 - 24 NA NA NA

1/4 4 7/16 - 20 155-760 9/16 - 18 157-037

5/16 5 1/2 - 20 NA NA NA

3/8 6 9/16 - 18 155-705 11/16 - 16 157-038

1/2 8 3/4 -16 155-706 13/16 - 16 157-039

5/8 10 7/8 - 14 155-707 1 - 14 157-040

3/4 12 1-1/16 - 12 155-709 1-3/16 - 12 157-017

7/8 14 1-3/16 - 12 155-747 NA NA

1 16 1-5/16 - 12 155-748 1-7/16 - 12 155-714

1-1/4 20 1-5/8 - 12 155-702 1-11/16 - 12 NA

1-1/2 24 1-7/8 - 12 157-001 2 -12 NA

2 32 2-1/2 - 12 NA NA NA

2-1/2 40 3 - 12 NA NA NA

3 48 3-1/2 - 12 NA NA NA

P40/P80

VER.02 ID0134857

Related Publications

Component Ass’y P/N

Model:

P40/P80 ............. Parts Manual ......................................................... ............ 050-684

P40/P80 .............. Operators Manual .................................................. ............ 054-451

P40/P80 .............. Supplementary Maint. Guide .................................. ............ 050-633

P40/P80 .............. Power Pac Parts Manual ........................................ ............ 050-582

P40/P80 .............. Power Pac Operator’s Manual ............................... ............ 054-416

Optional Kits

O-ring Repair Kit - FLG, ORS & SAE (15 different O-rings) ............................................. 190-051

O-ring Repair Kit - Field Service (46 different O-rings) .................................................... 190-052

100

ID0135001

Parts Manual Change Request

(Please print clearly)

Date: _______________________ Dealer No. (required): _____________________________

Your Name: _____________________________ Position: _____________________________

Phone: _________________ Fax: _________________ E-mail: __________________

Publication Information:

Parts Manual No.: _____-_____ Model: __________

Illustration Part No.: Manual Page No.:

1. _____-_____ .......................................................... 1. __________

2. _____-_____ .......................................................... 2. __________

3. _____-_____ .......................................................... 3. __________

Nature of Change Request:

 Text  Graphics  Missing Information

Describe change requested (if possible, include copy of publication page with changes marked.):

________________________________________________________________________________

Please fax completed form to

Parts Manual Department (580) 572-3525

Thank you for taking the time to submit this request. We will contact you if further information is

needed to process your request.

101

102

ID0040564

103

ID0135281

104

N/A Ditch Witch Welder PR95 P80 Parts Manual 050 684

Navigation menu

Versions of this User Manual:

Views

Navigation