Hammerhead 100XTR, Operator'S Manual

Page 1: ...TECHNICAL PUBLICATIONS Operator s Manual 100XTR CMW Issue 2 1 960 1015 Original Instruction...

Page 2: ...4 Bursting Unit Components 5 Receiver Antenna 6 Regulatory Notices 7 United States 7 Canada 7 EU Declaration of Conformity 7 RF Exposure Statement 8 Operator Orientation 9 Operating Area 9 About This...

Page 3: ...100XTR Operator s Manual Serial Number Location 2 Overview Serial Number Location Record serial numbers and date of purchase in spaces provided Date of manufacture Date of purchase j51om001w21 eps...

Page 4: ...other way is considered contrary to the intended use HammerHead pipe bursters and power units should be operated serviced and repaired only by persons familiar with their particular characteristics a...

Page 5: ...100XTR Operator s Manual Unit Components 4 Overview Unit Components 1 Wireless remote controller 2 Rod box 3 Extraction cage 4 Bursting unit j51om013w21 eps...

Page 6: ...100XTR Operator s Manual Unit Components Overview 5 Bursting Unit Components 1 Bungee 2 Push Pull carriage 3 Push Pull clamp 4 Spinner j51om002w21 eps 1 2 3 4...

Page 7: ...TR Operator s Manual Unit Components 6 Overview Receiver Antenna IMPORTANT Receiver antenna can stop working if damaged If receiver antenna is damaged replace with CMW approved components j51om018w21...

Page 8: ...dance with the instructions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does ca...

Page 9: ...omply with RF exposure requirements during normal operation this device must be held in front of the body horizontally The antenna must be vertical in line with the body with at least 4 100mm separati...

Page 10: ...ront of unit 2 Right side of unit 3 Rear of unit 4 Left side of unit Operating Area Operator and or pipe loader should stand only in the locations marked by number 1 IMPORTANT Top view of unit is show...

Page 11: ...ew 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 procedur...

Page 12: ...t copy contact your HammerHead dealer If you need assistance in locating a dealer visit our website at www hammerheadtrenchless com or write to the following address HammerHead Trenchless Equipment 50...

Page 13: ...1 Issue Date 03 22 Part number 960 1015 Copyright 2021 2022 by The Charles Machine Works Inc HammerHead and HydroBurst are registered trademarks of The Charles Machine Works Inc This product and its u...

Page 14: ...pecting and classifying the jobsite planning the installation and preparing the jobsite for work 37 Transport procedures for lifting and hauling 49 Burst Pipe procedures for setting up equipment and p...

Page 15: ...rator s Manual 14 Contents Support the warranty policy for this machine and procedures for obtaining warranty consideration and training 99 Service Record a record of major service performed on the ma...

Page 16: ...rt Classification 16 Guidelines 17 Grounding Instructions 19 Emergency Procedures 20 Electric Strike Description 20 If an Electric Line is Damaged 20 If a Gas Line is Damaged 21 If a Fiber Optic Cable...

Page 17: ...els DANGER WARNING and CAUTION Learn what each level means indicates a hazardous situation that if not avoided will result in death or serious injury This signal word is to be limited to the most extr...

Page 18: ...ergency procedures and individual responsibilities with all personnel before work begins Safety Data Sheets SDS are available at www hammerheadshop com resources technical sheets Fully inspect equipme...

Page 19: ...se the risk of electric shock Store machine out of the reach of children Do not allow persons unfamiliar with machine to operate Do not let familiarity gained from frequent use of machine to allow you...

Page 20: ...properly installed and grounded in accordance with all local codes and ordinances Electric shock Improper connection of equipment grounding conductor will cause death or serious injury Contact qualif...

Page 21: ...electric strikes are not noticeable but indications of a strike include power outage smoke explosion popping noises arcing electricity If any of the occur assume an electric strike has occurred If an...

Page 22: ...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...

Page 23: ...Operator s Manual Emergency Procedures 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 emer...

Page 24: ...int See Transport chapter for more information 2 Tiedown location See Transport chapter for more information 3 Moving parts could crush hand Stay away 4 Misuse of machine can cause death or serious in...

Page 25: ...lasses and hard hat 7 Crushing weight could kill or seriously injure Stay away 8 Crushing weight could cause death or serious injury Stay away 9 Moving tools will kill or injure Never use pipe wrenche...

Page 26: ...100XTR Operator s Manual Controls 25 Controls Chapter Contents Bursting Unit 26 Manual Controls 26 Stabilizer Controls 28 Miscellaneous Controls 30 Wireless Remote Controller 32...

Page 27: ...rols IMPORTANT Manual controls are used as a backup in the event the remote becomes inoperable See Setup and Configuration on page 56 1 Bungee clamp control 2 Spinner clamp control 3 Spinner control 4...

Page 28: ...spinner clamp press down 3 Spinner control To rotate spinner clockwise makeup pull up To rotate spinner counterclockwise breakout push down 4 Clamp control To open clamp pull up To close clamp push do...

Page 29: ...r Controls NOTICE Raising one side of bursting unit too much can cause the unit to tip over 1 Left stabilizer control 2 Right stabilizer control 3 Rear stabilizer control Item Description Notes 1 Left...

Page 30: ...TR Operator s Manual Bursting Unit Controls 29 2 Right stabilizer control To raise pull back To lower push forward 3 Rear stabilizer control To raise pull back To lower push forward Item Description N...

Page 31: ...100XTR Operator s Manual Bursting Unit 30 Controls Miscellaneous Controls Item Description Notes Auxiliary outlet Provides power for other equipment Power output is fused to 15A j51om006w21 eps...

Page 32: ...ual Bursting Unit Controls 31 Miscellaneous Controls Item Description Notes Remote engine stop switch To stop engine press Engine will not start until control is returned to neutral position j51om017w...

Page 33: ...t Pullback mode switch 6 Stop button 7 Communication link indicator 8 Power status indicator 9 Power Horn Start Set 10 Push Pullback control joystick extend retract clamp switch 11 Pullback force swit...

Page 34: ...ogic output move joystick up To activate CCW logic output move joystick down In manual override mode To close bungee clamp move joystick right To open bungee clamp move joystick left Joystick Switch o...

Page 35: ...ommunication link Flashing green indicates good communication link Steady red indicates an internal problem Contact your Ditch Witch dealer 8 Power status indicator Indicates battery status and cable...

Page 36: ...tch down In limit setting mode To increase decrease setting move switch up down respectively In auto or manual mode Start job set to 50 tons and adjust to 100 tons as needed Pullback force switch oper...

Page 37: ...Unit will automaticallypower off after 300 seconds since the last switch input or joystick movement is detected and the accelerometer input is changed Auto backlight off If transmitter LCD is on and...

Page 38: ...l 38 Plan for Emergency Services 38 Inspect Site 39 Identify Hazards 39 Select Installation and Bursting Pit Locations 40 Classify Jobsite 41 Select a Classification 41 Apply Precautions 42 Plan Pull...

Page 39: ...US or Canada call 811 US or 888 258 0808 US and Canada Also contact any local utilities that do not participate in the One Call service In countries that do not have a One Call service contact all loc...

Page 40: ...round traffic access soil type and condition depths of existing pipes Have an experienced locating equipment operator sweep area within 20 6 m to each side of burst path to verify previously marked li...

Page 41: ...enough space for installation and bursting pits Check that installation area has enough space for product to be installed Check that there is enough space to work Access Consider shade wind fumes and...

Page 42: ...subscribe to One Call Comply with all utility notification regulations before digging or bursting Verify location of previously marked underground hazards Mark jobsite clearly and keep spectators awa...

Page 43: ...xcavation Have service shut down while work is in progress Have electric company test lines before returning them to service Natural Gas Jobsite Precautions Position equipment upwind from gas lines an...

Page 44: ...ose knowledgeable about hazards present at each site to determine which precautions should be taken or if job should be attempted Plan Pull Path Plan the pull path from entry to end before job begins...

Page 45: ...Use and maintain proper safety equipment To help avoid injury If jobsite classification is in question or the possibility of unmarked electric utilities exists classify jobsite as electric Cutting hi...

Page 46: ...ig Bursting Pit Dimensions Minimum Bursting Pit Length A Width B Depth C U S metric U S metric U S metric 110 2 8 m 48 1 2 m 18 0 5 m Add 73 5 1 9 m of length of bursting pit if using the extraction c...

Page 47: ...pit wall must be square 90 with pit floor Place steel road plate underneath bursting unit NOTICE Loose soil may need to be shored to support force of burst NOTICE Follow U S Department of Labor regul...

Page 48: ...pare Equipment Condition and Function all controls clean couplers hoses and valves inspect clean jaws inspect lube bowls Assemble Accessories Fire Extinguisher If required mount a fire extinguisher ne...

Page 49: ...100XTR Operator s Manual Check Supplies and Prepare Equipment 48 Prepare...

Page 50: ...100XTR Operator s Manual Transport 49 Transport Chapter Contents Lift 50 Points 50 Procedure 50 Tie Down 52 Points 52 Procedure 52...

Page 51: ...amage machinery Procedure Bursting Unit Use equipment capable of supporting the unit s size and weight See Specifications on page 83 or measure and weigh equipment before lifting Use supplied lift cha...

Page 52: ...ift Transport 51 Extraction Cage Use equipment capable of supporting the extraction cage s size and weight See Extraction Cage on page 96 Rod Box Use equipment capable of supporting the rod box s size...

Page 53: ...to trailer at other points can damage machinery Procedure Bursting Unit To tie down bursting unit use D rings shown Extraction Cage Use chain or strap to tie down and secure extraction cage Use D rin...

Page 54: ...100XTR Operator s Manual Tie Down Transport 53 Rod Box To tie down rod box use D rings shown j51om035w eps...

Page 55: ...100XTR Operator s Manual Tie Down 54 Transport...

Page 56: ...ipe 57 Burst Pipe Chapter Contents Setup and Configuration 58 Emergency Stop Procedure 61 Open Close Bungee 61 Close Bungee 61 Open Bungee 62 Push Rods 63 Connect Tooling String to Pilot Rod 65 Pull B...

Page 57: ...ng and trenching Part 1926 Subpart P and other similar regulations Entering a confined space without following all required procedures and having an effective emergency rescue plan can result in serio...

Page 58: ...traction cage is used place against pit wall Allow space for pipe pipe loader behind pulling unit 7 Use stabilizers to ensure front panel is square 90 with pit floor or end of the extraction cage See...

Page 59: ...Place rod box behind person loading rods in the safe zone See Operating Area on page 9 14 Remove end plate from rod box 15 Keep rod joint lube available for lubricating female rod threads as needed P...

Page 60: ...Open Close Bungee Bungee operates automatically based on the mode set on wireless remote controller In pullback mode bungee prevents forward rod movement In payout mode the bungee is open and free to...

Page 61: ...erator s Manual Open Close Bungee 62 Burst Pipe Open Bungee In manual mode when bungee clamp is open rod will move freely in either direction Use wireless remote controller to open bungee clamp j51om0...

Page 62: ...bursting unit Make sure all personnel are clear of moving parts Keep personnel at the proper operating area See Operating Area on page 6 Bursting unit may raise off pit floor under load Keep hands and...

Page 63: ...ockwise 13 Move carriage to front of unit 14 Open clamp 15 Move carriage to back of unit 16 Close clamp 17 Move carriage to back of unit 18 Open clamp 19 Move carriage to back of unit until joint is v...

Page 64: ...er safety instructions before use To help avoid injury Maintain 2 way communication between bursting pit and all other personnel Make sure all personnel are clear of moving parts Do not attempt to use...

Page 65: ...or product entering exiting pipe or bursting unit Turning shaft will kill you or crush arm or leg Stay away To help avoid injury Do not hold rod while turning Burrs and slight imperfections on rods c...

Page 66: ...wn 7 Close clamp 8 Move carriage back until rod lines up with end of skis shown 9 To disconnect rods rotate spinner control counterclockwise 10 Remove rod 11 Open clamp 12 Move carriage to front of ma...

Page 67: ...between bursting pit and all other personnel Ensure operator has good visibility of rods entering exiting bursting unit Make sure all personnel are clear of moving parts Keep personnel at the proper...

Page 68: ...raction cage between bursting unit and existing pipe and pit wall 5 Put bursting unit in pull mode and pull bursting splitting system into extraction cage 6 Remove extraction cage 7 Disconnect and rem...

Page 69: ...100XTR Operator s Manual Pull New Product 70 Burst Pipe...

Page 70: ...leshooting 71 Troubleshooting Chapter Contents Display Does Not Turn On 72 No Connection to Down Hole Unit 73 Tooling Stuck in Pipe Ground 74 Push Pull Clamp Stuck Closed 74 Bungee Clamp Stuck Closed...

Page 71: ...72 Troubleshooting Display Does Not Turn On 1 Check battery levels in wireless remote control 2 Change batteries if needed 3 If replacement batteries are not available connect battery back up cable t...

Page 72: ...e communication If wireless remote control still does not work contact your dealer If battery and communication link indicators both display red for several seconds and then the wireless remote contro...

Page 73: ...ylinders 5 If clamp releases follow push pull clamp slip greasing procedure 6 If clamp remains closed contact factory for further assistance Bungee Clamp Stuck Closed 1 Switch wireless remote control...

Page 74: ...100XTR Operator s Manual Systems and Equipment 75 Systems and Equipment Chapter Contents Tooling String 76 Bursting String 76 Slitter String 76 Bursting Splitting Heads 77 Extraction Cage 77...

Page 75: ...String Slitter String Ref Description 1 pipe pilot 2 flex joint 3 expander 4 expander rod assembly 5 pipe puller Ref Description 1 flex joint 2 slitter assembly 3 trailing pivot rod assembly 4 expande...

Page 76: ...n and Uses Extraction Cage The extraction cage allows room to remove the bursting splitting assembly from the new product after it enters the bursting pit Ref Type Uses 1 slitter ductile iron steel ca...

Page 77: ...100XTR Operator s Manual Extraction Cage 78 Systems and Equipment...

Page 78: ...100XTR Operator s Manual Complete the Job 79 Complete the Job Chapter Contents Disconnect Hoses 80 Stow Components 81 Restore Jobsite 81 Stow Tools 81 Store Machine 81 Decommission Machine 81...

Page 79: ...nit Pressurized fluid or air could pierce skin and cause severe injury Refer to operator s manual for proper use To help avoid injury Always connect return line first and remove last Before using syst...

Page 80: ...d on trailer Store Machine To store ensure equipment is stowed machine is properly rinsed and all fluids are at appropriate levels For more information on filling fluids see Maintenance chapter Decomm...

Page 81: ...100XTR Operator s Manual Decommission Machine 82 Complete the Job...

Page 82: ...100XTR Operator s Manual Service 81 Service Chapter Contents Service Precautions 82 Remove Install Front Panel 82 Recommended Lubricants Service Key 83 Each Use 84 50 Hour 86 200 Hour 88 As Needed 89...

Page 83: ...2 to set in place 3 Remove lifting chain Misuse of machine can cause death or serious injury Read and understand operator s manual and all other safety instructions before use 273 475 To help avoid in...

Page 84: ...ditions service machine more frequently Use only recommended lubricants Item Description EPRG Extreme Pressure Grease high temperature red D4950 07 LB GC RJL Rod Joint Grease Antiseize MIL A 907E Chec...

Page 85: ...more than 1 8 3 2 mm on hollow sections cracked Clean Jaw Clean spinner carriage and bungee jaw with high pressure water after each job Brush jaws with wire brush to remove debris Tasks Notes Inspect...

Page 86: ...100XTR Operator s Manual Each Use Service 85 Clean Rod Wiper Clean rod wiper with high pressure water after each use IMPORTANT Replace rod wiper if damaged or worn j51om004w19 eps...

Page 87: ...an hands to search for leaks Wear protective clothing including gloves and eye protection Before disconnecting a hydraulic line turn engine off and operate all controls to relieve pressure Lower block...

Page 88: ...100XTR Operator s Manual 50 Hour Service 87 Change Hydraulic Pressure Filter initial Change hydraulic pressure filter after 50 hours initially and every 200 hours thereafter j51om001w eps...

Page 89: ...100XTR Operator s Manual 200 Hour 88 Service 200 Hour Change Hydraulic Pressure Filter Change hydraulic pressure filter every 200 hours Task Notes Change hydraulic pressure filter j51om001w eps...

Page 90: ...w insert 3 5 Install replacement jaw insert 6 Reinstall pin 7 Reinstall rod wiper and rod guide 8 Lower front of machine down into place See Remove Install Front Panel on page 82 Task Notes Replace ja...

Page 91: ...7 Reinstall snap ring and rod guide Replace Rod Catcher 1 Remove bolts holding plastic guides in place 2 Remove worn guides 3 Reinstall new guides using existing hardware Replace Rod Wiper 1 Lift off...

Page 92: ...e 91 Lube Rod Pipe Threads Lube with RJL antiseize lubricant as needed NOTICE Apply lubricant to female threads only If rod pipe threads are damaged replace immediately Ensure rods pipes are free from...

Page 93: ...move front plate 2 Remove rod wiper 3 Remove rod guide 4 Apply five pumps of EPRG to each grease zerk shown on each slip Carriage Vise 1 Move carriage to rear of machine 2 Remove snap ring and rod gui...

Page 94: ...vetail ramp 4 spinning slip bowl 5 spinner jaw 6 4 Apply a light layer of RJL to dovetail ramp 4 spinning slip bowl 5 surfaces that make contact with spinner jaw 6 bottom of spinner jaw 6 5 Reinstall...

Page 95: ...100XTR Operator s Manual As Needed 94 Service...

Page 96: ...457 mm Weight mass 3200 lb 1452 kg Operational U S Metric Push force 10 ton 9 1 tonne Pullback force 100 ton 91 tonne Working pressure 4450 4550 psi 307 314 bar Working flow rate 41 43 gpm 155 163 L m...

Page 97: ...100XTR Operator s Manual Extraction Cage 96 Specifications Extraction Cage Dimensions U S Metric L length 73 5 in 1 9 m W width 34 in 864 mm H height 34 in 864 mm Weight mass 1045 lb 474 kg...

Page 98: ...o 70 C Storage temperature 40 to 185 F 40 to 85 C IP rating IP65 Electrical Internal supply Primary 9VDC 6 AA Alkaline batteries External supply 9 30VDC via backup harness Current consumption 500 mA W...

Page 99: ...XX Type machine type Engine Power xxx kW Serial Number model XXXXX Conforms to the requirements of 2006 42 EC Machinery Directive 2004 108 EC Electromagnetic Compatibility Directive 2000 14 EC Noise E...

Page 100: ...chase Return damaged parts to dealer for inspection and warranty consideration if in warranty time frame Order genuine HammerHead replacement or repair parts from your authorized HammerHead dealer Use...

Page 101: ...Mills Wisconsin No part shall be returned without prior written authorization from ETC and this warranty does not obligate ETC to bear any transpiration charges in connection with the repair or repla...

Page 102: ...100XTR Operator s Manual Service Record 101 Service Record Service Performed Date Hours...

Page 103: ...100XTR Operator s Manual 102 Service Record Service Performed Date Hours...