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Hammerhead HG2200AT Operator's Manual

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T E C H N I C A L P U B L I C AT I O N S
Operator's
Manual
HG2200/HG2200AT
Issue 2.1
960-1119
Original Instruction

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Table of Contents
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Summary of Contents for Hammerhead HG2200AT

  • Page 1 T E C H N I C A L P U B L I C AT I O N S Operator's Manual HG2200/HG2200AT Issue 2.1 960-1119 Original Instruction...

  • Page 2: Table Of Contents

    HG2200/HG2200AT Operator’s Manual Overview Chapter Contents Serial Number Location ..... . 2 Intended Use ....... 3 Equipment Modification .

  • Page 3: Serial Number Location

    HG2200/HG2200AT Operator’s Manual Serial Number Location Serial Number Location Record serial numbers and date of purchase in spaces provided. j64om002w.eps date of manufacture date of purchase winch unit serial number (1) engine serial number (2) 2 - Overview...

  • Page 4: Intended Use

    Use in any 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 and acquainted with the relevant safety procedures.

  • Page 5: Unit Components

    HG2200/HG2200AT Operator’s Manual Unit Components Unit Components Tracked Unit j64om003w.eps 1. Winch 5. Wireless remote control lights 2. Mast 6. Stabilizer 3. Tracks 7. Downhole unit 4. ESID strobe* *Optional 4 - Overview...

  • Page 6: Wheeled Unit

    HG2200/HG2200AT Operator’s Manual Unit Components Wheeled Unit j64om004w.eps 1. Winch 5. Wireless remote control lights 2. Mast 6. Stabilizer 3. Tires 7. Downhole unit 4. ESID strobe* 8. Hitch *Optional Overview - 5...

  • Page 7: Operator Orientation

    HG2200/HG2200AT Operator’s Manual Operator Orientation Operator Orientation Tracked IMPORTANT: Top view of unit is shown. 1. Front of unit 2. Right side of unit 3. Rear of unit 4. Left side of unit j64om001w.eps Wheeled Unit IMPORTANT: Top view of unit is shown.

  • Page 8: Operating Area

    HG2200/HG2200AT Operator’s Manual Operating Area Operating Area Winch IMPORTANT: Top view of unit is shown. Operator should stand only in the location marked by number 1. j64om006w.eps Tracks IMPORTANT: Top view of unit is shown. Operator should stand only in the location marked by number 1.

  • Page 9: About This Manual

    HG2200/HG2200AT Operator’s Manual About This Manual 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.

  • Page 10: Foreword

    If you sell your equipment, be sure to give this manual to the new owner. If you need a replacement 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 500 South C.P.
  • Page 11 HG2200/HG2200AT Operator’s Manual HG2200/HG2200AT Operator’s Manual Issue number 2.1/OM/09/11 Part number 960-1119 Copyright 2017, 2018, 2019 by Earth Tool Company LLC ® ® ® HammerHead , and HydroBurst are registered trademarks of Earth Tool Company LLC. This product and its use may be covered by one or more patents at http://patents.charlesmachine.works.
  • Page 12 HG2200/HG2200AT Operator’s Manual Contents Overview machine serial number, information about the type of work this machine is designed to perform, basic machine components, and how to use this manual Foreword part number, revision level, and publication date of this manual, and factory contact...

  • Page 13: Contents

    HG2200/HG2200AT Operator’s Manual Support the warranty policy for this machine, and procedures for obtaining warranty consideration and training Service Record a record of major service performed on the machine Appendix ® additional information about HammerHead equipment 12 - Contents...

  • Page 14: Safety

    HG2200/HG2200AT Operator’s Manual Safety Chapter Contents Guidelines ....... . 14 California Proposition 65 Warning .

  • Page 15: Guidelines

    • Only operate equipment in well-ventilated areas. Contact your HammerHead dealer if you have any question about operation, maintenance, or equipment California Proposition 65 Warning This product may contain chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

  • Page 16: Emergency Procedures

    HG2200/HG2200AT Operator’s Manual Emergency Procedures Emergency Procedures Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. Before operating any equipment, review emergency procedures and check that all safety precautions have been taken.

  • Page 17: If An Electric Line Is Damaged

    HG2200/HG2200AT Operator’s Manual Emergency Procedures If an Electric Line Is Damaged If you suspect an electric line has been damaged and you are in pit, DO NOT MOVE and DO NOT TOUCH ANYTHING. Remain in pit and take the following actions. The order and degree of action will depend upon the situation.

  • Page 18: If A Gas Line Is Damaged

    HG2200/HG2200AT Operator’s Manual Emergency Procedures If a Gas Line is Damaged Fire or explosion possible. Fumes could ignite and cause burns. No smoking, no flame, no spark. Explosion possible. Serious injury or equipment damage could occur. Follow directions carefully. If you suspect a gas line has been damaged, take the following actions. The order and degree of action will depend on the situation.

  • Page 19: If A Fiber Optic Cable Is Damaged

    HG2200/HG2200AT Operator’s Manual Do not look into cut ends of fiber optic or unidentified cable. Vision damage can If a Fiber Optic Cable is Damaged Do not look into cut ends of fiber optic or unidentified cable. Vision damage can occur. Contact utility California Proposition 65 Warning company.
  • Page 20 HG2200/HG2200AT Operator’s Manual Emergency Procedures • power outage • smoke • explosion • popping noises • arcing electricity If any of these occur, assume an electric strike has occurred. Safety - 19...
  • Page 21 HG2200/HG2200AT Operator’s Manual Emergency Procedures If an Electric Line Is Damaged If you suspect an electric line has been damaged and you are in pit, DO NOT MOVE and DO NOT TOUCH ANYTHING. Remain in pit and take the following actions. The order and degree of action will depend upon the situation.
  • Page 22 HG2200/HG2200AT Operator’s Manual Emergency Procedures If a Gas Line is Damaged Fire or explosion possible. Fumes could ignite and cause burns. No smoking, no flame, no spark. Explosion possible. Serious injury or equipment damage could occur. Follow directions carefully. If you suspect a gas line has been damaged, take the following actions. The order and degree of action will depend on the situation.

  • Page 23: If Machine Catches On Fire

    HG2200/HG2200AT Operator’s Manual Emergency Procedures If a Fiber Optic Cable is Damaged Do not look into cut ends of fiber optic or unidentified cable. Vision damage can occur. Contact utility company. 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.

  • Page 24: Safety Alert Classifications

    HG2200/HG2200AT Operator’s Manual Safety Alert Classifications Safety Alert Classifications These classifications and the icons defined on the following pages work together to alert you to situations which could be harmful to you, jobsite bystanders or your equipment. When you see these words and icons in the book or on the machine, carefully read and follow all instructions.

  • Page 25: Machine Safety Alerts

    HG2200/HG2200AT Operator’s Manual Machine Safety Alerts Machine Safety Alerts Moving parts can crush and cut hand or foot. Stay away. Lift point. See Transport chapter for more information. Crushing weight could cause death or serious injury. Stay away. 24 - Safety...
  • Page 26 HG2200/HG2200AT Operator’s Manual Machine Safety Alerts Tiedown location. See Transport chapter for more information. Crush hazard. Machine can move during operation. Lower stabilizers and chock wheels or tracks before operating winch. Hot parts may cause burns. Do not touch until cool or wear gloves.
  • Page 27 HG2200/HG2200AT Operator’s Manual Machine Safety Alerts Equipment can be operated by remote control. Stay away. Fire or explosion possible. Do not use starter fluid. Exposure to high noise levels may cause hearing loss. Wear hearing protection. 26 - Safety...

  • Page 28: Controls

    HG2200/HG2200AT Operator’s Manual Controls Chapter Contents Winch Controls ......28 Wireless Remote Controller ....34 •...

  • Page 29: Winch Controls

    HG2200/HG2200AT Operator’s Manual Winch Controls Winch Controls j64om008w.eps 1. Manual throttle 10. Wireless remote controller enable switch 2. Electronic throttle switch 11. Stabilizer control switch* 3. Hydraulic fluid warm-up switch 12. Mode selection switch 4. Capstan speed control switch 13. Mast control 5.
  • Page 30 HG2200/HG2200AT Operator’s Manual Winch Controls Item Description Notes 1. Manual throttle IMPORTANT: Pushing throttle To decrease engine speed, press center button and push adjustment control all the way in does knob in. not stop the engine. To increase engine speed, press center button and pull knob out.
  • Page 31 HG2200/HG2200AT Operator’s Manual Winch Controls Item Description Notes 4. Capstan speed control IMPORTANT: To achieve maximum To select high for capstan switch drive motor, move up. pull force switch must be in the low speed. To select low for capstan drive motor, move down.
  • Page 32 HG2200/HG2200AT Operator’s Manual Winch Controls Item Description Notes 9. Auxiliary light switch To turn lights on, move up. Controls lights on unit. To turn lights off, move down. c00ic245w.eps 10. Wireless remote To enable wireless remote Enabling wireless remote controller controller enable switch controller, press top.
  • Page 33 HG2200/HG2200AT Operator’s Manual Winch Controls Item Description Notes 13. Mast control To raise mast, move up and hold. To lower mast, move down and hold. To rotate mast clockwise, move to the right and hold. c00ic247w.eps To rotate mast counterclockwise, move to the left and hold.
  • Page 34 HG2200/HG2200AT Operator’s Manual Winch Controls Item Description Notes 17. Cable speed control IMPORTANT: There is a minimum To increase speed while pulling cable in, turn knob to setting that needs to be achieved the right. before cable will start to move.

  • Page 35: Wireless Remote Controller

    HG2200/HG2200AT Operator’s Manual Wireless Remote Controller Wireless Remote Controller j64om010w.eps 1. LCD display 7. Communication link indicator 2. Menu select switch 8. Power status indicator 3. Speed selection switch 9. Power/Start/Horn switch 4. Left multifunction joystick 10. Right multifunction joystick 5.
  • Page 36 HG2200/HG2200AT Operator’s Manual Wireless Remote Controller Item Description Notes 2. Menu select switch IMPORTANT: To move up through the secondary functions, move • Operator presence switches must be released and pressed again To move down through the after changing secondary secondary functions, move functions to enable new functions.
  • Page 37 HG2200/HG2200AT Operator’s Manual Wireless Remote Controller Item Description Notes 7. Communication link Indicates the status of the An active communication link is indicator transmitter and receiver link. required for wireless control. • Blinking yellow indicates no communication link. • Blinking green indicates good communication link.

  • Page 38: Wireless Remote Controller Secondary Functions

    HG2200/HG2200AT Operator’s Manual Wireless Remote Controller Item Description Notes 11. Operator presence IMPORTANT: Operator presence To operate wireless controller, switches press one or both switches. switches must be released and pressed again after changing To disable controller, release. secondary functions to enable new function.
  • Page 39 HG2200/HG2200AT Operator’s Manual Wireless Remote Controller Item Description Notes 3. Track drive To move the right track To select track drive speed, see forward, move the right “Speed selection switch” on page 35. joystick up. IMPORTANT: High speed should be To move the right track used for travel only.
  • Page 40 HG2200/HG2200AT Operator’s Manual Wireless Remote Controller Item Description Notes 6. Winch To push cable out, move the To select speed, see “Speed selection right joystick up. switch” on page 35. To pull cable in, move the right joystick down. c00ic771h.eps 7.

  • Page 41: Track Tethered Remote Control

    HG2200/HG2200AT Operator’s Manual Track Tethered Remote Control Track Tethered Remote Control j64om009w.eps 1. Left track control 2. Right track control Item Description Notes 1. Left track control To move left track forward, move lever forward. To move left track backward, move lever back.

  • Page 42: Gauges And Indicators

    HG2200/HG2200AT Operator’s Manual Gauges and Indicators Gauges and Indicators j64om011w.eps 1. Hydraulic pressure gauge 5. Voltage indicator 2. Hourmeter 6. Hydraulic fluid temperature indicator 3. Engine oil pressure indicator 7. Hydraulic fluid filter restriction indicator 4. High temperature indicator 8. Cold start wait indicator...
  • Page 43 HG2200/HG2200AT Operator’s Manual Gauges and Indicators Item Description Notes 2. Hourmeter Displays engine operating Use engine operating time to time. schedule service. 3. Engine oil pressure Flashes red on start-up and NOTICE: indicator when engine oil pressure is low. •...
  • Page 44 HG2200/HG2200AT Operator’s Manual Gauges and Indicators Item Description Notes 6. Hydraulic fluid Lights red when hydraulic NOTICE: If indicator lights, stop temperature indicator fluid is overheating. engine and service unit. 7. Hydraulic fluid filter Lights yellow when hydraulic NOTICE: If indicator lights, stop restriction indicator fluid filter flow is restricted.

  • Page 45: Optional Electric Strike System (Esid)

    HG2200/HG2200AT Operator’s Manual Electric Strike System* (ESID) Electric Strike System* (ESID) ESID.eps ESID.eps 1. LCD display 5. Voltage limiter problem indicator 2. Electrical power supply indicator 6. Current detection problem indicator 3. ESID OK indicator 7. ESID Alarm interrupt button 4.
  • Page 46 HG2200/HG2200AT Operator’s Manual Electric Strike System* (ESID) Item Description Notes 2. Electrical power supply Green light means control Strike system is ready to operate if indicator box has sufficient electrical OK indicator is also on. power for operation. 3. ESID OK indicator Green light indicates ESID self test reports no problems.
  • Page 47 HG2200/HG2200AT Operator’s Manual Electric Strike System* (ESID) Item Description Notes 6. Current detection Blinking red light indicates a See “Troubleshoot Strike System” on problem indicator problem has been detected in page 97. the current sensing circuit. 7. ESID alarm interrupt...

  • Page 48: Manual Stabilizer Controls

    HG2200/HG2200AT Operator’s Manual Manual Stabilizer Controls Manual Stabilizer Controls j64om055w.eps 1. Rear stabilizers 3. Manual trailer jack handle (wheeled unit only) 2. Manual stabilizer handle (skid unit only) Item Description Notes 1. Rear stabilizers Pull down and secure with pins.

  • Page 49: Auxiliary Work Light

    HG2200/HG2200AT Operator’s Manual Auxiliary Work Light Auxiliary Work Light j64om068w.eps Item Description Notes 1. Auxiliary work light To turn auxiliary work light on, switch press top. To turn auxiliary work light off, press bottom. 2. Auxiliary work light Provides power for auxiliary See “Auxiliary Work Light”...

  • Page 50: Battery Disconnect

    HG2200/HG2200AT Operator’s Manual Battery Disconnect Battery Disconnect j64om013w.eps Item Description Notes Battery disconnect switch To connect, move right. NOTICE: To disconnect, move left. • Do not operate battery disconnect switch with engine running. • To avoid equipment damage, wait two minutes after turning engine off before disconnecting battery.
  • Page 51 HG2200/HG2200AT Operator’s Manual Battery Disconnect 50 - Controls...

  • Page 52: Prepare

    HG2200/HG2200AT Operator’s Manual Prepare Chapter Contents Gather Information ......52 • Review Job Plan ......... . .52 •...

  • Page 53: Gather Information

    HG2200/HG2200AT Operator’s Manual Gather Information Gather Information A successful job begins before the pull. The first step in planning is reviewing information already available about the job and jobsite. Review Job Plan Review blueprints or other plans and make sure you have taken enlargement during pullback into account.

  • Page 54: Inspect Site

    HG2200/HG2200AT Operator’s Manual Inspect Site Inspect Site Identify Hazards Inspect jobsite before transporting equipment. Check for the following: • overall grade or slope • changes in elevation such as hills or open trenches • obstacles such as buildings, railroad crossings, or streams •...

  • Page 55: Select Installation And Bursting Pit Locations

    HG2200/HG2200AT Operator’s Manual Inspect Site Select Installation and Bursting Pit Locations Consider the following when selecting pit locations: Slope Unit should be parked on a level site. Consider how slope will affect unit setup and operation. Assess the risks on each slope to determine if factors affecting risks create an unsafe condition for pipe bursting.

  • Page 56: Classify Jobsite

    HG2200/HG2200AT Operator’s Manual Classify Jobsite Classify Jobsite Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. 274-050; 274-724 (2P) To help avoid injury: • Wear personal protective equipment including hard hat, safety eye wear, and hearing protection.

  • Page 57: Apply Precautions

    HG2200/HG2200AT Operator’s Manual Classify Jobsite Apply Precautions Once classified, precautions appropriate for jobsite must be taken. Follow U.S. Department of Labor regulations on excavating and trenching (Part 1926, Subpart P) and other similar regulations. Electric Jobsite Precautions Electric shock will cause death or serious injury. Stay away.
  • Page 58 HG2200/HG2200AT Operator’s Manual Classify Jobsite Crystalline Silica (Quartz) Dust Precautions Breathing crystalline silica dust may cause lung disease. Cutting, drilling, or working materials such as concrete, sand, or rock containing quartz may result in exposure to silica dust. Use dust control methods or appropriate breathing protection when exposed to silica dust.

  • Page 59: Plan Pull Path

    HG2200/HG2200AT Operator’s Manual Plan Pull Path Plan Pull Path Plan the pull path, from entry to end, before job begins. Locate the entire route of the pipe to be replaced to ensure a straight path. Expose all crossing or parallel utilities in accordance with local regulations.

  • Page 60: Dig Bursting Pit

    HG2200/HG2200AT Operator’s Manual Prepare Jobsite Dig Bursting Pit j64om014w.eps Minimum Bursting Pit Length (A) Width (B) U.S. (metric) U.S. (metric) 37.1” (94.2 cm) 40.0” (101.6 cm) Centerline of cable is 0.44” (11.2 mm) above the bottom plate (C). Prepare - 59...

  • Page 61: Check Supplies And Prepare Equipment

    HG2200/HG2200AT Operator’s Manual Check Supplies and Prepare Equipment Requirements j57om021w.eps Installation Pit (1) • Pit dimensions depend on pipe depth and product being installed. • Must be in line with existing pipe. • Sloped back end aids new product installation. Consider new product bend radius.

  • Page 62: Prepare Equipment

    HG2200/HG2200AT Operator’s Manual Check Supplies and Prepare Equipment Prepare Equipment Install Wire Cable Moving parts can crush and cut hand or foot. Stay away. To help avoid injury: Install wire cable with engine off. 1. Support shipping reel so it turns freely as it j57om068w.eps...

  • Page 63: Assemble Accessories

    HG2200/HG2200AT Operator’s Manual Check Supplies and Prepare Equipment Fluid Levels • fuel • hydraulic fluid • engine coolant • engine oil Condition and Function • all controls Improper control function could cause death or serious injury. If control does not work as described in instructions, stop machine and have it serviced.

  • Page 64: Drive

    HG2200/HG2200AT Operator’s Manual Drive - 63 Drive Chapter Contents Start Unit ....... . . 64 Steer Unit .

  • Page 65: Start Unit

    HG2200/HG2200AT Operator’s Manual Drive - 64 Start Unit Start Unit Before operating machine, read engine manufacturer’s starting and operating instructions. Misuse of machine can cause death or serious injury. Read and understand operator’s manual and all other safety instructions before use.

  • Page 66: Steer Unit

    HG2200/HG2200AT Operator’s Manual Drive - 65 Steer Unit Steer Unit IMPORTANT: These steer instructions cover the tracked unit only. To steer winch unit, follow instructions for type of steering desired. See page 30 for more information. To steer while moving forward, move one control slightly more than the other to turn in the desired direction.

  • Page 67: Tracked Unit

    HG2200/HG2200AT Operator’s Manual Drive - 66 Shut Down Unit Safe Slope Operation Tipover possible. Machine can tip over and crush you. To help avoid injury: • Always operate from the uphill side of the unit. • Drive cautiously at all times.

  • Page 68: Transport

    HG2200/HG2200AT Operator’s Manual Transport Chapter Contents Lift ........68 •...

  • Page 69: Lift

    HG2200/HG2200AT Operator’s Manual Lift Lift Crushing weight could cause death or serious injury. Stay away. To help avoid injury: • Use only appropriate lifting devices and lifting equipment. • Use only approved lifting points. • Stay away from lifted load.

  • Page 70: Wheeled Unit

    HG2200/HG2200AT Operator’s Manual Lift Wheeled Unit Use equipment capable of supporting the unit's size and weight. See “Specifications” on page 129 or measure and weigh equipment before lifting. j64om016w.eps Transport - 69...

  • Page 71: Haul

    HG2200/HG2200AT Operator’s Manual Haul Haul Wheeled Unit Crushing weight could cause death or serious injury. Stay away. Prepare Unit 1. Remove legs from downhole unit. Using pins, secure in storage location as shown. T j64om072w.eps 2. Turn downhole unit to the upright position and secure with pin (shown).
  • Page 72 HG2200/HG2200AT Operator’s Manual Haul Inspect Unit • Check hitch for wear and cracks. Lubricate if needed. • Check battery for 12 volt charge. • Inspect lights for cleanliness and correct operation. Inspect reflectors and replace if needed. • Check tire pressure. Check lug nut torque with a torque wrench.

  • Page 73: Tracked Unit

    HG2200/HG2200AT Operator’s Manual Haul Tracked Unit Load Unit 1. Stow mast in horizontal position. 2. Start unit. See “Start Unit” on page 64. 3. Raise stabilizers. 4. Move winch to rear of trailer and align with ramps. 5. Ensure engine is at full throttle and slowly drive unit onto trailer.

  • Page 74: Retrieve Tracked Unit

    HG2200/HG2200AT Operator’s Manual Retrieve Tracked Unit Unload Unit Crushing weight could cause death or serious injury. Use proper procedures and equipment or stay away. To help avoid injury: • Load and unload trailer on level ground. • Ensure trailer wheels are blocked.
  • Page 75 HG2200/HG2200AT Operator’s Manual Retrieve Tracked Unit 74 - Transport...

  • Page 76: Burst Pipe

    HG2200/HG2200AT Operator’s Manual Burst Pipe Chapter Contents Setup and Configure......76 • Setup Mast ..........77 Push Cable .

  • Page 77: Setup And Configure

    HG2200/HG2200AT Operator’s Manual Set Up and Configure Set Up and Configure j57om022w.eps 1. Tooling head 3. Winch 2. Wire cable NOTICE: Follow U.S. Department of Labor regulations on excavating and trenching (Part 1926, Subpart P) and other similar regulations. 1. Position winch unit outside of bursting pit with winch bumper approximately 4-6 in (100-150 mm) inside the edge of bursting pit or manhole.

  • Page 78: Setup Mast

    HG2200/HG2200AT Operator’s Manual Set Up and Configure Set Up Mast Moving parts can crush and cut hand or foot. Stay away. To help avoid injury: • Keep hands and fingers clear of the mast. • Ensure no personnel are in the pit as equipment is lowered.
  • Page 79 HG2200/HG2200AT Operator’s Manual Set Up and Configure 4. Ensure bushing (shown) is in place. Start unit. See “Start Unit” on page 64. 6. Move mode selection switch to winch position. 7. Move mast control switch to position mast over bursting pit or manhole.
  • Page 80 HG2200/HG2200AT Operator’s Manual Set Up and Configure Position Downhole Unit Legs 1. Ensure there is slack in cable before positioning downhole unit. 2. Use stabilizers to fine tune the downhole unit up or down from the centerline of the existing utility.

  • Page 81: Push Cable

    HG2200/HG2200AT Operator’s Manual Push Cable Push Cable Misuse of machine can cause death or serious injury. Read and understand operator’s manual and all other safety instructions before use. To help avoid injury: • Maintain 2-way communication between bursting pit and all other personnel.

  • Page 82: Connect Tooling Head

    HG2200/HG2200AT Operator’s Manual Connect Tooling Head Connect Tooling Head Misuse of machine can cause death or serious injury. Read and understand operator’s manual and all other safety instructions before use. To help avoid injury: • Maintain 2-way communication between bursting pit and all other personnel.

  • Page 83: Burst Head

    HG2200/HG2200AT Operator’s Manual Connect Tooling Head Burst Head 1. Pull wire cable (1) through existing utility leaving the swaged button-end of the cable at the installation pit. 2. Connect the burst head (3) to the product (4) using burst head bolts (5).

  • Page 84: Pull New Product

    HG2200/HG2200AT Operator’s Manual Pull New Product Pull New Product Misuse of machine can cause death or serious injury. Read and understand operator’s manual and all other safety instructions before use. To help avoid injury: • Maintain 2-way communication between bursting pit and all other personnel.
  • Page 85 HG2200/HG2200AT Operator’s Manual Pull New Product 1. Ensure winch control lever is in neutral. 2. Start unit. See “Start Unit” on page 64. 3. Set mode selection switch to the winch position. 4. Move winch control lever to pull cable in.

  • Page 86: Finish Installation

    HG2200/HG2200AT Operator’s Manual Finish Installation Finish Installation Once the installation is finished, remove the tooling head. Same Path™ Pipe Slitting Technology 1. Shut down unit. See “Shut Down Unit” on page 66. 2. Remove pipe puller from swivel. 3. Remove wire cable from jaws and pull out of the blade set and expander.
  • Page 87 HG2200/HG2200AT Operator’s Manual Finish Installation 86 - Burst Pipe...

  • Page 88: Systems And Equipment

    HG2200/HG2200AT Operator’s Manual Systems and Equipment Chapter Contents Wireless Remote Controller ....88 • Before Each Use ......... . .88 •...

  • Page 89: Wireless Remote Controller

    HG2200/HG2200AT Operator’s Manual Wireless Remote Controller Wireless Remote Controller Before Each Use 1. Check transmitter unit battery status. Replace batteries if necessary. See page 127. 2. Ensure USB key (shown) is installed. This key is a lockout feature to prevent unauthorized use.

  • Page 90: Troubleshooting

    If communication link indicator is red, communication has been lost. Shut down wireless remote and restart ® to try to enable communication. If that doesn’t work, contact your HammerHead dealer. If battery and communication link indicators both display red for several seconds and then the wireless controller shuts off, USB key is not installed.

  • Page 91: Auxiliary Work Light

    HG2200/HG2200AT Operator’s Manual Track Tethered Remote Control Track Tethered Remote Control The track tethered controller should be used if the wireless remote controller is damaged or cannot be used. IMPORTANT: • The track tethered remote control is intended for emergency use only. Do not use for normal operation.

  • Page 92: Same Path™ Pipe Slitting Technology

    HG2200/HG2200AT Operator’s Manual Same Path™ Pipe Slitting Technology 2. Connect light to auxiliary work light outlet and turn auxiliary work light switch to the on position. See “Auxiliary Work Light” on page 90. j64om070w.eps Same Path™ Pipe Slitting Technology The tooling is used when installing polyethylene and high-density polyethylene pipe.

  • Page 93: Wire Cable

    HG2200/HG2200AT Operator’s Manual Wire Cable Wire Cable Wire Cable Length cable, 7/8” 2590 feet (789 m) 2500 feet (762 m) usable Maintaining Wire Cable Misuse of machine can cause death or serious injury. Read and understand operator’s manual and all other safety instructions before use.

  • Page 94: Electric Strike System (Optional)

    Read and follow “Prepare Jobsite” on page 58. Review safety procedures before each job. ® If an electric strike occurs, immediately contact your local HammerHead dealer to have the electric strike system tested.

  • Page 95: Assemble Voltage Detector

    HG2200/HG2200AT Operator’s Manual Electric Strike System (ESID) Assemble Voltage Detector 1. Drive voltage stake into ground at least 6’ (2 m) away from any part of system. 2. Clip voltage limiter to voltage stake. Assemble Grid Mat 1. Remove mat from storage.

  • Page 96: Test Strike System

    HG2200/HG2200AT Operator’s Manual Electric Strike System (ESID) Test Strike System If system fails any part of this test, see “Troubleshoot Strike System” on the following page. Do not winch until test is completed successfully. 1. Turn on unit. “Start Unit” on page 64 2.
  • Page 97 HG2200/HG2200AT Operator’s Manual Electric Strike System (ESID) Code Display Condition Result STR COIL strike current input error POST AC V self-test ac voltage input error self-test of ac voltage stake failed POST AC I self-test ac current input error self-test of ac current coil failed...

  • Page 98: Troubleshoot Strike System

    HG2200/HG2200AT Operator’s Manual Electric Strike System (ESID) Troubleshoot Strike System When strike system detects a problem, an error icon will be displayed. Anytime this happens, press self test button to retest. If error icon is still displayed and does not appear in this chart, have control module checked or replaced.
  • Page 99 HG2200/HG2200AT Operator’s Manual Electric Strike System (ESID) Problem Possible cause Possible solution Alarm on unit does not work Improper connections with Check connections and wiring during total test control module harness Defective alarm 1. Disconnect alarm and connect to external 12V power source.

  • Page 100: Use Electric Strike Simulator

    HG2200/HG2200AT Operator’s Manual Electric Strike System (ESID) Use Electric Strike Simulator Use the Electric Strike Simulator to test voltage and current sensors on ESID. If readings are less than indicated here, replace 9V battery in simulator and retest. If readings are still less than indicated, contact ®...
  • Page 101 HG2200/HG2200AT Operator’s Manual Electric Strike System (ESID) Voltage Test 1. Place voltage limiter on something insulated from ground and unit (such as dry board or tire), but near frame of unit. 2. Clip one lead to frame. 3. Clip other lead to one voltage limiter mount.

  • Page 102: Complete The Job

    HG2200/HG2200AT Operator’s Manual Complete the Job Chapter Contents Stow Components ......102 Restore Jobsite ......102 Stow Tools .
  • Page 103 HG2200/HG2200AT Operator’s Manual Stow Components Stow Components Load unit as specified. See “Transport” on page 67 for more information. Restore Jobsite Fill in installation, bursting and service connection pits. Stow Tools Make sure all accessories and tools are loaded and properly secured on trailer.

  • Page 104: Service

    HG2200/HG2200AT Operator’s Manual Service Chapter Contents Service Precautions ..... . . 104 • Welding Precaution ........104 •...

  • Page 105: Service Precautions

    HG2200/HG2200AT Operator’s Manual Service Precautions Service Precautions Misuse of machine can cause death or serious injury. Read and understand operator’s manual and all other safety instructions before use. To help avoid injury: • Unless otherwise instructed, all service should be performed with engine off and engine cool.

  • Page 106: Recommended Lubricants/Service Key

    Service intervals listed are minimum requirements. In extreme conditions, service machine more frequently. Use only recommended lubricants. Use only genuine HammerHead parts and approved lubricants to maintain warranty. For more information on engine lubrication and maintenance, see your engine manual.

  • Page 107: Engine Oil Temperature Chart

    HG2200/HG2200AT Operator’s Manual Recommended Lubricants/Service Key Engine Oil Temperature Chart SAE30 SAE10W-30 SAE15W-40 SAE10W-30 SAE15W-40 SAE10W-30 j60om070w.eps Temperature range anticipated before next oil change Approved Coolant This unit was filled a 50/50 anti-freeze mix. Refill with 0.82 gal (3.1 L) of 50/50 mix. Add or replace only with coolant meeting this specification.

  • Page 108: Approved Fuel

    In certain markets, higher blends may be used if certain steps are taken. Extra attention is needed when using biodiesel, especially when operating in cold weather or storing fuel. Contact your HammerHead dealer or the engine manufacturer for more information. Service - 107...

  • Page 109: Each Use

    HG2200/HG2200AT Operator’s Manual Each Use Each Use Tasks Notes Check engine oil level Check engine coolant level DEAC Check hydraulic fluid level Check tire pressure and lug nut torque Wheeled unit, 90 ft•lb (122 N•m) Check fuel level and refuel...
  • Page 110 HG2200/HG2200AT Operator’s Manual Each Use Check Engine Coolant Level Contents under pressure. Relieve pressure before opening. Death or injury could occur. To help avoid injury: • Do not remove the pressure cap from a hot engine. • Wait until the coolant temperature is below 122°F (50°C) before removing pressure cap.
  • Page 111 HG2200/HG2200AT Operator’s Manual Each Use Check Tire Pressure and Lug Nut Torque (Wheeled Unit) Check tire pressure and lug nut torque before start up and every 10 hours of operation. Tighten lugnuts in a star pattern using a three stage sequence.
  • Page 112 HG2200/HG2200AT Operator’s Manual Each Use Grease Level Wind Follower and Level Wind Shaft Bearings Grease level wind follower and level wind shaft bearings (shown) before startup and every 10 hours of operation with EPG. j64om031w.eps Grease Level Wind Shaft Grease level wind shafts before startup and every 10 hours of operation with EPG j64om032w.eps...
  • Page 113 HG2200/HG2200AT Operator’s Manual Each Use Check Track Tension and Condition (Tracked Unit) Check track tension and adjust or replace before startup and every 10 hours of operation. To adjust: 1. Lift right track using right stabilizer. IMPORTANT: Raise enough to allow the track to hang freely from the machine.
  • Page 114 HG2200/HG2200AT Operator’s Manual Each Use Clean Dust Ejector Valve Check dust ejector valve (shown) before startup and every 10 hours of operation. Ensure that valve is not inverted, damaged, plugged, or cracked. j64om036w.eps Inspect Wire Cable Inspect wire cable before each use. Replace damaged wire cable immediately. Obvious damage includes permanent bends, flat spots, worn spots, broken wires, frays, rust, and corrosion.

  • Page 115: 50 Hour

    HG2200/HG2200AT Operator’s Manual 50 Hour 50 Hour Task Notes Change engine oil and filter Initial service, DEO Clean air filter Check fuel lines Grease bull wheel sprockets Check hydraulic hoses Grease mast pivots Grease mast cable sheave bearings Change Engine Oil and Filter...
  • Page 116 HG2200/HG2200AT Operator’s Manual 50 Hour Check Fuel Lines Check fuel lines after 50 hours for wear or cracks. Check fuel line for loose or broken clamp bands. j64om039w.eps Grease Bull Wheel Sprockets Grease the bull wheel sprockets every 50 hours with MOB.
  • Page 117 HG2200/HG2200AT Operator’s Manual 50 Hour Check Hydraulic Hoses Pressurized fluid or air could pierce skin and cause severe injury. Refer to operator’s manual for proper use. To help avoid injury: • Use a piece of cardboard or wood, rather than hands, to search for leaks.
  • Page 118 HG2200/HG2200AT Operator’s Manual 50 Hour Grease Mast Pivots Grease mast pivots (shown) every 50 hours with EPG. j64om041w.eps Grease Mast Cable Sheave Bearings Grease mast cable sheave bearings (shown) every 50 hours with EPG. j64om042w.eps Service - 117...

  • Page 119: 100 Hour

    HG2200/HG2200AT Operator’s Manual 100 Hour 100 Hour Task Notes Change engine oil and filter Check fan belt Check battery Change Engine Oil and Filter Change engine oil and filter every 100 hours. To change: 1. While oil is warm, remove drain plug (3). Drain oil and replace plug.
  • Page 120 HG2200/HG2200AT Operator’s Manual 100 Hour Check Battery Explosion possible. Serious injury or equipment damage could occur. Follow directions carefully. To help avoid injury: • Wear safety glasses and face shield and rubber gloves. • Use flashlight to check electrolyte level.

  • Page 121: 200 Hour

    HG2200/HG2200AT Operator’s Manual 200 Hour 200 Hour Task Notes Change hydraulic fluid filter Change fuel filter Add cooling system additive Change Hydraulic Fluid Filter Change hydraulic fluid filter after 200 hours or as indicated by the hydraulic fluid filter restriction indicator.
  • Page 122 HG2200/HG2200AT Operator’s Manual 200 Hour Add Cooling System Additive Add cooling system additive to radiator at fill (1) every 200 hours. Capacity is 0.8 oz (24 cc). j64om027w.eps Service - 121...

  • Page 123: 500 Hour

    HG2200/HG2200AT Operator’s Manual 500 Hour 500 Hour Task Notes Adjust brakes Wheeled unit Change fan belt Change engine coolant Adjust Brakes (Wheeled Unit) Adjust brakes every 500 hours. 1. Place adequate jack stands under frame and remove wheels. 2. Remove cover from adjusting slot (1) on bottom of backing plate.
  • Page 124 HG2200/HG2200AT Operator’s Manual 500 Hour Change Engine Coolant Drain and clean cooling system every year or 1000 hours. To change: 1. Remove drain plug (1) and drain old coolant. 2. Fill radiator with clean water at fill (2). 3. Check for signs of rust and add cooling system cleaner to the water if necessary.

  • Page 125: 1000 Hour

    HG2200/HG2200AT Operator’s Manual 1000 Hour 1000 Hour Task Notes Change hydraulic fluid Check wheel bearings Wheeled units, EPG Change Hydraulic Fluid Change hydraulic fluid every 1000 hours. To change: 1. Remove cap (1) and drain plug while (3) fluid is warm and drain.
  • Page 126 HG2200/HG2200AT Operator’s Manual 1000 Hour Adjust and Lubricate Wheel Bearings (Wheeled Unit) Adjust and lubricate bearings every 1000 hours. 1. Place adequate jack stands under frame rails and remove wheels. 2. Unscrew grease cap (1) while holding the hub stationary.

  • Page 127: As Needed

    HG2200/HG2200AT Operator’s Manual As Needed As Needed Task Notes Change air filter Change wireless remote controller batteries Change battery Change Air Filter Replace air filter as needed. To change: 1. Remove wing nut (1) to remove cover (2). 2. Remove filter element (3).
  • Page 128 HG2200/HG2200AT Operator’s Manual As Needed Change Battery Explosion possible. Serious injury or equipment damage could occur. Follow directions carefully. To help avoid injury: • Use a single 12V maximum source for charging. Do not connect to rapid chargers or dual batteries.
  • Page 129 HG2200/HG2200AT Operator’s Manual As Needed 128 - Service...

  • Page 130: Specifications

    HG2200/HG2200AT Operator’s Manual Winch Unit Specifications Winch Unit j64om054w.eps Dimensions U.S. Metric L, length (with trailer tongue) 17 ft 5.2 m L, length (without trailer tongue) 14.1 ft 4.3 m W, width 7 ft 2.1 m H1, height 6.5 ft...
  • Page 131 HG2200/HG2200AT Operator’s Manual Winch Unit Dimensions U.S. Metric Tracked unit 15,000 lbs 6804 kg Wheeled unit 14,500 lbs 6577 kg Operational U.S. Metric Pullback force, maximum 22 tons 20 tonnes Working pressure, maximum 3475-3525 psi 240-243 bar Working flow rate...
  • Page 132 HG2200/HG2200AT Operator’s Manual Declaration of Conformity Information Declaration of Conformity Information Countries in the European Union should have received a Declaration of Conformity (DOC) with this machine similar to the example below. Earth Tool Company, LLC. 500 South C.P. Avenue...
  • Page 133 HG2200/HG2200AT Operator’s Manual Declaration of Conformity Information 132 - Specifications...
  • Page 134 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 of another manufacturer's parts may void warranty consideration.
  • Page 135 Dealer shall furnish parts without charge for any HammerHead product that fails because of defects in material and workmanship. Warranty is void unless warranty registration card is returned within ten days from the date of purchase. This warranty and any...
  • Page 136 HG2200/HG2200AT Operator’s Manual Service Record Service Performed Date Hours Service Record - 135...
  • Page 137 HG2200/HG2200AT Operator’s Manual Service Performed Date Hours 136 - Service Record...
  • Page 138 HG2200/HG2200AT Operator’s Manual Appendix - 137 Appendix Chapter Contents Tire Safety Information...
  • Page 139 AFETY NFORMATION 1.1. STEPS FOR DETERMINING CORRECT LOAD LIMIT – TRAILER Determining the load limits of a trailer includes more than understanding the load limits of the tires alone. On all trailers there is a Federal certification/VIN label that is located on the forward half of the left (road) side of the unit.
  • Page 140 The Tire Information Placard is attached adjacent to or near the trailer’s VIN (Certification) label at the left front of the trailer. 1.1.2. TRAILERS OVER 10,000 POUNDS GVWR (NOTE: These trailers are not required to have a tire information placard on the trailer.) 1.
  • Page 141 Innerliner separation - the parting of the innerliner from cord material in the carcass. Light truck (LT) tire - a tire designated by its manufacturer as primarily intended for use on lightweight trucks or multipurpose passenger vehicles. Load rating - the maximum load that a tire is rated to carry for a given inflation pressure. Maximum load rating - the load rating for a tire at the maximum permissible inflation pressure for that tire.
  • Page 142 1.4. TIRE SAFETY - EVERYTHING RIDES ON IT The National Traffic Safety Administration (NHTSA) has published a brochure (DOT HS 809 361) that discusses all aspects of Tire Safety, as required by CFR 575.6. This brochure is reproduced in part below. It can be obtained and downloaded from NHTSA, free of charge, from the following web site: http://www.nhtsa.dot.gov/cars/rules/TireSafety/ridesonit/tires_index.html Studies of tire safety show that maintaining proper tire pressure, observing tire and trailer load limits (not carrying more weight in your trailer than your tires or trailer can safely handle), avoiding...
  • Page 143 1.5.2. UNDERSTANDING TIRE PRESSURE AND LOAD LIMITS Tire inflation pressure is the level of air in the tire that provides it with load-carrying capacity and affects the overall performance of the trailer. The tire inflation pressure is a number that indicates the amount of air pressure–...
  • Page 144 1.5.5. TIRE SIZE To maintain tire safety, purchase new tires that are the same size as the trailer's original tires or another size recommended by the manufacturer. Look at the tire information placard, the owner's manual, or the sidewall of the tire you are replacing to find this information. If you have any doubt about the correct size to choose, consult with your dealer.
  • Page 145 1.5.9.2. Information on Light Truck Tires Please refer to the diagram below. Tires for light trucks have other markings besides those found on the sidewalls of passenger tires. LT - indicates the tire is for light trucks or trailers. ST - indicates the tire is for trailer use only. Max.

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