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Hammerhead PB30X Operator's Manual

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PB30X™
Operator's
Manual
Issue 1.0
960-1020
Original Instruction

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Summary of Contents for Hammerhead PB30X

  • Page 1 PB30X™ Operator’s Manual Issue 1.0 960-1020 Original Instruction...
  • Page 2 ™ PB30X Operator’s Manual Overview Chapter Contents Serial Number Location ..... . 2 Intended Use ....... 3 Equipment Modification .
  • Page 3 ™ PB30X Operator’s Manual Serial Number Location Serial Number Location Record serial numbers and date of purchase in spaces provided. j99om001w23.eps Date of manufacture Date of purchase 2 - Overview...
  • Page 4 HammerHead dealer. Use in any other way is considered contrary to the intended use. HammerHead pipe bursters and control units should be operated, serviced, and repaired only by persons familiar with their particular characteristics and acquainted with the relevant safety procedures.
  • Page 5 ™ PB30X Operator’s Manual Unit Components Unit Components j99om002w23.eps 1. Bursting unit 3. Extraction cage (optional) 2. Tooling head 4 - Overview...
  • Page 6 ™ PB30X Operator’s Manual Operator Orientation Operator Orientation IMPORTANT: Top view of unit is shown. 1. Front of unit 2. Right side of unit 3. Rear of unit 4. Left side of unit j99om003w23.eps Operating Area IMPORTANT: Top view of unit is shown.
  • Page 7 ™ PB30X Operator’s Manual About This Manual About This Manual This manual contains information for the proper use of this machine. Cross references such as “See page 50” will direct you to detailed procedures. Bulleted Lists Bulleted lists provide helpful or important information or contain procedures that do not have to be performed in a specific order.
  • Page 8 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 9 Copyright 2024 by The Charles Machine Works, Inc. dba Hammerhead Trenchless HammerHead is a registered trademark of The Charles Machine Works, Inc. This product and its use may be covered by one or more patents at http://patents.charlesmachine.works. 8 - Foreword...
  • Page 10 ™ PB30X Operator’s Manual Contents Contents Overview machine serial number, information about the type of work this machine is designed to perform, basic machine components, and how to use this manual Foreword part number, revision level, and publication date of this manual, and factory contact...
  • Page 11 ™ PB30X Operator’s Manual Contents Service Record a record of major service performed on the machine 10 - Contents...
  • Page 12 PB30X™ Operator’s Manual Safety Chapter Contents Safety Alert Classification ....12 Guidelines ....... . 13 Emergency Procedures .
  • Page 13 PB30X™ 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 14 • Fully inspect equipment before operating. Repair or replace any worn or damaged parts. Replace missing or damaged safety shields, safety signs, and decals. Contact your HammerHead dealer for assistance. • Use equipment carefully. Stop operation and investigate anything that does not look or feel right.
  • Page 15 PB30X™ Operator’s Manual Emergency Procedures Emergency Procedures Jobsite hazards. Exposure can cause death or serious injury. Use correct equipment and work methods. Use and maintain appropriate safety equipment. Before operating any equipment, review emergency procedures and check that all safety precautions have been taken.
  • Page 16 PB30X™ Operator’s Manual Emergency Procedures If an Electric Line is Damaged If you suspect an electric line has been damaged, DO NOT MOVE. Take the following actions. The order and degree of action will depend on the situation. • If you are in pit: •...
  • Page 17 PB30X™ Operator’s Manual Emergency Procedures If Machine Catches on Fire Perform emergency shutdown procedure and then take the following actions. The order and degree of action will depend on the situation. • Immediately move battery disconnect switch (if equipped and accessible) to disconnect position.
  • Page 18 ™ PB30X Operator’s Manual Machine Safety Alerts Machine Safety Alerts Cable may break while pulling and strike you. Serious injury or death may occur. Stay away. Moving parts. Contact can cause serious injury. Stay away. Underground utilities. Contact can cause death or serious injury.
  • Page 19 ™ PB30X Operator’s Manual Machine Safety Alerts Lift point. See Transport chapter for more information. Hot parts. Contact can cause burns. Only touch when cool or wear gloves. Sudden cable movement can cause serious injury or death. Stay away. Sudden cable movement can cause serious injury or death.
  • Page 20 ™ PB30X Operator’s Manual Controls Chapter Contents Bursting Unit ......20 Control Unit ......20...
  • Page 21 ™ PB30X Operator’s Manual Bursting Unit Bursting Unit j99om010w23.eps Item Description Notes 1. Jaw lockout knob To let jaws float, loosen knob. To secure jaws, tighten. 2. Spring piston To secure jaws, push in. Control Unit For control unit controls, see hydraulic control unit operator’s manual.
  • Page 22 ™ PB30X Operator’s Manual Prepare Chapter Contents Gather Information ......22 • Review Job Plan ......... . .22 •...
  • Page 23 ™ PB30X 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 24 ™ PB30X Operator’s Manual Inspect Site Inspect Site Inspect jobsite before transporting equipment. Check for the following: • changes in elevation such as hills or open trenches • obstacles such as buildings, railroad crossings, or streams • signs of utilities –...
  • Page 25 ™ PB30X Operator’s Manual Inspect Site Identify Hazards • Identify safety hazards. Follow U.S. Department of Labor regulations on excavating and trenching (Part 1926, Subpart P) and other similar regulations. • Have an experienced locating equipment operator sweep area within 20’ (6 m) to each side of burst path.
  • Page 26 ™ PB30X Operator’s Manual Inspect Site Select Installation and Bursting Pit Locations Consider the following when selecting pit locations: Traffic Vehicle and pedestrian traffic must be a safe distance from pulling equipment. Allow at least 10’ (3 m) buffer zone around equipment.
  • Page 27 ™ PB30X 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 28 ™ PB30X Operator’s Manual Prepare Jobsite Dig Bursting Pit Dimensions j99om005w23.eps Minimum Bursting Pit Length (A) Width (B) U.S. (metric) U.S. (metric) 3’ (0.9 m) 4’ (1.2 m) Centerline of cable is 2.25” (5.7 cm) above the bottom plate (C).
  • Page 29 ™ PB30X Operator’s Manual Prepare Jobsite Requirements j99om006w23.eps Installation Pit (1) • Pit dimensions depend on pipe depth and product being installed. Installation pit length typically needs to be three times the installation pit depth. NOTICE: Shortening the installation pit may cause increased friction as well as raise the grade of the new line for the first several feet.
  • Page 30 ™ PB30X Operator’s Manual Check Supplies and Prepare Equipment Check Supplies and Prepare Equipment Check Supplies • marking flags or paint • barrier cones and tape • wire cable (See “Wire Cable” on page 49.) • personal protective equipment, such as hard hat and safety glasses •...
  • Page 31 ™ PB30X Operator’s Manual Check Supplies and Prepare Equipment 30 - Prepare...
  • Page 32 ™ PB30X Operator’s Manual Transport Chapter Contents Lift ........32 •...
  • Page 33 ™ PB30X Operator’s Manual Lift Lift Lifted load. Crushing can cause death or serious injury. Stay away from lifted load and its range of movement. Points Lifting points are identified by lifting decals. Lifting at other points is unsafe and can damage machinery.
  • Page 34 ™ PB30X Operator’s Manual Tie Down Tie Down Procedure Tie down machine at locations shown. NOTICE: Ensure tie-down strap is behind the manifold (below), not over it. j99om008w23.eps j99om019w23.eps Transport - 33...
  • Page 35 ™ PB30X Operator’s Manual Disassembling the Unit Disassembling the Unit j99om011w23.eps Unit can be disassembled for easy transport. 1. Turn unit off. NOTICE: After turning unit off, cycle controls on control unit to relieve pressure in the hoses. See hydraulic control unit operator’s manual for more information.
  • Page 36 ™ PB30X Operator’s Manual Burst Pipe Chapter Contents Set Up and Configure ..... . . 36 Connect Bursting Head ..... 37 ®...
  • Page 37 ™ PB30X Operator’s Manual Set Up and Configure Set Up and Configure j99om009w23.eps Tooling head Hydraulic connection hoses 2. Wire cable Extraction cage (optional) Bursting unit 3. Control unit NOTICE: Follow U.S. Department of Labor regulations on excavating and trenching (Part 1926, Subpart P) and other similar regulations.
  • Page 38 ™ PB30X Operator’s Manual Connect Bursting Head Connect Bursting Head Misuse of machine can cause death or serious injury. Read and understand operator’s manual and all other safety instructions before use. Know how to use all controls. To help avoid injury: •...
  • Page 39 ™ PB30X Operator’s Manual Connect Bursting Head 5. Remove the retaining screw and place the button-end of the cable in the slot in the end of the bursting head as shown. 6. Pull the cable back and reinsert retaining screw to secure cable in place.
  • Page 40 ™ PB30X Operator’s Manual Connect Bursting Head 5. Once it has gripped the pipe, tighten the assembly until it no longer rotates. NOTICE: A pipe wrench may be used to tighten the bursting head if needed. 6. Remove the shoulder screw from the slitter head and place the eye of the pipe puller assembly into the clevis of the slitter head.
  • Page 41 ™ PB30X Operator’s Manual Pull New Product Pull New Product Install Cable In Burster Read operator’s manual. Know how to use all controls. Your safety is at stake. To help avoid injury: • Maintain 2-way communication between bursting pit and all other personnel.
  • Page 42 ™ PB30X Operator’s Manual Pull New Product Install Cable Keeper Arm and Cable 1. Pull out and rotate indexing plungers (1) to retract plunger pins from cable keeper arm (2). 2. Lift and hold cable keeper arm up (as shown) and rotate indexing plungers to extend the plunger pins.
  • Page 43 ™ PB30X Operator’s Manual Pull New Product Install Cable and Jaw Assembly 1. Apply thin layer of synthetic gear oil to both jaw block surfaces and all 4 jaw sliding surfaces (shown). j99om004w24.eps 2. Hold one jaw assembly above lower jaw block with jaws on either side of cable.
  • Page 44 ™ PB30X Operator’s Manual Pull New Product Burst Pipe and Pull New Product Cable may break while pulling and strike you. Serious injury or death may occur. Stay away. Sudden cable movement can cause serious injury or death. Stay clear.
  • Page 45 ™ PB30X Operator’s Manual Pull New Product 2. Start control unit. Use control unit controls to pull wire cable in and install new pipe. See hydraulic control unit operator’s manual. j99om014w23.eps NOTICE: Closely monitor position of the backing plate to ensure it remains square (90°) with pit floor.
  • Page 46 ™ PB30X Operator’s Manual Shut Down Shut Down Read operator’s manual. Know how to use all controls. Your safety is at stake. To help avoid injury: • Maintain 2-way communication between bursting pit and all other personnel. • Make sure all personnel are clear of moving parts.
  • Page 47 ™ PB30X Operator’s Manual Shut Down Disengage Cable Keeper Arm 1. Push and hold cable keeper arm (2). 2. While keeping cable keeper arm down, pull and rotate indexing plungers (1) to disengage pins from cable keeper arm. 3. Once cable keeper arm is disengaged, release and raise arm.
  • Page 48 ™ PB30X Operator’s Manual Shut Down Remove Same Path™ Pipe Slitting Technology/HydraSlitter™ System 1. Shut down machine. 2. Remove pipe puller from swivel. 3. Remove wire cable from jaws and pull out of blade set and expander. Remove Slitter Head 1.
  • Page 49 ™ PB30X Operator’s Manual Shut Down 48 - Burst Pipe...
  • Page 50 ™ PB30X Operator’s Manual Systems and Equipment Chapter Contents Extraction Cage ......50 Shore Plate ....... 50 Tooling .
  • Page 51 Shore Plate The shore plate can be installed in the bursting pit to assist in the pull. Tooling j99om015w23.eps The following tooling options are available for use with the PB30X. Tooling Polyethylene and high-density polyethylene pipe ® Quick Grip Slitter Blade PVC, Aldyl A, HDPE, MDPE pipe Same Path™...
  • Page 52 ™ PB30X Operator’s Manual Wire Cable Wire Cable Part Number Description 912-3161 cable, swaged 3/4” x 75’ 912-3162 cable, swaged 3/4” x 150’ 912-3163 cable, swaged 3/4” x 100’ 912-7172 cable, swaged 3/8” x 50’ 912-7116 cable, swaged 3/8” x 120’...
  • Page 53 ™ PB30X Operator’s Manual Wire Cable 52 - Systems and Equipment...
  • Page 54 ™ PB30X Operator’s Manual Complete the Job Chapter Contents Stow Components ......54 • Roll Wire Cable ..........54 Restore Jobsite .
  • Page 55 ™ PB30X Operator’s Manual Stow Components Stow Components Load unit as specified, or disassemble to transport. See “Transport” on page 33 for more information. Roll Wire Cable After cable is removed from burster, roll wire cable to store. Restore Jobsite Fill in installation, bursting and service connection pits.
  • Page 56 ™ PB30X Operator’s Manual Maintenance Chapter Contents Maintenance Precautions ....56 Recommended Lubricants/Service Key ..56 Each Use .
  • Page 57 In extreme conditions, service machine more frequently. Use only recommended lubricants. NOTICE: • Use only genuine HammerHead parts and approved lubricants to maintain warranty. • Use the “Service Record” on page 65 to record all required service to your machine. 56 - Maintenance...
  • Page 58 ™ PB30X Operator’s Manual Each Use Each Use Tasks Notes Lube jaw pins SGO, before each use Inspect wire cable before each use Clean jaw threads after each use Lube Jaws NOTICE: Failure to apply SGO to jaw before each use may result in jaw slippage, shortening jaw life and possibly causing job failure.
  • Page 59 ™ PB30X Operator’s Manual Each Use 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. For more information, see “Wire Cable” on page 49.
  • Page 60 ™ PB30X Operator’s Manual Specifications j99om018w23.eps Dimensions U.S. Metric L, length 17.3 in 43.9 cm W, width 17.5 in 44.5 cm H, height 24.6 in 62.4 cm H2, centerline of cable from bottom plate 2.25 in 5.7 cm Total system weight, mass 213 lb 96.6 kg...
  • Page 61 ™ PB30X Operator’s Manual 60 - Specifications...
  • Page 62 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 63 HammerHead shall, at its option, supply a functionally equivalent replacement product or request the return of the product to its plant in Lake Mills, Wisconsin so that HammerHead may repair it, each without charge. Such repair or replacement is the purchaser’s sole and exclusive remedy against Hammerhead, whether in contract or arising out of warranties, representations, or defects.
  • Page 64 PB30X™ Operator’s Manual Resources authorized to give any other warranty, or to assume any additional obligation on HammerHead’s behalf unless made in writing, and signed by an officer of HammerHead. THIS WARRANTY AND ANY POSSIBLE LIABILITY OF HAMMERHEAD HEREUNDER IS IN LIEU OF...
  • Page 65 PB30X™ Operator’s Manual Resources 64 - Warranty...
  • Page 66 PB30X™ Operator’s Manual Service Record Service Performed Date Hours Service Record - 65...
  • Page 67 PB30X™ Operator’s Manual Service Performed Date Hours 66 - Service Record...