Hammerhead 100XTR User manual

TECHNICAL PUBLICATIONS
Operator's
Manual
100XTR
CMW
Issue 2.1
960-1015
Original Instruction

100XTR Operator’s Manual
Overview - 1
Overview
Chapter Contents
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . 2
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Equipment Modification . . . . . . . . . . . . . . . . . . . . . . 3
Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Manual . . . . . . . . . . . . . . . . . . . . . . . . . 10
• Bulleted Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
• Numbered Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
California Proposition 65
Cancer, birth defects, and other reproductive harm. www.P65warnings.ca.gov.

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
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100XTR Operator’s Manual
Intended Use
Overview - 3
Intended Use
HammerHead® pipe bursters are intended for the replacement of 4” (10.2 cm) to 16” (40.6 cm) diameter
buried pipes and conduits. The 100XTR produces 100 tons (91 t) of pullback force. A power unit provides
hydraulic power to run the pipe bursting unit.
The unit is designed for operation in temperatures typically experienced in earth moving and construction
work environments. Provisions may be required to operate in extreme temperatures. Contact your
HammerHead dealer. 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.
Equipment Modification
This equipment was designed and built in accordance with applicable standards and regulations.
Modification of equipment could mean that it will no longer meet regulations and may not function properly
or in accordance with the operating instructions. Modification of equipment should only be made by
competent personnel possessing knowledge of applicable standards, regulations, equipment design
functionality/requirements and any required specialized testing.

100XTR Operator’s Manual
Unit Components
4 - Overview
Unit Components
1. Wireless remote controller
2. Rod box
3. Extraction cage
4. Bursting unit
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100XTR Operator’s Manual
Unit Components
Overview - 5
Bursting Unit Components
1. Bungee
2. Push/Pull carriage
3. Push/Pull clamp
4. Spinner
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100XTR 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.
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100XTR Operator’s Manual
Regulatory Notices
Overview - 7
Regulatory Notices
United States
This device complies with Part 15 of the FCC Rules. Operation is subject to the following conditions: (1) this device
may not cause harmful interference, and (2) this device must accept any interference received, including interference
that may cause undesired operation. Changes or modifications not expressly approved by The Charles Machine
Works, Inc. could void the user’s authority to operate the equipment.
This machine has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of
the FCC rules. These limits are designed to provide reasonable protection against harmful interference when the
equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency
energy, and, if not installed and used in accordance with the instructions, can cause harmful interference to radio
communications. Operation of this equipment in a residential area could cause harmful interference which the user will
be required to correct at his own expense. Changes or modifications not expressly approved by The Charles Machine
Works, Inc. could void the user’s authority to operate the equipment.
This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of
the FCC rules. These limits are designed to provide reasonable protection against harmful interference in a residential
installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in
accordance 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 cause harmful interference
to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged
to try to correct the interference by one or more of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect equipment into an outlet on a circuit different from that to which the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.
Contains FCC ID: ITQ-TR2 & KQL-RM02410.
Canada
CAN ICES-2/NMB-2
This device complies with Industry Canada license-exempt RSS standard(s). Operation is subject to the following two
conditions: (1) this device may not cause interference, and (2) this device must accept any interference, including
interference that may cause undesired operation of the device.
Contains IC: 3598A-TR2I & 2268C-RM02410.
Le présent appareil est conforme aux CNR d'Industrie Canada applicables aux appareils radio exempts de licence.
L'exploitation est autorisée aux deux conditions suivantes: (1) l'appareil ne doit pas produire de brouillage, et (2)
l'appareil doit accepter tout brouillage radioélectrique subi, même si le brouillage est susceptible d'en compromettre le
fonctionnement.
Contient IC: 3598A-TR2I & 2268C-RM02410.
EU Declaration of Conformity
Hereby, Charles Machine Works declares that the radio equipment type SSCRTX remote control
transmitter is in compliance with Directive 2014/53/EU. The full text of the EU declaration of conformity is
available by visiting https://subsite.com/about-us/contact-us or by emailing a request to
[email protected].

100XTR Operator’s Manual
Regulatory Notices
8 - Overview
RF Exposure Statement
In order to comply 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) separation distance from
the body.
This device complies with Health Canada’s Safety Code Section 6.

100XTR Operator’s Manual
Operator Orientation
Overview - 9
Operator Orientation
1. Front 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 shown.
IMPORTANT: Top view of unit is shown.
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1
3
24
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11

100XTR Operator’s Manual
About This Manual
10 - Overview
About This Manual
This manual contains information for the proper use of this machine. See Operation Overview for basic
operating procedures. Cross references such as “See page 50” will direct you to detailed procedures.
Bulleted Lists
Bulleted lists provide helpful or important information or contain procedures that do not have to be
performed in a specific order.
Numbered Lists
Numbered lists contain illustration callouts or list steps that must be performed in order.

100XTR Operator’s Manual
Foreword - 11
Foreword
This manual is an important part of your equipment. It provides safety information and operation
instructions to help you use and maintain your HammerHead® equipment.
Read this manual before using your equipment. Keep it with the equipment at all times for future reference.
If you sell your equipment, be sure to give this manual to the new owner.
If you need a replacement copy, contact your 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. Avenue
Lake Mills, WI 53551
USA
The descriptions and specifications in this manual are subject to change without notice.HammerHead
Trenchless Equipment reserves the right to improve equipment. Some product improvements may have
taken place after this manual was published. For the latest information on HammerHead equipment, see
your HammerHead dealer.
Thank you for buying and using HammerHead equipment.

100XTR Operator’s Manual
12 - Foreword
100XTR
Operator’s Manual
Issue number 2.1
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 use may be covered by one or more patents at http://patents.charlesmachine.works.

100XTR Operator’s Manual
Contents - 13
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
1
Foreword
part number, revision level, and publication date of this manual, and factory contact
information
11
Safety
machine safety alerts and emergency procedures
15
Controls
machine controls and indicators and how to use them
25
Prepare
procedures for inspecting 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 performing the burst
55
Troubleshooting
procedures for troubleshooting equipment
69
Systems and Equipment
bursting string, accessory kit
73
Complete the Job
procedures for restoring the jobsite and storing equipment
77
Service
service intervals and instructions for this machine including lubrication, replacement
of wear items, and basic maintenance
81
Specifications
machine specifications including weights, measurements, power ratings, and fluid
capacities
95

100XTR Operator’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 machine
101

100XTR Operator’s Manual
Safety - 15
Safety
Chapter Contents
Safety Alert 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 is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
• If Machine Catches on Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Machine Safety Alerts . . . . . . . . . . . . . . . . . . . . . . 21

16 - Safety
100XTR 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. YOUR SAFETY IS AT
STAKE.
Watch for the three safety alert levels: 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 extreme situations.
indicates a hazardous situation that, if not avoided, could result in death or serious injury.
indicates a hazardous situation that, if not avoided, could result in minor or moderate
injury.
Watch for two other words: NOTICE and IMPORTANT.
NOTICE indicates information considered important, but not hazard-related (e.g., messages relating to
property damage).
IMPORTANT can help you do a better job or make your job easier in some way.

100XTR Operator’s Manual
Guidelines
Safety - 17
Guidelines
When you see this safety alert sign, carefully read and follow all instructions.
YOUR SAFETY IS AT STAKE. Read this entire section before using your equipment.
SAVE THESE INSTRUCTIONS.
Follow these guidelines before operating any jobsite equipment.
• Complete proper training and read operator’s manual before using equipment.
• Mark proposed path with white paint and have underground utilities located before working. In the 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 local
utility companies to have underground utilities located.
• Classify jobsite based on its hazards and use correct tools and machinery, safety equipment, and work
methods for jobsite.
• Mark jobsite clearly and keep spectators away.
• Wear personal protective equipment including long pants, hard hat, eye protection, hearing protection,
and protective footwear.
• Do not wear jewelry or loose clothing.
• Review jobsite hazards, safety and emergency 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 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.
• Do not operate unit where flammable gas, liquid, or dust may be present.
• Only operate equipment in well-ventilated areas.
• Contact your HammerHead dealer if you have any question about operation, maintenance, or
equipment use.
• To reduce risk of injury, close supervision is necessary when a product is used near children.
• Know how to stop the product and bleed pressures quickly.
• Stay alert — watch what you are doing.
• Do not operate product when fatigued or under the influence of alcohol or drugs.
• Do not overreach or stand on unstable support. Keep good footing and balance at all times.
• To disconnect, turn all controls to the off (“O”) position, then remove plug from outlet.
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.

18 - Safety
100XTR Operator’s Manual
Guidelines
• Do not unplug by pulling on cord. To unplug, grasp the plug, not the cord.
• Unplug from outlet when not in use and before servicing or cleaning.
• For a grounded appliance, connect to a properly grounded outlet only. See grounding instructions.
• Do not expose machine to rain or wet conditions. Water entering a power tool will increase 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 to become complacent and
ignore tool safety principles.
• Remove any adjusting key or wrench before turning machine on.
• Avoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges, and
refrigerators.
• Do not force the power tool. Use the correct power tool for your application.
• Do not use machine if remote shutdown switch does not turn it on and off.

100XTR Operator’s Manual
Grounding Instructions
Safety - 19
Grounding Instructions
This product must be grounded. If it should malfunction or breakdown, grounding provides a path of least
resistance for electric current to reduce risk of electric shock. This product is equipped with a cord with
equipment-ground and a grounding plug (shown). The plug must be plugged into an appropriate outlet that
is 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 qualified
electrician to ensure outlet is properly grounded.
To help avoid injury:
• Never modify plug provided with product. If plug will not fit outlet, have a proper outlet installed by a
qualified electrician.
• Never use an adapter.
• Check with a qualified electrician or serviceman if the grounding instructions are not completely
understood, or if in doubt as to whether the appliance is properly grounded.