Hammerhead HG2200AT User manual

TECHNICAL PUBLICATIONS
Operator's
Manual
HG2200/HG2200AT
Issue 2.1
960-1119
Original Instruction

HG2200/HG2200AT Operator’s Manual
Overview - 1
Overview
Chapter Contents
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . 2
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Equipment Modification . . . . . . . . . . . . . . . . . . . . . . 3
Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
• Tracked Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
• Wheeled Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Operator Orientation. . . . . . . . . . . . . . . . . . . . . . . . . 6
• Tracked Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
• Wheeled Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Operating Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
• Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
• Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 8
• Bulleted Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
• Numbered Lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

HG2200/HG2200AT 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
winch unit serial number (1)
engine serial number (2)
j64om002w.eps
12

HG2200/HG2200AT Operator’s Manual
Intended Use
Overview - 3
Intended Use
HammerHead® winches are intended for pedestrian controlled pipe bursting, pipe slitting, slip lining, and
cable pulling. The HG2200 HydroGuide® Winch is a dual capstan design winch with the capacity of
utilizing multiple sizes of wire cable. The HG2200 provides up to 22 tons (20 tonnes) of constant tension
for pipe bursting, pipe slitting, slip lining, and cable pulling.
The unit is designed for operation in temperatures typically experienced in earth moving and construction
work environments. Contact your HammerHead dealer for provisions required for operating in extreme
temperatures. 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.

HG2200/HG2200AT Operator’s Manual
Unit Components
4 - Overview
Unit Components
Tracked Unit
1. Winch
2. Mast
3. Tracks
4. ESID strobe*
5. Wireless remote control lights
6. Stabilizer
7. Downhole unit
*Optional
j64om003w.eps
12
3457 6

HG2200/HG2200AT Operator’s Manual
Unit Components
Overview - 5
Wheeled Unit
1. Winch
2. Mast
3. Tires
4. ESID strobe*
5. Wireless remote control lights
6. Stabilizer
7. Downhole unit
8. Hitch
*Optional
j64om004w.eps
12
346578

HG2200/HG2200AT Operator’s Manual
Operator Orientation
6 - Overview
Operator Orientation
Tracked
1. Front of unit
2. Right side of unit
3. Rear of unit
4. Left side of unit
Wheeled Unit
1. Front of unit
2. Right side of unit
3. Rear of unit
4. Left side of unit
IMPORTANT: Top view of unit is shown.
IMPORTANT: Top view of unit is shown.
j64om001w.eps
1
3
24
j64om005w.eps
1
3
24

HG2200/HG2200AT Operator’s Manual
Operating Area
Overview - 7
Operating Area
Winch
Operator should stand only in the location marked by
number 1.
Tracks
Operator should stand only in the location marked by
number 1.
IMPORTANT: Top view of unit is shown.
IMPORTANT: Top view of unit is shown.
j64om006w.eps
1
j64om007w.eps
1

HG2200/HG2200AT Operator’s Manual
About This Manual
8 - 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.

HG2200/HG2200AT Operator’s Manual
Reporting Safety Defects
Foreword - 9
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. Earth Tool
Company LLC 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.
Reporting Safety Defects
If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you
should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to
notifying The Charles Machine Works, Inc, Attn: Product Safety Coordinator.
If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists
in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become
involved in any individual problems between you, your Ditch Witch dealer, or The Charles Machine Works,
Inc.
To contact NHTSA you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (366-0123 in
Washington, DC area) or write to:
NHTSA
U.S. Department of Transportation
400 7th Street SW (NSA-11)
Washington, DC 20590
You can also obtain other information about motor vehicle safety from the Hotline.

HG2200/HG2200AT Operator’s Manual
10 - Foreword
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.
®

HG2200/HG2200AT Operator’s Manual
Contents - 11
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
9
Safety
machine safety alerts and emergency procedures
13
Controls
machine controls and indicators and how to use them
27
Prepare
procedures for inspecting and classifying the jobsite, planning the installation, and
preparing the jobsite for work
51
Drive
procedures for startup, cold start, driving, and shutdown
63
Transport
procedures for lifting and hauling
67
Burst Pipe
procedures for setting up equipment and performing the pipe replacement
75
Systems and Equipment
bursting string, accessory kit, tooling
87
Complete the Job
procedures for restoring the jobsite and storing equipment
101
Service
service intervals and instructions for this machine including lubrication, replacement
of wear items, and basic maintenance
103
Specifications
machine specifications including weights, measurements, power ratings, and fluid
capacities
129

HG2200/HG2200AT Operator’s Manual
12 - Contents
Support
the warranty policy for this machine, and procedures for obtaining warranty
consideration and training
133
Service Record
a record of major service performed on the machine
135
Appendix
additional information about HammerHead® equipment
137

HG2200/HG2200AT Operator’s Manual
Safety - 13
Safety
Chapter Contents
Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
California Proposition 65 Warning . . . . . . . . . . . . 14
Emergency Procedures . . . . . . . . . . . . . . . . . . . . . 15
• Electric Strike Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
• If an Electric Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
• If a Gas Line is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
• If a Fiber Optic Cable is Damaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
• If Machine Catches on Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Safety Alert Classifications . . . . . . . . . . . . . . . . . . 17
Machine Safety Alerts. . . . . . . . . . . . . . . . . . . . . . . 18

14 - Safety
HG2200/HG2200AT Operator’s Manual
Guidelines
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.
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.
• 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 and safety signs. 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 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
California Proposition 65 Warning
This product may contain chemicals known to the State of California to cause cancer, birth defects, or other
reproductive harm.
• battery posts, terminals, and related accessories
• engine exhaust
• ethylene glycol

HG2200/HG2200AT Operator’s Manual
Emergency Procedures
Safety - 15
Emergency Procedures
Before operating any equipment, review emergency procedures and check that all safety precautions have
been taken.
Electric Strike Description
When working near electric cables, remember the following:
• Electricity follows all paths to ground, not just path of least resistance.
• Pipes, hoses, and cables will conduct electricity back to all equipment.
• Low voltage current can injure or kill. Many work-related electrocutions result from contact with less
than 440 volts.
Most electric strikes are not noticeable, but indications of a strike include:
• power outage
• smoke
• explosion
• popping noises
• arcing electricity
If any of these occur, assume an electric strike has occurred.
Jobsite hazards could cause death or serious injury. Use
correct equipment and work methods. Use and maintain proper safety
equipment.
EMERGENCY SHUTDOWN - Turn ignition switch to stop position or push remote engine stop button (if
equipped).
Electric shock. Contacting electric lines will cause death
or serious injury. Know location of lines and stay away.

16 - Safety
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.
• Warn people nearby that an electric strike has occurred. Instruct them to leave the area and contact
utility.
• Contact utility company to shut off power.
• Do not leave pit until given permission by utility company.
If you suspect an electric line has been damaged and you are out of pit, DO NOT TOUCH ANYTHING.
Take the following actions. The order and degree of action will depend upon the situation.
• LEAVE AREA. The ground surface may be electrified, so take small steps with feet close together to
reduce the hazard of being shocked from one foot to the other.
• Contact utility company to shut off power.
• Do not return to jobsite or allow anyone into area until given permission by utility company.
If you suspect an electric line has been damaged and you are on other piece of equipment, DO NOT
MOVE. Remain on truck or trailer and take the following actions. The order and degree of action will
depend upon the situation.
• Warn people nearby that an electric strike has occurred. Instruct them to leave the area and contact
utility.
• Contact utility company to shut off power.
• Do not return to area or allow anyone into area until given permission by utility company.

HG2200/HG2200AT Operator’s Manual
Emergency Procedures
Safety - 17
If a 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 safely and quickly.
• Remove any ignition source(s), if this can be done safely and quickly.
• Warn others that a gas line has been cut and that they should leave the area.
• Leave jobsite as quickly as possible.
• Immediately call your local emergency phone number and utility company.
• If jobsite is along street, stop traffic from driving near jobsite.
• Do not return to jobsite until given permission by emergency personnel and utility company.
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.

18 - Safety
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
company. California Proposition 65 Warning
This product may contain chemicals known to the State of California to cause cancer, birth defects, or other
reproductive harm.
• battery posts, terminals, and related accessories
• engine exhaust
• ethylene glycol
Emergency Procedures
Before operating any equipment, review emergency procedures and check that all safety precautions have
been taken.
Electric Strike Description
When working near electric cables, remember the following:
• Electricity follows all paths to ground, not just path of least resistance.
• Pipes, hoses, and cables will conduct electricity back to all equipment.
• Low voltage current can injure or kill. Many work-related electrocutions result from contact with less
than 440 volts.
Most electric strikes are not noticeable, but indications of a strike include:
Jobsite hazards could cause death or serious injury. Use
correct equipment and work methods. Use and maintain proper safety
equipment.
EMERGENCY SHUTDOWN - Turn ignition switch to stop position or push remote engine stop button (if
equipped).
Electric shock. Contacting electric lines will cause death
or serious injury. Know location of lines and stay away.

HG2200/HG2200AT Operator’s Manual
Emergency Procedures
Safety - 19
• power outage
• smoke
• explosion
• popping noises
• arcing electricity
If any of these occur, assume an electric strike has occurred.