Catamount Pneumatic Piercing Tool - Amazon Web Services · __ Check tailcone or tailbolts. For 2-1/2” Mole torque tailbolts to 28 ft lb (37 Nm). For 3” and 4-3/8” Mole torque

Operator’s and Maintenance Manual

CatamountPneumatic Piercing Tool

Serial No. 121831 and Higher

Manual PN OM2101v.090128.1

Introduction

This manual explains the proper operation of your machine. Study and understand these instructions thoroughly before operat-ing or maintaining the machine. Failure to do so could result in personal injury or equipment damage. Consult your Hammer-Head Mole dealer if you do not understand the instructions in this manual, or need additional information.

The instructions, illustrations, and specifi cations in this manual are based on the latest information available at time of publica-tion. Your machine may have product improvements and features not yet contained in this manual.

Earth Tool Company LLC reserves the right to make changes at any time without notice or obligation.

Operation and maintenance instructions are included in the Operator’s Manuals provided with the machine.

Additional copies of the manuals are available from your dealer. Use the reorder number on the front cover to order additional manuals.

Copyright © 2009 Earth Tool Co. LLC All rights reservedEarth Tool Co. LLC1300 Capitol Drive

Oconomowoc, WI 53066 USA

Patents - 3Catamount

VERMEER®, VERMEER® Logo, NAVIGATOR™ are registered trademarks of Vermeer Manufacturing Company

HAMMERHEAD MOLE®, ACTIVE HEAD®, and CATAMOUNT™ are trademarks of Earth Tool Company, LLC.

Patents - 4 Catamount

HAMMERHEAD EQUIPMENT LIMITED WARRANTY

EARTH TOOL COMPANY LLC, hereinafter sometimes referred to as ETC warrants each new industrial product of its own manufacture to be free fromdefects in material and workmanship, under normal use and service for one full year after delivery to the owner or 1000 operating hours, whichever oc-curs fi rst. During the warranty period, the authorized selling HammerHead 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 possible liability of Earth Tool Company LLC hereunder is in lieu of all other warranties, express, implied, or statutory, including, but not limited to any warranties of merchantability or fi tness for a particular purpose.

The parties agree that the Buyer’s SOLE AND EXCLUSIVE REMEDY against ETC, whether in contract or arising out of warranties, representations, or defects shall be for the replacement or repair of defective parts as provided herein. In no event shall ETC’s liability exceed the purchase price of the product. The Buyer agrees that no other remedy (including, but not limited to, incidental or consequential loss) shall be available to him. If, during the warranty period, any product becomes defective by reason of material or workmanship and Buyer immediately notifi es ETC of such defect, ETC shall, at its option, supply a replacement part or request the return of the product to its plant in Oconomowoc, Wisconsin. No part shall be returned with-out prior written authorization from ETC, and this warranty does not obligate ETC to bear any transportation charges in connection with the repair or replacement of defective parts. Earth Tool Company LLC will not accept any charges for labor and/or parts incidental to the removal or remounting of parts repaired or replaced under this Warranty.

This Warranty shall not apply to any part or product which shall have been installed or operated in a manner not recommended by ETC nor to any part or product which shall have been neglected, or used in any way which, in ETC’s opinion, adversely affects its performance; nor negligence of proper maintenance or other negligence, fi re or other accident; nor with respect to wear items; nor if the unit has been repaired or altered outside of an ETC authorized dealership in a manner of which, in the sole judgment of ETC affects its performance, stability or reliability; nor with respect to batteries which are covered under a separate adjustment warranty; nor to any product in which parts not manufactured or approved by ETC have been used, nor to normal maintenance services or replacement of normal service items. Equipment and accessories not of our manufacture are warranted only to the extent of the original Manufacturer’s Warranty and subject to their allowance to us, if found defective by them.

ETC reserves the right to modify, alter, and improve any products or parts without incurring any obligation to replace any product or parts previously sold with such modifi ed, altered, or improved product or part.

No person is authorized to give any other Warranty, or to assume any additional obligation on ETC’s behalf unless made in writing, and signed by an offi cer of ETC.

EARTH TOOL COMPANY, LLC.Oconomowoc, Wisconsin USA

Table of Contents - 5Catamount

Table of ContentsIntroduction .................................................................................2

HammerHead Limited Warranty ................................................4

Receiving and Delivery Report .................................................7 Dealer Prep ..............................................................................7 Review of Operation ................................................................7 Dealer or Customer Information ........................................8

Identifi cation Numbers - Record ...............................................9

Safety Messages ..................................................................10-11 Safety Decals .......................................................................11-21 Inspecting Safety Decals ..................................................11-21

How the Catamount Piercing Tool Works ..........................20-25

Oiler Controls .......................................................................30-27 Air Valve ............................................................................30-27 Tool Oiler ...........................................................................30-27 Pressure Relief ..................................................................30-27 Oil - Check and Add .........................................................30-28 Oiler - Adjust .....................................................................30-28

Operating the Tool ...............................................................32-29 Rear Whip Hose ................................................................32-29 Vari-Pitch Level .................................................................32-29

Maintenance - 120 Service Hours or 6 Months .................35-31 Striker Wear Rings - Check ..............................................35-31 Valve Wear Ring - Check ..................................................35-31

Maintenance - 200 Service Hours or Yearly .......................37-33 Disassemble .....................................................................37-33 Striker - Inspect ................................................................37-34 Valve - Inspect/Replace ....................................................37-36 Valve Ring - Inspect/Replace ...........................................37-36 Control Stem and Isolator - Inspect ..................................37-39 2.5” Catamount Piercing Tool - Assemble ........................37-41

Maintenance - As Required ................................................40-47

Maintenance - 120 Service Hours or 6 Months .................55-49 Striker Wear Rings - Check ..............................................55-49 Valve Wear Ring - Check ..................................................55-49

Maintenance - 200 Service Hours or Yearly .......................57-51 Disassemble .....................................................................57-51 Striker - Inspect ................................................................57-52 Valve - Inspect/Replace ....................................................57-54 Valve Ring - Inspect/Replace ...........................................57-54 Control Stem and Isolator - Inspect ..................................57-57 3” Catamount Piercing Tool - Assemble ...........................57-59


Table of Contents - 6 Catamount

Table of ContentsMaintenance - 120 Service Hours or 6 Months .................65-67 Striker Wear Rings - Check ..............................................65-67 Valve Wear Ring - Check ..................................................65-67

Maintenance - 200 Service Hours or Yearly .......................67-51 Disassemble .....................................................................67-69 Striker - Inspect ................................................................67-71 Valve - Inspect/Replace ....................................................67-73 Valve Ring - Inspect/Replace ...........................................67-73 Control Stem and Isolator - Inspect ..................................67-76 4-3/8” Catamount Piercing Tool - Assemble .....................67-78


Troubleshooting ...................................................................75-86 Tool Will Not Start ..............................................................75-86 Tool Will Not Reverse Direction .........................................75-87 Tool Runs But Will Not Move In Hole ................................75-87 Tool Cycles Fast and Seems Low on Power .....................75-88 Tool Slows Down During Long Bores ...............................75-88 Tool Runs But is Low on Power .........................................75-88

Specifi cations ......................................................................80-90 Lubricants .........................................................................80-90 HammerHead Mole Oil ...............................................80-90 HammerHead Biodegradable Oil ...............................80-90 HammerHead Mole Winter Oil ....................................80-90

General Specifi cations ........................................................80-91

Receiving and Delivery Report - 7Catamount

Receiving and Delivery Report

DEALER PREP

Check or perform the following:

__ Check tailcone or tailbolts. For 2-1/2” Mole torque tailbolts to 28 ft lb (37 Nm). For 3” and 4-3/8” Mole torque tailbolts to 35 ft. lb. (47 Nm.).

__ Check for foreign material around the hose connection at the tool and exhaust ports.

__ Check for foreign material in the hose and around the hose coupler.

__ Check forward and reverse valve for proper function.

__ Check internal striker by tipping tool back and forth. The striker should slide freely.

__ Check the condition of the decals.

REVIEW OF OPERATION

Review and demonstrate with the customer the various aspects of tool operation:

__ Overall explanation of how HammerHead Mole pneumatic boring tool works.

__ HammerHead Mole safety measures.

__ Preparing the HammerHead Mole boring tool for operation.

Receiving and Delivery Report - 8 Catamount

Dealer or Customer Information

Dealer Owner

Address Address

City City

State / Province State / Province

Zip / Postal Code Zip / Postal Code

Country Country

Receiving and Delivery Report - 9Catamount

IDENTIFICATION NUMBERS - RECORD

Machine Model Number ___________________________________

Machine Serial Number ___________________________________

This page intentionally left blank.

Safety Messages 10 - 11 Catamount

Section 10: Safety MessagesGeneral safety messages appear in this Safety Messages section. Specifi c safety messages are located in appropriate sections of the manualwhere a potential hazard may occur if the instructions nor procedures are not followed.

UNDERSTANDING SAFETY ALERT SYMBOL

This is the safety alert symbol. This symbol placed on your machine or in the manual is used to alert you to the potential for bodily injury of death.

UNDERSTANDING SIGNAL WORDS

A signal word “DANGER”, “WARNING”, or “CAUTION” is used with the safety alert symbol.

Safety signs with signal word DANGER, WARNING, or CAUTION are located near specifi c haz-ards.

DANGER - Imminent hazards which, if not avoided, will result in serious personal injury or death.

WARNING - Potential hazards or unsafe practices which, if not avoided, could result in serious personal injury or death.

CAUTION - Potential hazards or unsafe practices which, if not avoided, could result in minor per-sonal injury or product or property damage.

10 - 12 Safety Messages Catamount

READ, UNDERSTAND, AND FOLLOW INSTRUCTIONS

Do not operate the machine unless the instructions in the following manuals have been carefully read and under-stood.

• This HammerHead Mole Operator’s Manual.

• Air Compressor Manual.

Read and understand all safety messages in this manual and on your machine safety decals.

Safety decals located on your machine contain important information that will help you operate your equipment safely. Keep safety decals in good condition. Replace missing or damaged safety decals.

Allow only responsible, properly instructed individuals to operate the machine. Carefully supervise inexperienced operators.


CALL YOUR ONE-CALL SYSTEM FIRST

WARNING: Electricity or gas explosion can kill. Laser light in cut cable can result in eye damage. Locate utilities before drilling. Call 811 or 1-888-258-0808 (U.S. or Canada) or local utility companies or national regulating authority.

Before you start any digging project, don’t forget to call the local One-Call system in your area and any utility company that does not subscribe to the One-Call system. For areas not represented by One-Call Systems International, contact the appropriate utility companies or national regulating authority to locate and mark the underground installations. If you don’t call, you may have an accident, suffer injuries, cause interruption of services, damage the environment, or experience job delays.

The One-Call representative will notify participating utility companies of your proposed digging activities. If you are in the U.S. or Canada, and do not know the number for the local One-Call representative in your area, you can dial the North America One-Call number 1-888-258-0808 for this information. Utilities will then mark their underground facilities by using the following international marking codes:

Red..............................................................Electric Green/Brown.................................................Sewer

Yellow....................................Gas, Oil or Petroleum White.....................................Proposed Excavation

Orange..................Communication, Telephone, TV Pink.........................................................Surveying

Blue...................................................Potable Water


UNDERGROUND UTILITY CONTACT

WARNING: Contact with buried utilities can cause death or serious injury. • Cut electric cables can shock or electrocute. • Ruptured gas lines can cause fi re or explosion. • Laser light from cut fi ber optic cables can cause serious eye damage.Before excavating or drilling, contact the local One-Call system and any utility company that does not sub-scribe to the One-Call System, to locate all buried utilities in and around the proposed excavation or bore.

OSHA CFR 29 1926.651 requires that the estimated location of underground utilities be determined before beginning the excavation or under-ground drilling operation. When the actual excavation or bore approaches an estimated utility location, the exact location of the underground instal-lation must be determined by a safe, acceptable and dependable method. If the utility cannot be precisely located, it must be shut off by the utility company.

Before excavating or boring, contact the One-Call System to locate all buried utilities in and around the bore path.

• Select a boring path that will not intersect buried utilities.

• Never bore on a path toward electric or gas lines.

• If the utility cannot be precisely located, have the utility company shut it off before starting any underground work.


PERSONAL PROTECTION

Wear required personal protective equipment.

Wear close fi tting clothing and confi ne long hair.

Avoid wearing jewelry, such as rings, wristwatches, necklaces, or bracelets.

Always wear:

• Safety glasses• Work shoes• Hard hat• High visibility clothing when working near traffi c (safety vest)• Hearing protection

CHECK LAWS AND REGULATIONS

Know and obey all Federal, State, and local laws and regulations that apply to your work situation.

DO NOT WORK IN TRENCH

Do not work in trench with unstable sides which could cave in. Specifi c requirements for shoring or sloping trench walls are available from several sources including federal and state O.S.H.A. Offi ces. Be sure to contact suitable authorities for these requirements before working in the trench.


Keep Spectators Away From MachineKeep all spectators and other workers away from the machine and work area while in operation

WORK IN VENTILATED AREA

Exhaust fumes can be fatal.

If operating the machine in a closed area, remove the exhaust fumes with an exhaust pipe extension to the outside


KEEP MACHINE IN GOOD CONDITION

Be sure the machine is in good operating condition and that all safety devices are installed and functioning properly.

Visually inspect the machine daily before starting the machine. Refer to the daily pre-starting inspection section.

Make no modifi cations to your equipment unless specifi cally recommended or requested by Vermeer Manufacturing Company.

Confi ned Space Regulation

Do not work in a confi ned space, such as a sewer, until requirements are met to ensure a hazard free envi-ronment. Specifi c requirements for confi ned space entry are available from federal and state OSHA offi ces.


CLEAR WORK AREA

Clear the work area of all objects that might interfere with the proper operation of the tool or hoses. Avoid placing tools or other objects where they can fall into the boring pit.

HANDLING THE BORING TOOL

To avoid back injury, use proper lifting technique. Lift with your legs - not you back!

CHECK HARDWARE

Ensure all airline couplings are tightened and secured to eliminate the chance of accidental uncoupling. Use hose con-nection retaining devices such as locking rings, clips, pins, chains, or cables.

CHECK AIR COMPRESSOR

Be sure the air compressor is securely parked at a safe distance from the excavation pit to prevent pit cave-in. Chock the wheels to prevent the compressor from rolling or falling into the pit.

Maximum air pressure that can be delivered to the tool is 110 psi (7.6 bar). Do not exceed this pressure or damage to the tool, thereby voiding the tool warranty, or personal injury may result.


PRECAUTIONS DURING OPERATION

Two people are required to operate the boring tool. One person should always be outside the excavation pit and in control of the air supply to the tool in case of an emergency. The boring tool operator must monitor the tool to be sure that the air supply hose does not create an unsafe condition around the pit.

Eye protection is necessary when using the boring tool. Avoid looking into the bore hole while the boring tool is in use. High pressure exhaust can eject dirt, stones, or other materials. Be careful when blowing out the hose. Aim the hose away from yourself and other persons.

If the tool runs but does not move forward, turn off the air supply. Check to ensure the tool is not in contact with a gas line, waterline, electric line, or some other underground obstruction that can be damaged or cause personal injury.

Do not override any safety controls on the tool or any support machinery.

Shut down the unit at the fi rst sign of malfunction or hazardous condition.

Do not disconnect the air supply without fi rst shutting off the air valve. Serious injury may result from the air under high pressure or from uncon-trolled hose movement.

DURING SERVICE

Read and follow the service instructions in this manual before servicing the tool.

Shut off the air supply valve and disconnect the air line before servicing the tool.

Use only authorized parts for repair or replacement. These replacement parts, including bolts, are specifi ed in this manual.

Check the air supply hose periodically for damage to the hose or fi ttings. Never use the boring tool with damaged or worn air lines or fi ttings. This will minimize chances or air line breakage while in use.


Check and tighten loose hose clamps and clamp bolts regularly.

Do not use a torch or welder on the boring tool. Applying heat may damage critical parts of the tool. Heating parts of the tool may alter the compo-nents strength and result in premature failure or personal injury.

When the tailcone and rear anvil are removed, be careful when elevating the tool. The heavy striker inside the tool body may slide out.

WARNING: Failure to follow any of the preceding safety instructions or those that follow within this manual, could result in serious injury or death. This manual is only to be used for those purposes for which it was intended as explained in this Operator’s Manual.

Safety Decals 11 - 21 Catamount

Section 11: Safety DecalsGeneral safety messages appear in this Safety Messages section. Specifi c safety messages are located in appropriate sections of the manualwhere a potential hazard may occur if the instructions nor procedures are not followed.

INSPECTING SAFETY DECALS

Safety decals located on your machine contain important and useful information that will help you operate your equipment safely.

To assure that all decals remain in place and in good condition, follow the instructions given below:

• Keep decals clean. Use soap and water - not mineral spirits, abrasive cleaners, or other similar cleaners that will damage the decal.

• Replace any damaged or missing decals except the decal (Vermeer) located on the tool body. When attaching decals, the temperature of the mounting surface must be at least 40° F (5° C). The surface must also be clean and dry.

• When replacing a machine component with a decal attached, replace the decal also.

• Replacement decals can be purchased from your Vermeer equipment dealer.

11 - 22 Safety Decals Catamount

Safety Decals 11 - 23 Catamount

11 - 24 Safety Decals Catamount

How it Works 20 - 25 Catamount

Section 20: How the Catamount Piercing Tool WorksThe Active Head Power Port tools use pneumatic power to drive the striker inside the tool forward at a very high velocity. The striker then impacts the bit shaft at the front of the tool driving only the bit shaft forward into the soil. As the striker travels forward, ports in the rear of the striker pass by the valve opening an air passage to the front of the tool. This allows the air to be redirected and push the striker towards the rear of the tool. Before the striker has a chance to hit the rear anvil, the striker passes the ports again and redirects the air, forcing the striker forward again. The striker travels forward again striking the anvil in the nose of the tool and simultaneously driving the body forward and resetting the bit shaft.

The Power Port Valve feature of the tool provides a 1/4 turn of the air supply hose to change the direction of the tool. Before the direction of the tool is changed, the air supply to the tool must be shut off.

When the tool is placed into reverse, the valve timing is changed so that the forward stroke of the striker becomes shorter and the reverse stroke becomes longer. This allows the striker to impact the rear anvil and not the front anvil propelling the tool in the reverse direction.


Oiler Controls 30 - 27 Catamount

Section 30: Oiler ControlsAIR VALVE

Position (1)(shown).............................................................................off

Position (2) parallel to valve body......................................................on

Tool speed is variable; the farther the handle is turned toward (2), the faster the speed of the striker.

TOOL OILER During operation, the oiler unit continuously lubricates the air power tool.

IMPORTANT: When operating the tool for the fi rst time, add 1/2 oz (15 cc) of oil directly to thetool whip hose to provide lubrication during start-up.

PRESSURE RELIEF

Upon closing the ball valve (3) the oiler stops oiling and the tank is depressurizedallowing for fi ll cap removal. All of the air must be drained out of the airhose before removing thefi ll cap.

• at the end of each use.

• before adding oil to the reservoir.

• before disconnecting hoses.

3

2

1

30 - 28 Oiler Controls Catamount

OIL - CHECK AND ADDStep 1: Turn off air supply. Allow air in hose to bleed out before removing fi ll plug.

Step 2: Remove fi ll plug (4) and check/add oil (refer to Specifi cations Page 80-90.)

IMPORTANT: Do not overfi ll the reservoir. The oiler requires a small air space to pressurize the oiler to force the oil into the air line.

Oiler - AdjustScrew (5) (inside the oiler) controls the amount of oil supplied to the tool. Remove the fi ll plugand use a screwdriver to turn the screw to adjust the rate of oil delivery.

Fully CW ................................................................................................................. closed3/8 Turn CCW from closed ...................................................... lowest recommended rate1 full turn CCW from closed ...................................................highest recommended rate

To adjust:

Step 1: Turn off air supply.

Step 2: Remove fi ll plug (4) and turn the adjustment screw (5) with a slotted screwdriver.

Step 3: Use the chart below for proper settings for each particular size tool.

NOTE: It may take up to 30 minutes before a setting change is noticed in the tool.

Tool Size Turns CCW from Closed

2-1/2” (63 mm) 7/8

3” (75 mm) 7/8

4-3/8” (111 mm) 1/2

5

6

4

NOTE: The adjustment screw has been set at the factory. To reset or adjust the oiler, turn adjustment screw clockwise until closed then turn screw counterclock-wise 1 full turn. This setting is suitable for 1-3/4” to 3” tools. Larger tools 4” - 5-5/8” will need to have the setting at 1/2 turn CCW from closed. The hash marks (6) represent 1/16 of a turn. For example to adjust the oiler to 7/8 open, fully close the screw then open 1 full turn. Note where the slot in the adjustment screw is and then close the screw 2 hash marks. The oiler is now set to 7/8 open.

Operating the Tool 32 - 29 Catamount

Section 32: Operating the ToolRear Whip Hose

Turning the whip hose (1) controls which direction the tool travels.

Clockwise .................................................................................... forward travel

Counterclockwise ........................................................................ reverse travel

IMPORTANT: Shut off the air supply to the tool before changing directions. Failure to do so will damage the valve assembly on the Catamount Piercing Tool.

The Power Port feature of the tools provide only a 1/4 turn to change direction from FORWARD to REVERSE or from REVERSE to FORWARD.

Vari-Pitch LevelUse the level to set the boring angle of the tool.

32 - 30 Operating the Tool Catamount

Level

The right edge of the bubble indicates the slope or pitch. The dashed line bubble indicates “level”. The solid bubble indicatesa 2% down pitch.

Maintenance 35 - 31 Catamount

2-1/2” MO

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Section 35: Maintenance - 120 Service Hours or 6 Months

STRIKER WEAR RINGS - CHECK

Striker rings may go through an initial break-in or seating period during the fi rst few initial uses. After this initial break in period, you may notice slightly diminished performance. If this occurs, remove the striker following the instructions given on pages 37-33. Do not replace the striker rings at this time but do trim the striker rings so that the ring gap is .115 - .135” (2.9 - 3.4 mm).

VALVE WEAR RING - CHECK

Instructions for checking the wear rings are included in the Maintenance - 150 Service Hours sub section.

• Follow the instructions in A - Catamount Tool - Disassembly, page 37 - 33.

• Proceed to Striker - Inspect, page 37 - 34, and Valve Inspect, page 37 - 36, instructions to check the wear rings and o-rings.

• Follow the applicable instructions in Catamount Piercing Tool - Assemble, page 37 - 41.


2-1/2” MO

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Maintenance 200 Hours 37 - 33 Catamount

2-1/2” MO

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Section 37: Maintenance - 200 Service Hours or Yearly

A. Disassemble

Step 1: Thoroughly clean the tool.

Step 2: Place the tool on a clean surface. Lay it fl at or with the nose down slightly to prevent the striker from falling out when the inner assembly is removed.

Step 3: Turn the rear whip hose (1) fully counterclockwise to REVERSE. Clamp the body (2) in a chain vise. Remove the external hose using a 1-1/16” wrench on fl ats (3). Plug fi ttings to prevent debris from entering the hoses.

Step 4: Use a 9 mm Hex Deepwell socket to loosen each bolt (4) fi ve or six turns.

Step 5: Rotate the tailcone counterclockwise to unthread the inner assembly from the body. It will take approximately 30 full turns.

Step 6: Remove the inner assembly (5) from the body.

Step 7: Tip the body and remove the striker (6). Be careful not to damage the body threads.

6

2

54

1

3

37 - 34 Maintenance 200 Hours Catamount

2-1/2” MO

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B. STRIKER INSPECT

Step 1: Inspect the front (1) and rear impact surfaces of the striker. If more than 50% of either surface is heavily chipped or cracked, replace the striker. Inspect hole for debris with fl ashlight.

Step 2: Check striker ring wear with a straightedge. If there is no space between the straightedge and the wear pad, replace the rings.

To replace ring: a. Clean the ring groove (2).

b. Oil all surfaces of the ring with HammerHead Mole Oil.

c. Install the ring (3). If the ring is over expanded, take the ring off, overlap the ends to make a tighter diameter, and then reinstall.

NOTE: The striker wear pads have been designed so the tool will operate with worn out rings. Although the tool will run, steel to steel contact will result in increased friction and internal wear, as well as shorten body and striker life.

1

2

3


2-1/2” MO

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Step 3: Check the end gap (4) of each ring fully seated in the striker ring groove. The gap should be .115 - .135” (2.9 - 3.4 mm). If it is less, remove the ring and trim enough off one end to ensure the proper gap.

IMPORTANT: Wear rings should be checked after the fi rst 120 hours of use, fi rst clean the ring and ring groove. Check ring gap and wear.

Step 4: Use a fl ashlight to inspect the striker valve bore for rust, debris and burrs. If needed, clean the bore with a soft abrasive, such as a Scotch Brite scouring pad on a drill extension.

IMPORTANT: The use of hard abrasives, such as a wire brush or emery cloth, can damage the bore by removing metal, creating a rough surface.

Step 5: Inspect the bore again for burrs. Burrs and nicks can accelerate valve wear. If burrs are still there, replace the striker.

4


2-1/2” MO

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C. Valve - Inspect/Replace

Step 1: Check for sand or other debris embedded in the ring. If any is found, replace the ring.

Step 2: Check the rings for scratched. Light scratching in the ring is acceptable. Replace a heavily scratched or scored ring.

Step 3: Check the valve ring wear with a straightedge. If there isn’t any space between the straightedge and the metal edge of the ring retainer (insert A) replace the ring.

IMPORTANT: Valve ring wear should be checked initially after 200 hours of use. First clean the ring and ring groove. Check side gap and wear. If it is over .020” (.5 mm) replace the valve ring.

NOTE: Valve groove wear will accelerate if the tool is run dirty or without oil.

Step 4: Replace the valve if there is visible damage (cracked, smashed or mushroomed edges/detentes). Remove the control stud using a 5/32” hex key and slide the old valve off the control stem. Install the new valve and control stud and torque to 50 in lb (2.2 Nm).

D. VALVE RING - INSPECT/REPLACE

Step 1: Remove valve ring from valve by prying the valve out of the ring groove (be careful not to damage the ring groove) or by cutting the ring with a utility knife.

Step 2: Clean the valve ring groove to make sure it is free from contaminants or debris.


2-1/2” MO

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Step 3: Place the new valve rings in a cup of warm 100° F (38° C) (not hot) water for approximately 1 min to soften the valve ring.

Step 4: Stretch the valve ring over the end of the valve and into the valve ring groove.

Step 5: The valve ring will now be stretched and fi t very loosely in the valve ring groove.


2-1/2” MO

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Step 6: Install the valve ring compressor tool over the end of the valve and valve ring.

Step 7: Tighten the hose clamp compressing the valve ring into the valve ring groove.

Step 8: Leave the valve ring compressor tool on the valve for a minimum of two minutes.

Step 9: Repeat the proccess for the remaining valve ring.


2-1/2” MO

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E. Control Stem and Isolator - InspectStep 1: Remove valve by removing the control stud (1) and following the instruction given on page 36 .

Step 2: Slide the control sleeve (2) over the control stem (3). Inspect the control sleeve and replace if any nicks, cuts, tears, twists or other deformities are found.

Step 3: Slide the rear anvil (4) off the isolator halves (5).

Step 4: Inspect the face of the rear anvil (6) which contacts the striker. If more than 50% of the surface is heavily chipped or cracked, replace the anvil.

Step 5: Thoroughly clean the rear anvil. Use an approved air nozzle and carefully blow out the air ports and bore.

3 2

1

5 46


2-1/2” MO

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Step 6: Inspect grooves (7) in isolator halves. If the material is torn, replace the isolator halves.

Step 7: Inspect the control stem (8) for any damage such as damaged control stud threads, damaged threads where the external whip attaches, bent control stem. If any of these problems are apparent, replace the control stem.

Step 8: Measure the length of the control stem according to the locations shown in the drawing below. The length should be 11.78” - 11.82” (299.2 mm - 300.2 mm). If the measument is outside this measurement range, replace the control stem.

7


2-1/2” MO

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F. 2.5” Catamount Piercing Tool - AssembleStep 1: Thoroughly clean and inspect the bore of the body assembly. Coat the inside of the body with Hammerhead Mole oil to provide initial start up lubrication.

Step 2: The front of the striker has a small hole (1) which the supply tube (2) located inside the front of the body slides into.

Step 3: With the tool body horizontal or slightly nose down, carefully slide the striker into the body. Apply a small amount of Hammerhead Mole oil to the striker rings prior to inserting the striker into the body. The tapered end of the striker goes into the body fi rst. If the striker stops short of the front anvil, it may be necessary to spin the striker to allow the supply tube to center itself inside the receiving hole in the front of the striker. When properly aligned, the striker will slide completely inside the body assembly, and impact the front anvil with a steel to steel sound. Do not force the striker into the body. Failing to do so will damage the straw located in the nose of the tool body.

21


2-1/2” MO

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Step 4: Apply a thin coat of anti-sieze to the inside of the isolator halves and the mating surfaces of the control stem (3). Install both halves onto the control stem.

Step 5: Slide the rear anvil onto the control stem and over the isolator halves. Align the larger holes (4) in the isolator with the threaded holes in rear anvil (5).

Step 6: Apply a light coat of HammerHead Mole oil to the outside of the control stem and slide the control sleeve over the end of the control stem. Line up the notches in the control sleeve (6) with the corresponding notches in the rear anvil (7). Make sure the notch in the control sleeve slide completely into the rear anvil.

3

54

6

7


2-1/2” MO

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Step 7: Install the Valve assembly onto the end of the control stem. Be sure to line up the notches in the end of the control sleeve (8) with the notches in the end of the valve (9).

Step 8: Apply a this coat of anti-seize on the threads of the control stud and thread into the ferule on the end of the control stem (10). If the threaded hole in the control stem is not visible through the slot in the valve, remove the valve, turn it 180° and reinstall the valve. Torque the control stud to 50 in lb (5.6 Nm).

Step 9: Install the tailcone over the isolator end of the control stem. Align the notch in the rear anvil (11) with the notch in the tailcone (12). The tailcone will only fi t correctly when the notches are lined up. Insert the 4 tailbolts and fi nger tighten.

10

9

8

12

11


2-1/2” MO

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Step 10: Apply a light coat of Hammerhead Mole oil to the valve and valve rings and slide the valve/control stem assembly into the end of the tool (13) and into the bore of the striker.

Step 11: Prior to threading the rear anvil (14) into the end of the body assembly (15), coat the threads of the rear anvil with anti-sieze. Thread the rear anvil into the body assembly completely. Hand tighten the rear anvil to the back of the body.

Step 12: Imobilize the body assembly and torque the tailbolts to 28 ft lb (38 Nm)

13

15

14


2-1/2” MO

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Step 13: Thread the external whip into the rear of the control stem (16) being careful not to cross-thread the fi tting.

Step 14: Either using a long 1/2” hex socket (17) placed through the inside of the external whip or a 1-1/16” wrench on the fl ats of the front ferule (18), torque the external whip to 60 ft lb (82 Nm).

Step 15: Install and torque the coupling on the end of the external whip hose (19) to 90 ft lb (122 Nm). Do not use pipe tape or other thread sealants on the threads.

Step 16: Unclamp the piercing tool and tilt the nose of the tool up and down several times to distribute the lubrication throughout the tool and to make sure that the striker slides freely back and forth.

16

1718

19


2-1/2” MO

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Maintenance - As Required 40 - 47Catamount

2-1/2” MO

LE

Section 40: Maintenance - As RequiredSTORAGE

Pour 1 oz (30 cc) of HammerHead Mole Oil into the end of the external whip hose. Oil should be added with the tool’s nose down. Wait 30 seconds for the oil to get into the tool. Tip the tool back and forth 20 to 30 times while rotating the tool to disperse the oil. Tape or cap the tool whip hose to prevent dirt and sand from entering the tool.


2-1/2” MO

LE


3” MO

LE

Section 55: Maintenance - 120 Service Hours or 6 MonthsSTRIKER WEAR RINGS - CHECK

Striker rings may go through an initial break-in or seating period during the fi rst few initial uses. After this initial break in period, you may notice slightly diminished performance. If this occurs, remove the striker following the instructions given on pages 57-52. Do not replace the striker rings at this time but do trim the striker rings so that the ring gap is .115 - .135” (2.9 - 3.4 mm).




• Proceed to Striker - Inspect, page 57 - 52, and Valve Inspect, page 57 - 54, instructions to check the wear rings.

• Follow the applicable instructions in Catamount Piercing Tool - Assemble, page 57-59.


3” MO

LE

Maintenance 200 Hours 57 - 51Catamount

3” MO

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A. Disassemble


Step 2: Place the tool on a clean surface. Lay it fl at or with the nose down slightly to prevent the striker from falling out when the inner assembly is removed.

Step 3: Turn the rear whip hose (1) fully counterclockwise to REVERSE. Clamp the body (2) in a chain vise. Remove the external hose using a 1-1/16” wrench on the fi tting (3). Plug fi ttings to prevent debris from entering the hoses.

Step 4: Use a 3/8” (9.5 mm) 12 point socket to loosen each bolt (4) fi ve or six turns.

Step 5: Rotate the tailcone counterclockwise to unthread the inner assembly from the body. It will take approximately 30 full turns.



1

3

6

2

54


3” MO

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B. STRIKER INSPECT

Step 1: Inspect the front (1) and rear impact surfaces of the striker. If more than 50% of either surface is heavily chipped or cracked, replace the striker. Inspect hole for debris with fl ashlight.






1

2

3


3” MO

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Step 5: Inspect the bore again for burrs. Burrs and nicks can accelerate valve skirt wear. If burrs are still there, replace the striker.

Step 6: Check the valve bore of the striker with a snap gauge. Take measurements 2” (5 cm) into the bore at the 12 o’clock and 3 o’clock positions. If the average bore diameter is more than 1.459” (37 mm), replacement of the striker will improve performance.

4


3” MO

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Step 4: Replace the valve if there is visable damage (cracked, smashed or mushroomed edges/detents). Remove the control stud using a 5/32” hex key and slide the old valve off the control stem. Install the new valve and control stud and torque to 50 in lb (2.2 Nm).


Step 1: Remove valve ring from valve by prying the valve out of the ring groove (be careful not to damage the ring groove) or by cutting the ring with a utility knife.

Step 2: Clean the valve ring groove to make sure it is free from contaminents or debris.


3” MO

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Step 3: Place the new valve rings in a cup of warm 100° F (38° C) (not hot) water for approximately 1 min to soften the valve ring.

Step 4: Stretch the valve ring over the end of the valve and into the valve ring groove.



3” MO

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Step 6: Install the valve ring compressor tool over the end of the valve and valve ring.


Step 8: Leave the valve ring compressor tool on the valve for a minimum of two minutes.

Step 9: Repeat the proccess for the remaining valve ring.


3” MO

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D. Control Stem and Isolator - InspectStep 1: Remove valve by removing the control stud (1) and following the instruction given in on page 54 .





3 2

1

5 46


3” MO

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Step 7: Inspect the control stem (8) for any damage such as damaged control stud threads, damaged threads where the external whip attaches, bent control stem. If any of these problems are apparent, replace the control stem.

Step 8: Measure the length of the control stem according to the locations shown in the drawing below. The length should be 12.125” - 12.175” (307.9 mm - 309.2 mm). If the measument is outside this measurement range, replace the control stem.

7

12.125” - 12.175”


3” MO

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E. 3” Catamount Piercing Tool - AssembleStep 1: Thoroughly clean and inspect the bore of the body assembly. Coat the inside of the body with Hammerhead Mole oil to provide initial start up lubrication.


Step 3: With the tool body horizontal or slightly nose down, carefully slide the striker into the body. Apply a small amount of Hammerhead Mole oil to the striker rings prior to inserting the striker into the body. The tapered end of the striker goes into the body fi rst. If the striker stops short of the front anvil, it may be necessary to spin the striker to allow the supply tube to center itself inside the receiving hole in the front of the striker. When properly aligned, the striker will slide completely inside the body assembly, and impact the front anvil with a steel to steel sound. Do not force the striker into the body. Failing to do so will damage the straw located in the nose of the tool body.

21


3” MO

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Step 5: Slide the rear anvil onto the control stem and over the isolator halves. Align the larger holes (4) in the isolator with the threaded holes in rear anvil (5).


3

54

6

7


3” MO

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Step 9: Install the tailcone over the isolator end of the control stem. Align the notch in the rear anvil (11) with the notch in the tailcone (12). The tailcone will only fi t correctly when the notches are lined up. Insert the 4 tailbolts and fi nger tighten.

10

9

8

12

11


3” MO

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Step 11: Prior to threading the rear anvil (14) into the end of the body assembly (15), coat the threads of the rear anvil with anti-sieze. Thread the rear anvil into the body assembly completely. Hand tighten the rear anvil to the back of the body.


13

15

14


3” MO

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Step 14: Either using a long 1/2” hex socket (17) placed through the inside of the external whip or a 1-1/16” wrench on the fl ats of the front ferule (18), torque the external whip to 60 ft lb (82 Nm).

Step 15: Install and torque the coupling on the end of the external whip hose (19) to 90 ft lb (122 Nm). Do Not Use pipe tape or any other threads sealants on the threads.


16

1718

19


3” MO

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Maintenance - As Required 59 - 65Catamount

3” MO

LE




3” MO

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4-3/8” MO

LE

Section 65: Maintenance - 120 Service Hours or 6 MonthsSTRIKER WEAR RINGS - CHECK

Striker rings may go through an initial break-in or seating period during the fi rst few initial uses. After this initial break in period, you may notice slightly diminished performance. If this occurs, remove the striker following the instructions given on pages 67 - 72. Do not replace the striker rings at this time but do trim the striker rings so that the ring gap is .120 - .140” (3.0 - 3.5 mm).




• Proceed to Striker - Inspect, page 67 - 71, and Valve Inspect, page 67 - 73, instructions to check the wear rings.

• Follow the applicable instructions in Catamount Piercing Tool - Assemble, page 67 - 78.


4-3/8” MO

LE


4-3/8” MO

LE


A. Disassemble


Step 2: Place the tool on a clean surface. Lay it fl at or with the nose down slightly to prevent the striker from falling out when the inner assembly is removed. Clamp the body securely in a chain vise to prevent the body from rotating. Use a 1-34”” wrench to loosen the external whip hose.

Step 3: Turn the rear whip hose (1) fully counterclockwise to REVERSE. Plug fi ttings to prevent debris from entering the hoses.

Step 4: Use a 3/8” (9.5 mm) 12 point socket to loosen each bolt (2) fi ve or six turns. There are 7 tailbolts on the 4-3/8” Tool.

Step 5: Rotate the tailcone counterclockwise to unthread the inner assembly from the body. It will take approximately 30 full turns. 3

2

1


4-3/8” MO

LE



3

4


4-3/8” MO

LE

B. STRIKER INSPECT

Step 1: Inspect the front (1) and rear impact surfaces of the striker. If more than 50% of either surface is heavily chipped or cracked, replace the striker. Use a fl ashlight to inspect the hole in the front of the striker for debris.






1

32


4-3/8” MO

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Step 5: Inspect the bore again for burrs. Burrs and nicks can accelerate valve skirt wear. If burrs are still there, replace the striker.

Step 6: Check the valve bore of the striker with a snap gauge. Take measurements 2” (5.1 cm) into the bore at the 12 o’clock and 3 o’clock positions. If the average bore diameter is more than 2.514” (63.9 mm), replacement of the striker will improve performance.

4


4-3/8” MO

LE







Step 4: Replace the valve if there is visible damage (cracked, smashed or mushroomed edges/detentes). Remove the control stud using a 1/4” hex key and slide the old valve off the control stem. Install the new valve and control stud and torque to 90 in lb (10.1 Nm).


Step 1: Remove valve ring from valve by prying the valve out of the ring groove (be careful not to damage the ring groove) or by cutting the ring with a utility knife.

Step 2: Clean the valve ring groove to make sure it is free from contaminants or debris.


4-3/8” MO

LE

Step 3: Stretch the new valve rings by hand to soften them.

Step 4: Place the valve rings in hot water 200° F (93.3° C) for 3 to 5 min.

WARNING: Hot water can scald and cause serious burns. Use caution when removing valve ring from heating source.

Step 5: The valve ring will now be stretched and installed into the valve ring groove.


4-3/8” MO

LE



Step 8: Repeat the process for the remaining valve ring.

Step 9: Leave the valve ring compressor tool on the valve for a minimum of ten minutes or until valve slides freely into the striker bore.


4-3/8” MO

LE

D. Control Stem and Isolator - InspectStep 1: Remove valve by removing the control stud (1) and following the instruction given in on page 73 .





2

3

1

5

4

6


4-3/8” MO

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Step 7: Inspect the control stem (8) for any damage such as the inserts being loose on either end of the control stem, damaged control stud threads, damaged threads where the external whip attaches, bent control stem and incorrect assembled length. If any of these problems are apparent, replace the control stem.

Step 8: Measure the length of the control stem according to the locations shown in the drawing below. The length should be 15.00” - 15.03” (381 mm - 381.8 mm). If the measurement is outside this measurement range, replace the control stem.

7

15.00”/15.03”381 mm / 381.8 mm


4-3/8” MO

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E. 4-3/8” Catamount Piercing Tool - AssembleStep 1: Thoroughly clean and inspect the bore of the body assembly. Coat the inside of the body with Hammerhead Mole oil to provide initial start up lubrication.


Step 3: With the tool body horizontal or slightly nose down, carefully slide the striker into the body. Apply a small amount of Hammerhead Mole oil to the striker rings prior to inserting the striker into the body. The tapered end of the striker goes into the body fi rst. If the striker stops short of completely entering the body, it may be necessary to spin the striker to allow the supply tube to center itself inside the receiving hole in the front of the striker. When properly aligned, the striker will slide completely inside the body assembly. DO NOT FORCE

21


4-3/8” MO

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Step 5: Slide the rear anvil (4) onto the control stem ( 5) and over the isolator halves.


3

5

4

6

7


4-3/8” MO

LE



Step 9: Install the tailcone over the isolator end of the control stem. Insert the 7 tailbolts and fi nger tighten.

10

9

8


4-3/8” MO

LE


Step 11: Prior to threading the rear anvil (12) into the end of the body assembly (13), coat the threads of the rear anvil with anti-sieze. Thread the rear anvil into the body assembly completely. Do not torque the rear anvil against the body assembly or back the rear anvil off 1/8 turn.


11

13

12


4-3/8” MO

LE


Step 14: Use a 1-3/4” wrench on the fl ats of the front ferule (15), torque the external whip to 120 ft lb (163 Nm).


14

15


4-3/8” MO

LE

69 - 84 Maintenance - As Required Catamount

4-3/8” MO

LE




4-3/8” MO

LE


Section 75: TroubleshootingTOOL WILL NOT START

Step 1: Check the compressor for Proper air output (90 - 110 psi or 620 -760 kPa). Improper or low air pressure settings can cause starting problems.

Step 2: Check that full pressure air is available at the tool and that the hoses and fi ttings are of the proper diameter.

Warning: High pressure air can forcefully eject dirt or other materials. Be careful when blowing out the hose. Aim the hose away from yourself and other persons.

Step 3: Follow these restart procedures whil the tool is in the ground.

a. Remove the air supply hose from the oiler to the tool and inject 1/2 oz of oil directly into the hose.

b. Turn the air supply hose into REVERSE if in FORWARD, or into FORWARD in in REVERSE.

c. Connect the supply line to the oiler and snap open the air control valve.

d. If the tool does not start, repeat steps a, b, and c.

Step 4: Take the tool apart and refer to Maintenance - 200 Service Hours or Yearly, in the appropriate corresponding tool section.

Step 5: Check that the internal control stem and external whip hose are free from obstruction.

Step 6: If the tool fails to start after the above steps have been performed, return the tool to your local HammerHead Dealer for inspection.

Maintenance - As Required 75- 87 Catamount

Tool Will Not Reverse DirectionRotate the air hose fully clockwise to FORWARD and then rotate the air hose fully counterclockwise back to REVERSE.

NOTE: The Power Port feature of the tool requires that the air supply to the tool must be shut off completely before attempting to reverse the tool. Air pressure locks the tool in either the forward or reverse directions.

1. If the air supply hose will not turn into the REVERSE position while in the ground, the tunnel may have collapsed on the air supply hose. Turn the air supply hose counterclockwise while the tool is running. The impact action of the tool will help loosen a stuck supply line. This should only be done to free up the air line. The tool will not be able to be turned into REVERSE while the tool is running.

2. Reversing in unstable soil conditions, such as gravel, sand, under trees or watery slick clays, may cause a tool to oscillate or “swim”. A reciprocating hose indicates the tool may be swimming. Reduce air fl ow at the control valve until traction is regained.

IMPORTANT: Ensure all airline couplings are tight and lock collars in place so they don’t come loose while reversing.

3. Check the air supply lines for possible obstructions.

Tool Runs But Will Not Move in HoleStep 1: Check to see if the hose is in FORWARD.

Step 2: If the tool is oscillating back and forth, partially reduce the air fl ow at the oiler valve. Soft or wet ground conditions can cause a tool to loose traction and oscillate.

Step 3: If the tool is unable to break through, reverse the tool and start a new hole away from the obstruction.

IMPORTANT: When shooting a new bore, the operator should move over a distance of 10 times the diameter of the tool or the tool may cross into the previous bore.


TOOL CYCLES FAST AND SEEMS LOW ON POWER

Step 1: Check the valve assembly overall length. An excessive short dimension will cause “fast” cycling with poor progress. Striker stroke is controlled by the valve overall length. Refer to the appropriate Maintenance - 200 Service Hours or Yearly Section for your tool model.

Step 2: Soil conditions are important to tool operation. Dry soil my slow a tools progress. Wet soil will reduce body friction allowing the tool to oscillate, lose traction or swim. Avoid loosing traction by reducing air fl ow at the control valve during the entire operation.

Tool Slows Down During Long BoresStep 1: Perform the striker tip test as follows: The striker should slide from front to back when the body is tipped from horizontal to aproximately 22°. A tool with high striker friction may have ingested dirt and should be taken apart before being shot again.

Step 2: The tunnel behind the tool may have colapsed, restricting air fl ow.

Tool Runs But Is Low on PowerStep 1: Check the compressor for proper air output and pressure.

Step 2: Check that the tool is using oil. (Refer to the Oiler Controls - Section 30)

Step 3: Turn or adjust tool air line. The hose may have become kinked.

Step 4: Check that the supply lines and fi ttings are properly sized.

Step 5: Perform striker tip test.

Step 6: Check Valve assembly overall length. Refer to the appropriate Maintenance - 200 Service Hours or Yearly Section for your tool model.

Step 7: Check valve ring end gap. Refer to the appropriate Maintenance - 200 Service Hours or Yearly Section for your tool model.


80 - 90 Specifi cations Catamount

Section 80: Specifi cationsLUBRICANTS

HAMMERHEAD MOLE OIL

Summer oil with a zinc and paraffi n hydraulic air line additive to reduce friction and inhibit rust (SAE-10W/ISO-22) is recommended for most ap-plications.

HAMMERHEAD BIODEGRADABLE OIL

Biodegradable Synthetic Rock Drill Fluid with anti wear and extreme pressure additives. This formula is safe to use in environmentally sensitive areas, with an operating range of -25° to 200° F (-31° to 93° C)

HAMMERHEAD MOLE WINTER OIL

Winter oil contains a fully synthetic base of ISO Propanol and additives that reduce corrosion, evaporation, and make it compatible with summer oil. Winter oil at full strength will prevent freeze up at temperatures as low as -10° F (-23° C) (ISO-46).

Specifi cations 80 - 91 Catamount

GENERAL SPECIFICATIONS

2-1/2” Catamount 3” Catamount 4-3/8” Catamount

Air Feed Line 616085 616085 616085

Mist Oiler 296273113 296273113 296273113

Diameter 2-1/2” (65 mm) 3” (76 mm) 4-3/8” (111 mm)

Length 49.3” (125.2 cm) 50.6” (128.5 cm) 63.0” (160.0 cm)

Weight 50 lb (23 kg) 67 lb (30 kg) 180 lb (82 kg)

Air Consumption 31 cfm (878 L/min) 32 cfm (906 L/min) 86 cfm (2,435 L/min)

Internal Access Via 4 Tailbolts Via 4 Tailbolts Via 7 Tailbolts

Tailbolt Torque 28 ft lb (38 Nm) 35 ft lb (47 Nm) 35 ft lb (47 Nm)

Valve Retainer 7 ft lb. (9.3 Nm 7 ft lb. (9.3 Nm 7.5 in lb (10.2 Nm)

Pneumatic Fitting Torque 90 ft lb. (120 Nm) 90 ft lb. (120 Nm) 90 ft lb. (120 Nm)

Operating Pressure 110 psi (7.6 Bar) 110 psi (7.6 Bar) 110 psi (7.6 Bar)

Rear Anvil Clamp Load 18k lb. (8.1k kg) 20k lb. (9k kg) 35k lb (15.8k kg)

Reversible 1/4 Turn 1/4 Turn 1/4 Turn

Blows per Minute 385 370 338

92 Revision Catamount

Revision History

Revision Date Pages Description090715.1 07/15/2009 All First Edition Release

Catamount Pneumatic Piercing Tool - Amazon Web Services · __ Check tailcone or tailbolts. For 2-1/2” Mole torque tailbolts to 28 ft lb (37 Nm). For 3” and 4-3/8” Mole torque

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