American Augers DD 100, DD 140 Directional Drill Instruction Manual

DD-100™/DD-140™ Directional Drill
Operation & Safety
Instruction Manual
WARNING
Unsafe use of this equipment could result in serious injury or death. This manual contains
important instructions for the safe operation and recommended maintenance of your directional drill. All who operate the directional drill must carefully read and understand this manual
before starting the machine. Keep this manual available both as a reminder for your experienced operator and as a training aid for your new staff. Replacement manuals are available by
calling American Augers.
A Division Of American Augers, Inc.
INTRODUCTION
American Augers was established in 1970 to provide a full line of modern equipment for the trenchless
excavation construction industry. The company is organized in three product divisions to serve the full range
of trenchless technology. American Directional Drill
is the division producing the leading line of Horizontal Directional Drills. We are proud of our equipment
and the job it can do. We encourage you to call us for
any and all of your drilling needs.
Every effort has been made to cover adequately the
operation of the DD-100™ and DD-140™ directional
drills. Specifications are subject to change without notice or obligation to retrofit units already in the field.
This manual will be constantly updated to remain current with new operations. Please call if there are areas
requiring further explanation or instruction. Material
contained herein may not be reproduced in whole or in
part without the express written permission of American Augers Inc., the Innovative Leader in the Trenchless
Industry.
Machine Serial Number
Engine Serial Number
Location of Machine SN Plate
Location of Engine SN Plate
DD-100 and DD-140 are trademarks of American Augers, inc.
Copyright © 2001 by American Augers
Part Number: DD100140BOOK-01 November 2001
Page 2
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
3.1 STORAGE
3.1.1
MINIMUM STORAGE SPACE
REQUIRED
3.1.1.1 PROTECTION WHILE IN
STORAGE
3.1.2
STORAGE SITE ENVIRONMENT
3.1.3
PROCEDURES OF STORAGE
3.1.3.1 DRAIN OR PROTECT FLUID
COURSE
3. STORAGE AND TRANSPORT
2.2.12 ZAP ALERT®
2.2.13 UNDERCARRIAGE
2.2.14 CRANE
2.3 PURPOSE OF THE MACHINE
2.4 STRUCTURE
2.5 TECHNICAL SPECIFICATIONS
2.5.1
GENERAL FEATURES (DD-100)
2.5.2
GENERAL FEATURES
(DD-140B)
2.5.3
DIESEL ENGINE (DD-100)
2.5.4
DIESEL ENGINE (DD-140B)
2.5.5
ELECTRICAL SYSTEM
2.5.6
HYDRAULIC SYSTEM (DD-100)
2.5.7
HYDRAULIC SYSTEM (DD-140B)
2.5.8
PERFORMANCE AS SUPPLIED
(DD-100)
2.5.9
PERFORMANCE AS SUPPLIED
(DD-140B)
2.5.10 VIBRATION
2.5.11 NOISE
2.6 RESPONSIBILITY
2.1 PARTS OF THE MACHINE
2.2 DESCRIPTION OF THE MACHINE
2.2.1
THRUST FRAME
2.2.2
CARRIAGE
2.2.3
REAR THRUST STABILIZERS
2.2.4
FRONT STABILIZERS
2.2.5
FIXED WRENCH
2.2.6
BREAKOUT WRENCH
2.2.7
MUD
2.2.8
MUD PUMP
2.2.9
TIE DOWN SYSTEM
2.2.10 DRILL PIPE
2.2.11 ES!LOK®
Page 3
CONVENTIONS OF TERMINOLOGY
TYPOGRAPHIC CONVENTIONS
2. DESCRIPTION
1.11.1
1.11.2
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
1.1 USE AND MAINTENANCE MANUAL
1.1.1
DATA OF MANUAL
1.1.2
CONTENTS OF MANUAL
1.1.3
WHO SHOULD USE THIS MANUAL
1.1.3.1 TRANSPORTER
1.1.3.2 USER
1.1.3.3 MAINTENANCE TECHNICIAN
1.1.4
OWNERSHIP OF INFORMATION
1.2 MANUFACTURER IDENTIFICATION DATA
1.3 MACHINE IDENTIFICATION DATA
1.4 DECLARATION OF EC CONFORMITY
1.5 GENERAL INFORMATION ON SAFETY
1.5.1
SAFETY STANDARD
1.5.1.1. SAFETY AWARENESS
PROGRAM
1.5.2
QUALIFICATION OF PERSONNEL
1.5.3
USE OF PERSONAL PROTECTIVE
EQUIPMENT
1.5.4
DANGEROUS ZONES—SAFE DISTANCES
1.6 LEGAL VALUE OF THE MANUAL
1.7 USES ALLOWED
1.7.1
FEATURES OF THE SOIL TO BE
DRILLED
1.7.1.1 TYPES OF SOIL
1.7.1.2 GROUND LEVELING
1.7.1.3 AMBIENT CONDITIONS
1.7.2
FEATURES OF TRANSPORT
1.7.3
MACHINE HANDLING
PROCEDURES
1.7.3.1 TRANSPORT
1.7.3.2 USE
1.7.3.3 MAINTENANCE
1.8 USES NOT ALLOWED
1.9 WARRANTY
1.9.1
GENERAL CONDITIONS
1.9.2
LIMITATIONS OF WARRANTY
1.9.3
WARRANTY CERTIFICATE
1.9.4
REQUEST FOR SERVICE
SUPPORT
1.9.5
WARRANTY AND SERVICE FOR
CATERPILLAR ENGINE
1.10 SERVICE AGREEMENT
1.11 CONVENTIONS
1. GENERAL INFORMATION
TABLE OF CONTENTS
Page 4
4.9
DRILLING PROCESS
4.9.1
DEEP CROSSINGS- THE SET UP
4.9.2
DEEP CROSSINGS - STEERING
SYSTEM
4.9.3
DEEP CROSSINGS - DRILLING
METHOD
4.9.4
SHALLOW CROSSINGS -THE
PROCESS
4.9.5
APPLICATION OF DRILLING FLUID
TO HORIZONTAL BORING
4.9.6
DRILLING FLUID - THE PROCESS
4.9.7
CALCULATION OF VOLUME OF
FLUID TO VOLUME OF SOIL
4.9.8
FLUID DISPOSAL
4.9.9
WATER QUALITY
4.9.10 MUD MIXING
4.6.4
ZAP ALERT™ SYSTEM
4.7 OPERATION
4.7.1
STARTING THE ENGINE
4.7.2
MOVEMENT OF THE MACHINE
4.8 SET-UP
4.8.1
POSITION THE DRILL
4.8.2
EXTEND THE DRILLER’S CONSOLE
4.8.3
REMOVE HOSE CARRIER HOLD-DOWN
4.8.4
INSTALL HANDRAILS
4.8.5
POSITION REAR THRUST STABILIZERS
4.8.6
POSITION THE CRANE
4.8.7
POSITION THE FRONT STABILIZERS
4.8.8
THRUST FRAME ANGLE
4.8.9
THRUST FRAME EXTENSION
4.8.10 ANCHOR THE MACHINE
4.8.10.1 PLACING THE TIE DOWN STAKES
4.8.10.2 OTHER METHODS OF ANCHORING
4.8.10.3 POUR A CONCRETE ANCHOR
4.8.10.4 CONSTRUCT A “DEAD MAN”
ANCHOR
4.8.11 EXCAVATE THE ENTRY PIT
GENERAL ARRANGEMENT
4.6.2.3 CONTROL CONSOLE
4.6.2.4 SET-UP CONTROL PANEL
4.6.2.5 CRANE PENDANT CONTROL
4.6.2.6 TRAMMING CONTROL
4.6.2.7 BATTERY SWITCHES AND
BATTERY EQUALIZER
4.6.3
ES!LOK® LOCKOUT SYSTEM
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
4.3.1.9 REAMING TOOLS
4.3.1.10 DIESEL ENGINE AND MUFFLER
4.3.1.11 PERSONAL PROTECTIVE
EQUIPMENT
4.4 QUALIFICATION OF THE OPERATOR
4.5 POSITION OF THE OPERATOR
4.6 CONTROLS AND INSTRUMENTS
4.6.1
CONTROLS
4.6.1.1 TRAMMING CONTROL
4.6.1.2 EMERGENCY STOP PUSH BUTTONS
4.6.2
INSTRUMENTS (LIST)
4.6.2.1 ENGINE PANEL
4.6.2.2 CONTROL PANEL
4.1.4
LIGHTING
4.1.5
OPERATING TEMPERATURES
4.1.6
RELATIVE HUMIDITY
4.1.7
MAXIMUM ALTITUDE
4.1.8
ATMOSPHERIC CONDITIONS
4.2 FUNCTION OF THE MACHINE
4.2.1
NORMAL OPERATION
4.3 DANGEROUS ZONES—SAFE DISTANCES
4.3.1
DANGEROUS PARTS AND
DESCRIPTION OF THE RISK
4.3.1.1 TIE DOWN
4.3.1.2 REAR THRUST STABILIZERS
4.3.1.3 FRONT STABILIZERS
4.3.1.4 CARRIAGE
4.3.1.5 WRENCH ASSEMBLY
4.3.1.6 CUTTING HEAD
4.3.1.7 DRILL PIPE
4.3.1.8 MUD SYSTEM
4.1 WORKING SITE PHYSICAL FEATURES
4.1.1
MINIMUM SPACE REQUIRED
4.1.2
GROUND LEVELING
4.1.3
TYPE OF GROUND
4. USE
3.2 TRANSPORT
3.2.1
PRELIMINARY OPERATIONS FOR
LOADING THE MACHINE FOR
TRANSPORTATION
3.2.2
PROCEDURES OF POSITIONING
3.2.3
TRANSPORTATION
3.2.4
LOADING OF THE MACHINE FOR
TRANSPORTATION
3.2.5
TRANSPORT CONDITIONS
3.2.6
UNLOADING OPERATIONS
3.3 LIFTING THE MACHINE
5.3.9.2 HYD. PUMP DRIVE, FILLING
PROCEDURE
5.3.9.3 CARRIAGE ROTARY GEAR BOX
5.3.9.4 CARRIAGE ROTARY GEAR BOX,
CHECK LEVEL
5.3.9.5 CARRIAGE ROTARY GEAR BOX,
FILLING PROCEDURE
5.3.9.6 TRACK DRIVE GEAR BOXES
5.3.9.7 TRACK DRIVE GEAR BOXES,
LEVEL CHECK
5.3.9.8 TRACK DRIVE GEAR BOXES,
FILLING PROCEDURE
5.3.10 TRACK TENSION
5.3.11 WELDING
5.3.12 RADIATOR
5.3.13 HYDRAULIC PISTON RODS
5.3.14 CLEANING
5.4 OTHER INSPECTION AND
MAINTENANCE (50 HOURS)
5.4.1
BOLTS AND NUTS
Page 5
5.2.2
FREQUENCY OF INSPECTIONS
5.3 SCHEDULED INSPECTION AND
MAINTENANCE
5.3.1
MAINTENANCE SCHEDULES OF
DIRECTIONAL DRILL MODEL DD-100
AND DD-140
5.3.1.1 DAILY (OR 10 HOURS)
5.3.1.2 WEEKLY (OR 50 HOURS)
5.3.1.3 MONTHLY (OR 250 HOURS)
5.3.1.4 SIX MONTHS (OR 500 HOURS)
5.3.1.5 YEARLY (OR 1000 HOURS)
5.3.1.6 AFTER EACH JOB
5.3.2
EMERGENCY STOP
5.3.3
GREASING
5.3.3.1 GREASE POINTS (LIST)
5.3.4
ENGINE OIL
5.3.5
ENGINE COOLANT
5.3.6
AIR FILTERS
5.3.7
FUEL
5.3.8 HYDRAULIC OIL CIRCUIT
5.3.8.1 PROCEDURE FOR REPLACEMENT OF
FILTERS
5.3.8.2 PROCEDURE FOR REPLACEMENT
OF HYD. OIL
5.3.9 GEARBOXES AND PUMP DRIVE
5.3.9.1 PUMP DRIVE, LEVEL CHECK
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
5.1 DANGEROUS ZONES—SAFE DISTANCES
5.2 ORDINARY, PERIODICAL AND
PREVENTIVE MAINTENANCE
5.2.1
QUALIFICATION OF THE TECHNICIAN
5. MAINTENANCE
4.10 HANDLING PIPE
4.10.1 ADDING PIPE (FIRST SECTION)
4.10.2 INSTALLING A WIRELINE GUIDANCE
INSTRUMENT
4.10.3 USING A MUD MOTOR
4.10.4 ADDING PIPE (ADDITIONAL
SECTIONS)
4.10.5 REMOVING PIPE
4.10.6 CALCULATING ROTARY TORQUE
FORCE
4.10.6.1 LIMITING ROTARY TORQUE
4.10.7 CALCULATING THRUST AND
PULLBACK FORCE
4.10.7.1 LIMITING THRUST AND
PULLBACK FORCE
4.11 START OF THE DRILLING OPERATION
4.12 END OF DRILLING OPERATIONS
4.13 START OF PULLBACK OPERATIONS
4.14 END OF PULLBACK OPERATIONS
4.14.1 REMOVING TIE DOWN
STAKES
4.14.2 CLEAN UP
4.15 SWITCHING OFF THE ENGINE
4.16 EMERGENCY STOP
4.17 START AFTER AN EMERGENCY STOP
4.18 CHECKS DURING OPERATION
4.19 NORMAL OPERATING RANGES OF
INSTRUMENTS
4.20 ES!LOK® LOCKOUT SYSTEM
4.20.1 START AFTER USE OF ES!LOK®
4.21 USE OF ZAP ALERT®
4.21.1 START AFTER USE OF ZAP
ALERT™
4.22 OPERATION WITH AMBIENT
TEMPERATURES BETWEEN
-40 & -15°C
4.22.1 PRE-HEATING DEVICES
4.22.2 STARTING THE ENGINE (with the
machine kept warm through pre-heaters)
4.22.3 STARTING THE ENGINE (without use of
preheaters)
4.22.4 PROTECTING THE FLUID COURSE
FROM FREEZING
4.22.4.1 DRAIN THE FLUID COURSE
Page 6
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6 Machine Labels
Fig. 7 Placement of Labels, 1 of 2
Fig. 8 Placement of Labels, 2 of 2
Fig. 9 Transporting The Drill
Fig. 10 Lifting The Drill
Fig. 11 Transport Dimensions DD-100
Fig. 12 Max. Drill Angle Dimensions DD-100
Fig. 13 Transport Dimensions DD-140B
Fig. 14 Max. Drill Angle Dimensions DD-140B
Fig. 15 Tooling
Fig. 16 Down Hole (Mud) Motor
Fig. 17 Steering
Fig. 18 Clock Face Display
Fig. 19 Tramming
Fig. 20 Hose Carrier Hold Down
Fig. 21 Hand Rails
Fig. 22 Console Lock Chain
Fig. 23 Extending Console
Fig. 24 Storage Box
Fig. 25 Positioning Crane
Fig. 26 Carriage Lock
Fig. 27 Hand Rail Installation
Fig. 28 Engine Panel
Fig. 29 Control Console General Arrangement
Fig. 30 Instruments—Control Console
Fig. 31 Setup Controls
Fig. 32 Crane Controls
Fig. 33 Tramming Control
Fig. 34 Battery Switch & Equalizer
Fig. 35 Pipe Support
Fig. 36 Tiedown Stakes
Fig. 37 Buried Anchor
Fig. 38 Thrust Conversion Table-DD-100
Fig. 39 Torque Conversion Table-DD-100
Fig. 40 Thrust Conversion Table-DD-140B
Fig. 41 Torque Conversion Table-DD-140B
Fig. 42 Air Cleaner
Fig. 43 Volume of Soil Formula
Fig. 44 Steering Radius
Fig. 45 Approved Replacement Fluids
Fig. 46 Maintenance Schedule
Fig. 47-49 Hydraulic Schematics—DD-100
Fig. 50-52 Electrical Schematics—DD-100
Fig. 53-57 Hydraulic Schematics—DD-140B
Fig. 58-61 Electrical Schematics—DD-140B
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Declaration of EC Conformity
Warranty Certificate
Exit Pit Warning
Pipe Wrench Warning
Electrical Hazard Warning
5.4.2
PIPES AND HOSES
5.4.3
LEAKS
5.4.4
GAUGES AND INSTRUMENTS
5.4.5
BATTERIES
5.4.5.1 BATTERY EQUALIZER
5.4.6
UNDERCARRIAGE
5.5 OTHER INSPECTIONS AND
MAINTENANCE (EVERY 250 HOURS)
5.5.1
MOTOR MOUNTS AND RADIATORS
5.5.2
UNDERCARRIAGE ROLLERS
5.5.3
BREATHER PIPES
5.5.4
TRACK TENSION
5.6 OTHER CHECKS & MAINTENANCE
(EVERY 500 HOURS)
5.6.1
ENGINE BELTS
5.6.2
COOLING SYSTEM
5.6.3
ENGINE OIL BREATHER PIPE
5.6.4
ELECTRIC SYSTEM
5.7 OTHER CHECKS (EVERY 1000 HOURS
OR EVERY YEAR)
5.7.1
ENGINE FUEL FILTERS
5.7.2
ENGINE COOLING SYSTEM
5.7.3
EMERGENCY STOP
5.7.4
HYDRAULIC OIL AND FILTERS OF
HYDRAULIC SYSTEM
5.8 INSPECTIONS AND MAINTENANCE
EVERY 24 MONTHS
5.8.1
ENGINE STOP
5.8.2
ENGINE COOLING SYSTEM
5.9 OTHER CHECKS (EVERY 2000 HOURS)
6. DIAGNOSTIC
6.1 OPERATING FAULTS
6.1.1
CLOGGED AIR FILTER
6.1.2
ENGINE OIL PRESSURE ALARM
6.1.3
ENGINE COOLANT TEMPERATURE
ALARM
6.1.4
ROTARY AND CARRIAGE DO NOT
OPERATE
6.1.5
CLOGGED OIL FILTER(S)
7. DEMOLITION
7.1 MACHINE DEACTIVATION
7.2 RESIDUAL RISKS
Cat 3126 or 3306 Diesel Engines.
Es!lok® Operator’s Manual
Zap-Alert Instructions
Crane Operator’s Manual
Battery Equalizer Instructions
AMERICAN AUGERS, INC.
135 U.S. Rt. 42, P.O. Box 814
West Salem, Ohio 44287 USA
Tel. 419-869-7107 • Fax 419-869-7425
Page 7
1.2 MANUFACTURER IDENTIFICATION DATA
1.1.4 OWNERSHIP OF INFORMATION
American Augers, Inc. reserves all rights to the
information in this manual.
The manual cannot be reproduced or photocopied in part on in whole without previous written
authorization from American Augers, Inc. The use
of the manual is restricted to the customer who
received it and only for purposes of installation,
use and maintenance of the relevant machine.
American Augers declares that the information
contained in this manual fits the technical and
safety specifications of the machine. American
Augers disclaims responsibility for direct or indirect damages to persons or property caused when
the manual or the machine are used in in violation
of the information contained herein.
The information contained in the manual refers
only to the machine mentioned in Paragraph 1.3.
IDENTIFICATION DATA OF THE MACHINE.
American Augers reserves the right to modify or
improve the manual and the machines without notice.
1.1.3.3 MAINTENANCE TECHNICIAN
The technician in charge of maintenance must get
acquainted with operation and handling of the
machine, he must be able to check that there are
no faults in order to carry out maintenance work
with adequate equipment and protection. In case
the technician is not qualified, he must inform a
qualified person so that skilled personnel are called
for special work (example: adjustment of Caterpillar engine, welding, etc.). The technician must
read and follow the manual.
manual for any other subsequent training. The authorized dealer is always available for any further
information or instruction. The user must read and
follow the manual.
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
1.1.3.2 USER
At consignment of the machine, a technician either from the authorized dealer or from American
Augers is available for training one or more operators. Only trained personnel are qualified to operate and maintain the machine.
We recommend following the procedure of the
acceptance and test-run certificate, which must always come with the machine together with the
1.1.3.1 TRANSPORTER
The transporter is not authorized to handle the
machine nor start the engine. Only trained personnel having a written authorization are allowed to
load and unload the machine from the transport
vehicle (see: USER). Relevant parts of the manual
are in Chapter 3 Storage and Transport.
1.1.3 WHO SHOULD USE THIS MANUAL
1.1.2 CONTENTS OF MANUAL
Chapter 1 General Information
Chapter 2 Description
Chapter 3 Storage and Transport
Chapter 4 Use
Chapter 5 Maintenance
Chapter 6 Diagnostic
Chapter 7 Demolition
Part number: DD100140BOOK-01
1.1.1 DATA OF MANUAL
TITLE: Operation & Safety Instruction Manual,
Model DD-100 AND DD-140 Horizontal Directional Drill
EDITION: 2001
1.1 USE AND MAINTENANCE MANUAL
1. GENERAL INFORMATION
Attachment 1
Attachment 2
Attachment 3
Attachment 4
Attachment 5
Fig. 62 Machine Nomenclature
result in death or serious personal injury.
WARNING
indicates a potential hazard or unsafe
situation which, if not avoided, could
result in death or serious personal injury.
CAUTION
indicates a potential hazard or unsafe
practice, which if not avoided may result in minor personal injury or product or property damage.
Page 8
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
If you are the owner, operator, or the helper using an American Directional Drill, it is important
that you recognize that your drill is a powerful piece
of construction equipment. (IT MUST BE OPERATED WITH RESPECT AND CAUTION.)
All operators or trainees must carefully read and
thoroughly understand this Operation Manual before starting or using this machine. Thorough training of both operators and helpers is essential for
the safe operation of this equipment. Never allow
inexperienced personnel to operate or work near
the machine unless they are carefully supervised
during training. In the United States, workplace
1.5.1.1. SAFETY AWARENESS PROGRAM
safety is regulated by the Occupational Health and
Understanding Operation Safety
All references throughout this manual are to cur- Safety Administration (OSHA). OSHA regulations
rent models of the DD-100 AND DD-140 direc- are found in the Code Of Federal Regulations.,
tional drill. Please call American Augers if you en- Chapter 29. This is known as 29CFR1910. Information can be obtained from your Regional U.S.
counter problems not addressed in this manual.
Department of Labor Office.
BE AWARE OF SAFETY INFORMATION.
Please note the limited warranty included in this
manual. If you have questions on the warranty or
1.5.1 SAFETY STANDARD
In designing and construction of the machine,
standards have been adopted in order to satisfy essential safety requirements with subsequent modifications under applicable directives. In particular, suitable measures to prevent risks for operators during transport, use, maintenance and demolition of the machine have been completed. The
complete documentation of the measures adopted
for safety purposes is contained in the technical
file of the machine, registered by the manufacturer.
The detailed analysis of risks carried out by the
manufacturer are intended to eliminate most of the
risks connected with the conditions of use of the
machine, both foreseen and reasonably foreseeable.
The manufacturer recommends that the user carefully follows instructions, procedures and advice
contained in the manual and the laws in force on
the work site, as well as the use of all protective
equipment, both integrated in the machine and
personal protective equipment.
1.5 GENERAL INFORMATION ON SAFETY
This is the safety alert symbol. This symbol is
Type: Directional Drill
Model: DD-100 AND DD-140
placed in the manual to alert you to the potential for
Serial number: ..........
bodily injury or death.
Year of manufacture: ...........
Location of identification plate: see diagram on UNDERSTAND SIGNAL WORDS
page 2.
Signal words are used to identify safety information within the text of this manual, and are used on
1.4 DECLARATION OF EC CONFORMITY
the hazard alert signs used on the machine.
If required, the declaration of EC conformity is
issued at consignment of the machine together with
DANGER
the manual. REFER TO: Attachment 1 Declaraindicates an imminently hazardous
tion of EC Conformity.
situation which, if not avoided, will
1.3 MACHINE IDENTIFICATION DATA
1.7 USES ALLOWED
NOTICE
American Augers disclaims any responsibility for damages to persons
or property caused by the operation
of the machine in violation of the instructions contained in this manual
1.6 LEGAL ASPECT OF THE MANUAL
1.5.4 DANGEROUS ZONES—SAFE DISTANCES
Any zone inside or near the machine where the
presence of a person means a risk for his health
and security.
All the areas concerned with handling of parts or
machine.
During transport, keep a distance of at least 2 m
(6.5 feet) away from the drill.
While drilling, some drilling fluid can be sprayed
from the cutting head.
In addition, in case of striking a buried electric
cable, the earth around the drill can become electrically charged. Keep spectators at least 8 m (25
ft) from the drill and associated equipment.
During maintenance, use adequate supports before releasing bolts, pins, valves, pipes and pistons.
Safety distances during transport: 2 m (6.5 ft)
Safety during self-moving: 2 m
Safety distances during use: 8 m (25 ft)
Safety distances during maintenance: 8 m
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
WARNING
If personal protective equipment is not
used, serious injury or death of personnel can occur.
Page 9
Work allowed:
Installation of drill pipe into the earth. Rotation
of drill pipe. Use of bentonite fluid to create the
pilot bore. Removal of drill pipe from the earth.
Use of bentonite fluid to back ream the bore. PullThe operator and all other personnel on the ing a reamer through the pilot bore. Pulling prodworksite must use proper protective equipment uct pipe or cable through the bore.
1.5.3 USE OF PERSONAL PROTECTIVE
EQUIPMENT
NOTICE
American Augers disclaims any responsibility for damages to persons
or property caused by the operation
of the machine by untrained personnel.
.
1.5.2 QUALIFICATION OF PERSONNEL
If skilled personnel operate the machine according to the advice and instructions supplied in the
manual, the machine will operate safely. All the
operations of transport, use and maintenance must
be carried out only by skilled and authorized personnel, after studying and understanding the instructions supplied by the manual.
NOTICE
American Augers disclaims any responsibility for damages to persons
or property caused by operation in
violation of safety advice contained in
the manual.
they are placed on the DD-100 AND
DD-140. These hazard alert signs are
placed on the machine to inform your
operator and other personnel of potential hazards that exist while these
machines are in operation. These
signs must be kept clean and legible.
Replacement signs are available from
American Augers.
about any part of the machine operation, please according to their duties.
contact American Augers.
In addition to safety shoes, helmets and safety
glasses, it is necessary to wear hearing protection.
NOTICE
The driller, locating device operator and others in
Location of Hazard Alert Signs
contact with the machine should wear electric inThe drawings on Fig. 7 and Fig. 8 show
sulating boots in case of striking a buried electric
the locations of hazard alert signs as
cable.
Page 10
CAUTION
Stop working when any situations
compromise the safety of the operator or the integrity of the machine.
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
1.7.3.1 TRANSPORT
When the machine is loaded on a trailer, only one
operator is allowed to operate the tramming controls for safety reasons.
1.7.3 MACHINE HANDLING PROCEDURES
wear or damage to the machine.
1.7.3.2 USE
When the machine is used, only one operator is
allowed to operate the drilling functions for safety
reasons. Other trained personnel may work near
1.7.1.1 TYPE OF GROUND
The machine is suitable for working in the follow- the drill if they are wearing personal protective
equipment.
ing types of soil:
-Sand -Gravel -Loam -Clay -Shale -Rock
1.7.3.3 MAINTENANCE
During maintenance with the machine running,
1.7.1.2 GROUND LEVELLING
only one qualified technician is allowed to operate
Max. transversal inclination (lateral) :10°
the controls for safety reasons.
Max. longitudinal inclination (frontal): 15°
For maintenance operations with the machine off,
Max. height the machine will climb:150mm (6 in.)
other trained personnel may work on it.
1.7.1.3 AMBIENT CONDITIONS
Allowed temperature between -15°C and +40°C 1.8 USES NOT ALLOWED
The machine is not designed and built for any
[5°F and 105°F] (with oils and coolants recomuses
not specified in Paragraph 1.7. USES ALmended). For temperature lower than 0°C [32°F]
REFER TO Paragraph 4.21. OPERATION WITH LOWED.
In particular the uses not allowed are the followTEMPERATURES BETWEEN -40°C AND -15°C
ing:
[-40°F AND +5°F]. For temperatures not included
1) Drilling on sandy, collapsing or incoherent
in this range, get in touch with American Augers.
ground.
2) Drilling on boggy ground or with too
Relative humidity allowed during work: 100%
Max. altitude: 2000 m [6500 ft] above sea level much water that compromises the grip or the supAtmospheric conditions must allow adequate vis- port of the tracks. 3) Use of the machine for pullibility within the safety area. It is inadvisable to ing or pushing other machines. 4) Movement of
use the machine during rainy conditions where the machine pulled or pushed by other machines.
5) Use of the machine in explosive and/or inflamlightning is present.
mable area. 6) Use the front foot to lift the tie down
stakes out of the earth. 7) Any time when there are
1.7.2 FEATURES OF TRANSPORT
The machine must be transported on a truck vibrations which compromise the safety of the
trailer, according to the Highway laws in force in operator or the integrity of the machine. 8) Use
the relevant country. It must be properly secured when other persons different than the operator are
present within the dangerous zones indicated in
onto the trailer deck.
The thrust frame must be in the retracted posi- Paragraph 1.5.4. DANGEROUS ZONES—SAFE
tion. The front foot must be lowered to the trailer DISTANCES.
deck. REFER TO : Chapter 3 STORAGE AND
CAUTION
TRANSPORT
It
is
the
responsibility
of the user to
If the drill exceeds overall dimensions allowed,
decide whether to use the drill in conit is necessary to flag it according to the Highway
ditions which can cause excessive
laws of the countries involved in the transport.
1.7.1 FEATURES OF THE SOIL TO BE
DRILLED
1.11.1 CONVENTIONS OF TERMINOLOGY
As the directional drill is not a conventional construction machine we list some terms normally used
in the text with their description.
FRONT is the end with the wrenchs and foot.
LEFT or RIGHT as seen standing behind the machine facing FRONT. The operator’s console is on
the RIGHT side.
1.11 CONVENTIONS
NOTICE
This manual must be kept for the
whole lifetime of the machine so that
it can be easily found if needed. If the
machine is sold, the manual must be
provided to the new owner.
Contact the local dealer.
1.10 SERVICE AGREEMENT
warranty is valid worldwide. Only Caterpillar dealers are authorized to perform repairs under warranty and supply service and spare parts.
2.2 DESCRIPTION OF THE DIRECTIONAL DRILL
The machine consists of the following assemblies
(REFER TO: Fig. 47 & 48).
2.1 PARTS OF THE MACHINE
2. DESCRIPTION
REFER TO: Safety Awareness Program, Paragraph
1.5.1.1.
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Page 11
which contains the operator’s console, engine,
1.9.5 WARRANTY AND SERVICE FOR CAT- hydraulic system and fuel tank.
ERPILLAR ENGINE
The local Caterpillar dealer normally solves problems related to Caterpillar engine. The Caterpillar
1.9.4 REQUEST FOR SERVICE SUPPORT
For any request of service support in or out of
the warranty period, contact your authorized dealer.
Have available model number, serial number of
the machine and working hours indicated on the
instrument (Fig. 30, TACH).
1.9.3 WARRANTY CERTIFICATE
See Fig. 2.
1.9.2 LIMITATIONS OF WARRANTY
The warranty for all the components bought and
not produced by American Augers directly are sub- 1.11.2 TYPOGRAPHIC CONVENTIONS
ject to the original warranty of suppliers/manufacIn the manual different typographic notes have
turers and therefore defects in materials or work- been used for identifying dangerous conditions.
manship are considered valid only if they are rec- For example:
NOTICE
ognized by the same suppliers/manufacturers. In
Notices, cautions and warnings inparticular the warranty on the Caterpillar engine is
cluding important information are set
supplied by the Caterpillar dealer in the area where
apart from the text.
the drill is sold.
1.9.1 GENERAL CONDITIONS
Any warranty is subject to the conditions specified in the warranty certificate.
Except for the specified exclusions and limitation, the warranty certificate covers all the material supplied for a period of 6 months beginning
from the shipping date.
Extensions can be granted only by the President
of American Augers and must be signed and enclosed with the certificate consigned at the time of
sale.
No extension can be granted after sale.
1.9 WARRANTY
NOTICE
American Augers does not bear any
responsibility for damages caused by
the incorrect use of the machine, nor
for wear and damage caused by the
particular quality of the drilled material.
2.4 STRUCTURE
Page 12
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
2.2.10 DRILL PIPE specially designed pipe
The cutting head (connected to drill pipe held by
threaded on both ends that conducts thrust and pull- the machine) is positioned over the desired line of
back forces, and carries drilling fluid to the cut- advance of the bore. The entry angle of the cutting head.
ting head into the soil is determined by the length
and depth of the bore, in consideration of the al2.2.11 ES!LOK® an exit side lockout system that lowable bending of the drill pipe.
is capable of disabling the rotation and linear moveThe drill is anchored in place using the tie down
ment of the drill pipe.
system and by positioning the rear thrust stabilizers. Drilling fluid is prepared by a mud mixing
2.2.12 ZAP ALERT® an instrument that sounds an system (available separately). Operation of the mud
alarm should the drill become electrically ener- pump forces a jet of drilling fluid out orifices in
gized.
the cutting head.
At the same time, the pipe is advanced by opera2.2.13 UNDERCARRIAGE tracks and associated tion of the carriage. It is possible to steer the cutparts for support and movement of the machine.
ting head as it passes through the soil. By know-
2.2.9 TIE DOWN SYSTEM H-beam stakes which
are driven through the front foot to anchor the drill
to the earth.
American Augers disclaims any responsibility for differences in dimensions between theoretical and actual
bores.
2.2.2 CARRIAGE which imparts thrust and pull- 2.3 PURPOSE OF THE MACHINE
The directional drill is designed for the producback force, and rotary motion to the drill pipe
tion of a bore under the earth with a system more
2.2.3 REAR THRUST STABILIZERS (JACKS) efficient than conventional excavating. The main
which resists the tendency of the drill to move back- tool is the cutting head; it may be equipped with a
blade or with hard metal teeth and is able to reward when thrusting
move soil. The result is a bore with circular sec2.2.4 FRONT STABILIZERS (JACKS) which tion ready for positioning pipe or cable, without
widen the base of the machine and serve to level the need for back filling and compacting. The cutting head is advanced by connecting it to sections
the crane
of drill pipe which are added by the operation of
2.2.5 FIXED WRENCH a hydraulic clamp for the directional drill. In addition, soil is removed
holding the pipe during tightening or loosening the and the bore is lubricated by use of a mixture of
water, bentonite and other substances, which is
joints
forced into the drill pipe by the mud pump.
The actual bore dimension cannot be guaranteed
2.2.6 BREAKOUT WRENCH a moveable wrench
for
each bore. For example: depending on soil conthat applies enough force to loosen pipe joints
ditions and the size of the pipe or cable to be in2.2.7 MUD drilling fluid containing water and usu- stalled, it may be necessary to enlarge the bore by
ally bentonite and other additives depending on soil pulling a reamer through it. Operation in hard rock
requires additional special accessories which are
conditions.
not supplied and must be ordered separately.
2.2.8 MUD PUMP a pump separate from the maNOTICE
chine that forces drill fluid through the drill pipe.
2.2.1 THRUST FRAME which supports the car- 2.2.14 CRANE used to lift sections of pipe on and
riage
off the machine
2.5.3 DIESEL ENGINE (DD-100)
Fuel: diesel fuel
Piston displacement: 7.2 L [442 cu. inch]
Power: 194 kW (260 HP)
Fuel tank capacity: 568 L [150 U.S. Gallons]
Hours of operation per tankful: approx. 10 hours
REFER TO: Attachment 1, Caterpillar 3126 Diesel Engines.
*add 1524 mm (60 inches) when console is in
working position
REFER TO: Figs. 13, 14
Dimensions in transport position:
height: 3988 mm [13 ft 1 inch]
width: 2559 mm [8 ft 4-3/4 inches]
length: 14783 mm [48 ft 6 inches]
length: 14783 mm [48 ft 6 inches]
Voltage: 24 volt DC start and run; 12 volt accessory
REFER TO: Figs. 50-52 and 58-61
Page 13
Open loop: 345 bar [5000 psi]
Max. temperature allowed for hydraulic oil is 80°C
[175 °F].
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Dimensions in working position, 18° drill angle:
height: 5944 mm [16 ft 6 inches]
width*: 2559 mm [8 ft 4-3/4 inches]
2.5.6 HYDRAULIC SYSTEM (DD-100)
Pressures: Rotary (break-out): 290 bar [4200 psi]
*add 1524 mm (60 inches) when console is in Rotary (make-up): 273 bar [3950 psi]
working position
Open loop: 345 bar [5000 psi]
REFER TO: Figs. 11, 12
Max. temperature allowed for hydraulic oil is 80°C
[175 °F].
2.5.2 GENERAL FEATURES (DD-140B)
Approx. mass: 26,300 kg [58,000 lb]
2.5.7 HYDRAULIC SYSTEM (DD-140B)
Median pressure on the ground: 0.56 kg/cm2, 8 Pressures: Rotary (break-out): 269.9 bar [3900 psi]
psi
Rotary (make-up): 256 bar [3700 psi]
Dimensions in transport position:
height: 3073 mm [10 ft 1 inch]
width: 2413 mm [7 ft 11 inches]
length: 13564 mm [44 ft 6 inches]
2.5.4 DIESEL ENGINE (DD-140B)
2.5.1. GENERAL FEATURES (DD-100)
Fuel: diesel fuel
Approx. mass: 20,430 kg [45,000 lb]
Piston displacement: 10.5 L [638 cu. inch]
Median pressure on the ground: 0.59 kg/cm2, 8.5 Power: 224 kW (300 HP)
psi
Fuel tank capacity: 568L [150 U.S. Gallons]
Hours of operation per tankful: approx. 10 hours
Dimensions in working position, 18° drill angle: REFER TO: Attachment 1, Caterpillar 3306 Dieheight: 5563 mm [18 ft 3 inches]
sel Engines.
width*: 2413 mm [7 ft 11 inches]
length: 13564 mm [44 ft 6 inches]
2.5.5 ELECTRIC SYSTEM
2.5 TECHNICAL SPECIFICATIONS
ing the orientation of the cutting head, the operator can rotate the drill pipe to correct the path of
the bore. By continuously rotating the pipe, the
cutting head advances without steering. The drill
pipe and its joints have been designed to withstand
a certain amount of bending.
It is customary and desirable for the drilling fluid
to return to the surface at the entry point. This fluid
carries all the soil removed in the production of
the bore. A pit may be dug adjacent to the entry
point of the cutting head to store the returning drilling fluid.
The operator is seated to permit good visibility
of the operation of the drill and various gauges that
indicate performance. It is possible to control all
the functions by means of electric or hydraulic
controls under complete safety conditions for the
operator.
Page 14
3.1.3 PROCEDURES OF STORAGE
• Clean all mud and other foreign materials off the
machine.
• Position the machine on a level surface. Position
the carriage in the center of the thrust frame. Raise
the front foot by retracting the thrust frame.
• Switch off electric system by turning the battery
switches at the battery box.
• Lubricate the entire machine according to the
daily schedule. Coat all exposed hydraulic cylinder rods with oil to protect against corrosion.
• For long periods of storage (more than 30 days)
place the machine in a covered and dry site, consult and follow the instructions of storage for Caterpillar engine (mentioned in the relevant mainte-
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
NOTICE
American Augers disclaims any responsibility for inconvenience, faults
or malfunctioning of the machine in
circumstances where procedures
identified in paragraph 4.18 are not followed.
2.6 RESPONSIBILITY
the protection from risks caused by
noise.
2.5.10 VIBRATION
Vibration is an indication of incorrect operation, 3.1.1.1 PROTECTION WHILE IN STORAGE:
If the machine has been lubricated it can be stored
such as advancing the drill pipe too rapidly.
in an exposed area up to 30 days. For storage periods more than 30 days place it in a covered and
CAUTION
dry area. Level the storage site so that the tracks
Stop work in case of vibration, which
are fully supported.
could compromise the safety of the
operator or the integrity of the maDD-100: The surface must be able to support
chine. Modify operational procedure
20,430 kg (45,000 lb)
DD-140B: The surface must be able to support
2.5.11 NOISE
26,300 kg (58,000 lb)
People working near and always inside the minimum safety distance (8 m [25 feet] from the near- 3.1.2 STORAGE SITE ENVIRONMEN T
est point of the machine) must wear adequate hearTemperature allowed: between 0 and +50°C
ing protection suitable to their working position. [32°F and 120°F]. For temperatures between 0°
and -40°C [32°F and -40°F], consult the CaterpilDANGER
lar manual and follow the instructions for storage
The noise generated by the machine
of the engine. Verify that there is no water or drillmay cause injury to personnel. Obing fluid in the drilling fluid course and no water
serve the national laws in force about
in the diesel fuel and hydraulic oil tanks.
2.5.8 PERFORMANCE AS SUPPLIED (DD-100) 3. STORAGE AND TRANSPORT
Max. carriage speed: 30 m/min (100 FPM)
3.1 STORAGE
Rotary speed: 0—110 rpm
Drill angle: 10°-18°
3.1.1 MINIMUM STORAGE SPACE RE2.5.9 PERFORMANCE AS SUPPLIED (DD- QUIRED (TRANSPORT POSITION)
DD-100: level 3 x 15 m, height 3 m [118 x 590
140B)
inches, height 118 inches].
Max. carriage speed: 29 m/min (95 FPM)
DD-140B: level 3 x 15 m, height 3.2 m [118 x 590
Rotary speed: 0—95 rpm
inches, height 126 inches].
Drill angle: 10°-18°
Page 15
Start the engine.
Remove the locking bolt from the thrust frame
and the thrust frame support.
WARNING
Do not sit or stand on the machine
while tramming. Unexpected movement can cause death or serious injury. Use remote tramming control
only, while standing at ground level
with good visibility.
handle the machine according to Paragraph 4.7. OPERATION. Use the tethered tramming controls and stay clear
of the machine. Always use low speed
for loading and move the controls delicately.
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
CAUTION
Don’t direct water spray inside the
muffler, or the air filter, against electric components or control panels.
3.2.1 PRELIMINARY OPERATIONS FOR
LOADING THE MACHINE FOR TRANSPORTATION
Clean the machine by using a water spray.
WARNING
Transport of the machine must be carried out by trained and authorized personnel only, after learning the information supplied in the manual.
3.2 TRANSPORT
3.2.4 LOADING THE MACHINE FOR
3.1.3.1DRAIN OR PROTECT FLUID COURSE TRANSPORTATION
Drain water or bentonite slurry out of fluid course
including main mud pump and associated lines.
WARNING
Alternatively, add antifreeze. REFER TO: ParaMake sure that all personnel keep a
graph 4.23.4, PROTECTING THE FLUID
safe distance while loading the maCOURSE FROM FREEZING
chine for transportation. Start up and
3.2.3 TRANSPORTATION
Considering dimensions, weight and shape of the
machine, the transporter is responsible for using
the proper method of transport in conformity with
local regulations. Detailed information on the maThe machine must be kept away from salty or chine features are in: Chapter 1 GENERAL INacid environments, from solvents, gas and inflam- FORMATION and Chapter 2 DESCRIPTION
mable liquids and explosives. REFER TO: Attach- paragraph 2.5.1.
ment 1, Caterpillar 3126 or 3306 Diesel Engines.
charger to either a 12 v DC or 24 v DC
supply and recharge the es!lok® batteries. Make sure the es!lok® batteries
are charged before attempting to put
the machine back into service.
WARNING
nance manual), disconnect batteries and store them
Before loading the machine on a
separately at temperatures above 0°C (32°F).
trailer, follow the instructions supplied
Eliminate sediment and water from the tanks (diein this manual carefully.
sel fuel and oil), top up all the gearboxes and the
hydraulic oil tank.
• For periods longer than 30 days, disconnect the 3.2.2 PROCEDURES OF POSITIONING
Position the thrust frame in order to obtain a minies!lok® battery charger located inside the storage
box (Fig. 24-1). This charger is not affected by the mum overall dimension.
Remove the tie-down stakes from the front foot
battery switch. If left connected it could discharge
and store them in a safe location. Make sure to
the machine batteries.
retract the thrust frame and raise the rear thrust
stabilizers.
NOTICE
Position the carriage as far forward on the thrust
Before putting the machine back in
frame as possible.
service reconnect the es!lok® battery
Page 16
WARNING
Do not sit or stand on machine while
tramming. Unexpected movement can
cause death or serious injury. Use remote tramming control box only while
standing at ground level with good
visibility.
Switch ON the battery master switches (Fig. 343 and 34-4).
Insert the ignition key in the control panel (Fig.
31, SS3).
Make sure three emergency stop push buttons are
UP (Fig. 30, PB2; Fig. 31, PB1 and Fig. 33, PB2).
Start the engine by rotating the switch clockwise
(Fig. 31, SS6).
Always use low speed for shifting and move the
controls delicately.
Raise the front foot by tilting the thrust frame
(Fig. 31, SS22).
Raise the rear thrust stabilizers by selecting
REAR (Fig 31, SS18) then operate SS20 and SS21.
Connect the tethered tramming controls (Fig. 33).
Press the RESET button (Fig. 33, PB3). Propel the
machine using controls VD1 and VD2 and stay
clear of the machine . The tether is long enough
for the operator to walk along either side the machine for good visibility. There are three connectors for the tether—one on each side of the drill
and one on the back.
WARNING
Make sure that all personnel keep a
safe distance when unloading the
machine after transportation. Check
that the machine lost no liquids during transport or storage, in particular
check if there is the proper amount of
hydraulic oil in the tank.
3.2.6 UNLOADING OPERATIONS
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
3.2.5 TRANSPORT CONDITIONS
Anchor the machine.
Remove the ignition key from the control panel
(Fig. 31, SS3) and keep it in a safe place.
Switch off the main battery switches (Fig. 34-3
and 34-4).
Tie the machine to the trailer deck and secure the
front foot to the trailer deck with chains. REFER
TO: Fig. 9.
Operate the Thrust/Pullback control (Fig. 30,
PD2) to position the carriage at the Carriage Lock
(Fig. 26). Swing the Lock Plate (Fig. 26-1) into
the socket on the carriage and rotate the toggle bar
to hold the Lock Plate in position.
Operate the Thrust/Pullback control (Fig. 30,
PD2) to position the thrust frame in the transport
position.
Raise the front jacks.Retract the front jacks toward the center line of the machine.
Gather the control hoses and stow them on the
deck of the drill.
Push the console support arm to its storage position and anchor it with the chain (Fig. 22-1).
Rotate the crane boom towards the rear of the
machine and lower the boom onto the crane rest.
Tie off the hook block (Fig. 25).
Remove the handrails from the walkway and
store them on the machine (Fig. 21).
Install the hose carrier hold down (Fig. 20).
Tilt the thrust frame of the machine as necessary
in order to avoid the front end dragging the ramps
or trailer deck while loading or unloading.
Connect the tramming control box (Fig. 19).
There are three connections, one on each side and
one at the rear, so the operator can have the best
possible visibility.
Proceed slowly when passing the edge of the
trailer as the machine could swing, when changing the inclination.
After reaching the final position on the trailer,
make sure that the front foot is lowered totally.
Lower the rear thrust stabilizers (see Fig. 47) and
make sure the machine is switched off.
150mm [6 inches] high. Otherwise level the site
using earthmoving equipment.
Page 17
4.1.8 ATMOSPHERIC CONDITIONS: they must
allow adequate visibility within the safety area. It
is inadvisable to use the machine during rain where
lightning is present.
4.1.7 MAX. ALTITUDE: 2000 m [6500 ft] above
sea level.
4.1.6 RELATIVE HUMIDITY ALLOWED during
the work: 100%
4.1.5 OPERATING TEMPERATURE: between 15°C and +40°C [+5°F and 105°F] (with oils and
coolants recommended).
For temperature lower than 0°C [32°F] use winter fuel for easier starting and in order to avoid the
stoppage of filters from deposits of wax. Make sure
that all the liquids have suitable features. REFER
TO: Chapter 5 MAINTENANCE.
For temperature included between -40°C and 15°C [-40°F and +5°F] REFER TO: Paragraph 4.22
OPERATION UNDER AMBIENT TEMPERATURES BETWEEN -40°C AND -15°C [-40°F
AND +5°F].
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
4.1.2 GROUND LEVELING
The machine is able to operate on surfaces with a
max. lateral inclination of 10°, slope in the running direction up to 15° and to cross steps up to
4.1.1 MINIMUM SPACE REQUIRED
In working position 2.5 m [8 feet] width and at
least 15 m [50 feet] length. Height required for
working on flat ground: 8 m [26 feet] (to allow
adding or removing pipe ). Additional clear distance must be maintained between the crane and
any overhead electric wires. These dimensions do
not allow for storage of pipe or tooling nor the set
up and operation of a mud plant. In addition, mark
off a safety zone 8 m [25 ft] in each direction from
the machine and prevent spectators from entering
this zone.
4.1 WORKING SITE PHYSICAL FEATURES
4. USE
adequate capacity for weight. Position the machine
on the flat rack according to paragraph 3.2.4 above.
Switch off the engine.
Use chains to anchor the machine to the flat rack.
Attach the lifting lines to the flat rack, not to the
machine. Use spreader bars to ensure that the lifting lines do not come in contact with the machine
(Fig.10).
4.1.3 TYPE OF GROUND
The machine is designed to work on clay, asphalt,
cement, rock and normal soil. It is not suitable to
work on crumbling, marshy or inconsistent soil,
which cannot guarantee traction or support during
Angle the thrust frame as necessary in order to
work. REFER TO: Paragraph 1.7 USES ALmake sure that the front foot does not drag on the
LOWED and Paragraph 1.8 USES NOT ALground.
LOWED.
Proceed slowly when passing the edge of the
trailer as the machine could swing, when chang4.1.4 LIGHTING
ing the inclination.
There has to be enough light to guarantee good
visibility of all the movable parts. It may be nec3.3 LIFTING THE MACHINE
If the machine must be lifted (example: to load essary to equip the work area with portable lights
on a ship) place the machine on a flat rack with for night operation.
WARNING
A crushed or damaged tramming control could result in unexpected movement of the machine. Unexpected
movement can cause death or serious
injury; Always replace the tramming
control into its holder.
4.3.1.8 MUD SYSTEM presents a danger of high
pressure fluid spray
Page 18
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
The machine is designed to be operated by one
operator, with one additional worker to load and
unload pipe baskets as required. This worker may 4.3.1.9 REAMING TOOLS turn fast under high
also have the duty to mix and transfer mud to the power. While on the surface they present a danger
drill. Other personnel must keep a distance of 8m of becoming entangled.
4.3 DANGEROUS ZONES—SAFE DISTANCES
[25 ft] from the machine. A third worker may be
employed along the intended bore path to operate
NOTICE
the locating instruments and report their readings
For a detailed description of operation
to the operator.
and parts of the machine see Chapter
After moving into position, the machine remains
2 (DESCRIPTION.)
stationary in operation and has rotating parts, made
up by various movable components, therefore each
The directional drill is designed for the producpart has to be considered dangerous.
tion of a bore under the earth with a system more
efficient than conventional excavating and resto4.3.1 DANGEROUS PARTS AND DESCRIPration of the site. The main tool is the cutting head;
TION OF THE RISK.
it may be equipped with a metal shoe or with hard
metal teeth and is able to remove soil. The result is
4.3.1.1 TIE DOWN SYSTEM consisting of Ha bore with circular section ready for positioning
beams that are heavy and present a danger of pinchpipe or cable, without the need for back filling and
ing while being installed.
compacting.
The cutting head is advanced by connecting it to
4.3.1.2 REAR THRUST STABILIZERS are exsections of drill pipe which are added by the optending parts that present a danger of crushing.
eration of the directional drill. In addition, soil is
removed and the bore is lubricated by use of a
4.3.1.3 FRONT STABILIZERS are extending
mixture of water, bentonite and other substances
parts that present a danger of crushing.
(drilling fluid, also called mud) , which is forced
into the drill pipe by the mud pump. The mud
4.3.1.4 CARRIAGE has movement forward and
circulates through the annulus of the bore and rebackward as well as rotating parts, that present
turns to the surface at the entry point.
pinch points and a danger of becoming entangled.
The actual bore dimension cannot be guaranteed
for each bore. For example: depending on soil con4.3.1.5 WRENCH ASSEMBLY presents the danditions and the size of the pipe or cable to be inger of pinch points
stalled, it may be necessary to enlarge the bore by
pulling a reamer through it. Operation in hard rock
4.3.1.6 CUTTING HEAD tools under fast moverequires additional special accessories which are
ment and high power. Can emit fluid under high
not supplied and must be ordered separately.
pressure for cutting the earth, also presents a danger of becoming entangled.
4.2.1 NORMAL OPERATION
The operator has manual control over the rota4.3.1.7 DRILL PIPE heavy objects that must be
tion of drill pipe, the advance and return of the
added or removed from the drill. If handled carecarriage, flow and volume of mud, and operation
lessly, can fall or swing. While being forced into
of the fixed wrench and breakout wrench. The opthe earth the drill pipe is exposed and may be in
erator also has manual control over the movements
rotation, presenting a danger of becoming enof the pipe loader. In addition the operator has
tangled.
manual control over the angle of the thrust frame.
4.2 FUNCTION OF THE MACHINE
4.6 CONTROLS AND INSTRUMENTS
WARNING
Before leaving the console, make sure
that all the controls are in OFF or NEUTRAL position.
WARNING
A crushed or damaged tramming control could result in unexpected movement of the machine. Unexpected
movement can cause death or serious
injury; Always replace the tramming
control into its holder.
WARNING
Do not sit or stand on machine while
tramming. Unexpected movement can
cause death or serious injury. Use remote tramming control box only while
standing at ground level with good visibility.
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Page 19
4.6.1 CONTROLS
The drilling functions are controlled by levers and
switches mounted on an extendable console. As
an option, the controls can be located inside a
weatherproof driller’s cabin.
One panel is at the rear of the engine. One panel
4.4 QUALIFICATION OF THE OPERATOR
is on the right side of the machine. The operating
After delivery of the machine, a technician from controls are on a hinged arm at the right front corthe authorized dealer or from American Augers is ner of the machine.
available for training one or more operators. After
training, personnel are qualified for operation and 4.6.1.1 TRAMMING CONTROL
maintenance of the machine.
The control box can be connected at one of three
The operator must know every part of the manual. locations. The only function of controls on this box
American Augers is available for any further in- is the positioning of the drill on the job site or for
formation or instruction. It is expected that cus- loading and unloading from a transport. This switch
tomer personnel will be available and ready for box is connected to the drill by a flexible coiled
training upon the scheduled arrival of the Ameri- cord, and a container has been provided to hold
can Augers trainer.
the switch box when it is not in use. The switch
box also contains an emergency stop push button.
4.5 POSITION OF THE OPERATOR
(Fig. 33, PB2).
During drilling the only position of the operator
for operating the machine is at the control conNOTICE
sole. Additional workers will assist with loading
The switch must be in the SET-UP poand unloading the pipe as required. The operator
sition (Fig. 31, SS24) to activate the
must not ride on the machine while it is moving.
tramming control.
WARNING
When using the machine, make sure
that all personnel keep a safe distance
(8 m [25 ft] in every direction). Use
adequate protective equipment for any
operation to be done near the machine. See Fig. 5.
4.3.1.11 PERSONAL PROTECTIVE
EQUIPMENT
Always wear suitable personal protective equipment:
-protection for hearing
-safety shoes
-helmet
-safety glasses
REFER TO: Paragraph 1.5.4 DANGEROUS
ZONES—SAFE DISTANCES
4.3.1.10 DIESEL ENGINE AND MUFFLER
produce high temperatures. Danger of burns.
Before approaching always wait until:
-the machine is motionless
-the engine is off
-the movable parts are on the ground or in rest
position
-the hot parts have cooled.
Page 20
4.6.2.4 Fig. 31—Set-up Control Panel
SS18
Jacks FRONT/REAR
SS21
Right Jack RAISE/LOWER
SS4
Mode TRAVEL/DRILL
SS22
Boom Foot UP/DOWN
SS20
Left Jack RAISE/LOWER
PB4
Horn
FU1
Fuse
FU2
Fuse
FU3
Fuse
SS9
Throttle SLOW/FAST
SS6
Reset/Start Engine
PG4
Elec. Jack Guidance Signal (+)
PG3
Elec. Jack Guidance Signal (-)
4.6.2.3Fig. 30—Control Console
LT3
Panel Light
GAGE2A Pullback Pressure
GAGE2B Thrust Pressure
GAGE2C Makeup Pressure
GAGE2D Rotating Clamp Pressure
GAGE2E Fixed Clamp Pressure
GAGE2F Rotary Pressure
SS7
Work Lights ON/OFF
SS14
Crane Power ON/OFF
SS12
Auxiliary ON/OFF
PB3
Horn
LT2
Service Filters Warning LIghts
PB3
Emergency Stop
SS5
Reset/Start Engine
SS8
Throttle
TACH
Engine Speed (RPM)
DM1
Rotary Speed Digital Display
SS11
Rotary Brake FREE/LOCK
SS13
Carriage Speed HIGH/LOW
POT1
Rotary Speed Limit
PD2
Carriage Push/Pullback
VD6
Wrench MAKEUP/BREAKOUT
VD7
Rotary Clamp GRIP/RELEASE
VD8
Fixed Clamp GRIP/RELEASE
PD1
Rotary MAKEUP/BREAKOUT
SS17
Wrench Travel
FORWARD/REVERSE
SS15
Upper Pipe Support
RAISE/LOWER
SS16
Lower Pipe Support
RAISE/LOWER
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
4.6.2.2Fig. 29—Controls General Arrangement
Fig. 29-1 Es!lok® Receiver
Fig. 29-2 Control Console
Fig. 29-3 Recycling System (Optional)
Fig. 29-4 Limit Rotary Force
Fig. 29-5 Limit Pullback
Fig. 29-6 Limit Thrust
4.6.2.1Fig. 28—Engine Panel
Fig. 28—1 Voltmeter
Fig. 28—2 Engine Coolant Temperature
Fig. 28—3 Engine Oil Pressure
Fig. 28—4 Service Meter
Fig. 28—5 Engine Start Switch
Fig. 28—6 Digital Engine Speed (RPM)
Fig. 28—7 Starting Aid
Fig. 28—8 Throttle
Fig. 28—9 Emergency Stop
4.6.2 INSTRUMENTS AND CONTROLS (LIST)
REFER TO: Figs. 28—34
NOTICE
It is not possible to restart the engine
if any emergency stop push-button is
on (down).
4.6.1.2 EMERGENCY STOP PUSH-BUTTONS
One red emergency stop push-button is positioned
on the tramming control switch box, a second is
located on the setup panel on the right side. A third
is located at the control console. These push-buttons stop the diesel engine and consequently all
the functions of the machine.
After an emergency stop, reset it by lifting the
push-button before attempting to restart the engine.
There are also reset buttons on near the Emergency
Stop buttons, (Fig. 30, SS5; Fig. 31, SS6; Fig. 33,
PB3).
WARNING
A crushed or damaged tramming control could result in unexpected movement of the machine. Unexpected
movement can cause death or serious
injury. Always replace the tramming
control into its holder.
Key Switch OFF/ON
Emergency Stop
Page 21
4.7.1 STARTING THE ENGINE
REFER TO: Fig. 28—34
REFER TO: Attachment 1, Caterpillar 3126 or
3306 Diesel Engines.
For temperature included between -40°C and 15°C [-40°F and +5°F] REFER TO: Paragraph
4.23, OPERATION UNDER AMBIENT TEMPERATURES BETWEEN -40°C AND -15°C [40°F AND +5°F].
Make sure that the battery master switches (Fig.
CAUTION
In case unusual noise, abnormal pressure values, or if signal lights appear,
stop the engine immediately and carry
out necessary repairs.
WARNING
Do not use starting fluid (ether). Immediate engine damage and personal
injury may result.
CAUTION
Read instruction manual before operating (optional) engine preheater.
Heater must be preheated up to 30
seconds before engine cranking. Do
not operate preheater for more than 3
minutes after engine starts.
4.7 OPERATION
4.6.4 ZAP ALERT™
Accidental contact with an underground electrified wire can cause death or serious injury to the
drilling crew from electric shock. Crew personnel
should wear personal protective equipment. It is
essential that the crew is aware if the drill and related equipment become energized. The ZAP
ALERT® device senses the difference in electric
potential (voltage) between the drill rig and earth
ground and sounds an alarm. REFER TO: Attachment 4, ZAP ALERT™ Manual.
WARNING
A wrench on rotating drill pipe can seriously injure or kill. Do not break out
tool joints with pipe wrenches.
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
WARNING
Do not attempt to bypass the es!lok®
system Operation of the drill with the
es!lok disabled can result in injury or
death.
4.6.3 ES!LOK® LOCKOUT SYSTEM
The exit side crew has to work in contact with
drill pipe and down hole tooling. Unexpected
movement or rotation of the drill pipe or tooling
can cause death or serious injury. The es!lok® exit
side lockout system (Fig. 29-1) allows the exit side
crew to lock out movement and rotation of the drill
pipe and tooling. REFER TO: Attachment 3,
ES!LOK® Owner’s Manual.
WARNING
Replace any malfunctioning signalling
instrument immediately.
WARNING
Make sure all the controls are in the
NEUTRAL or OFF position before
starting the engine.
4.6.2.7 Fig. 34—Battery Switches
and Battery Equalizer
34-1
Battery Equalizer
34-2
Battery Box
34-3
Battery Disconnect Switch
34-4
Battery Disconnect Switch
4.6.2.6 Fig. 33—Tramming Control
SS17
Travel Speed FAST/SLOW
PB2
Emergency Stop
VD1
Left Track FORWARD/REVERSE
PB3
Reset
VD2
Right Track FORWARD/REVERSE
4.6.2.5 Fig. 32—Crane Pendant Control
32-1
Power OFF/ON
32-2
Lift Load
32-3
Boom Extend Retract
32-4
Winch RAISE/LOWER
32-5
Rotate CLOCKWISE/
CONTER-CLOCKWISE
SS3
PB1
Page 22
Use the controls (Fig. 31, SS18) to select the rear
stabilizers. Use the controls (Fig. 31, SS20 and
SS21) lower the stabilizers to contact the ground.
The stabilizers are to resist the rearward movement
4.8.5 POSITIONING REAR THRUST STABILIZERS
(JACKS)
NOTICE
The handrail sections ARE NOT interchangeable. Each section is marked
with a numeral (Fig. 27-1) so you may
fit it into the matching socket (see Fig.
27-2).
4.8.4 INSTALL HANDRAILS ON THE WALKWAY
Remove the handrails from the storage area on
the drill. Install them in the sockets provided and
secure with a bolt and nut.
4.8.3 REMOVE HOSE CARRIER HOLD DOWN
See Fig. 20.
4.8.2 EXTEND THE DRILLER’S CONSOLE
The control console on the DD-100 AND DD140 pivots from travel position and minimum machine width to drilling position. It is necessary to
move the console into the drilling position before
operation (See Fig. 22 and 23).
4.8.1 POSITION THE DRILL
Using the tramming controls, move the drill and
position it over the intended center line of the bore.
Using levers (Fig. 23-1 and 23-2), position the
thrust frame to the desired angle.
NOTICE
Efficient set-up requires the driller
plus one additional person.
4.8 SET-UP
WARNING
A crushed or damaged tramming control could result in unexpected movement of the machine. Unexpected
movement can cause death or serious
injury; Always replace the tramming
control into its holder.
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
WARNING
Do not sit or stand on machine while
tramming. Unexpected movement can
cause death or serious injury. Use remote tramming control box only while
standing at ground level with good
visibility.
4.7.2 MOVEMENT OF THE MACHINE
Insure that all personnel and objects are clear from
the intended path of travel. Place switch (Fig. 31,
SS4) in the TRAVEL mode. Adjust the engine
speed to low (Fig. 28-9; Fig. 30, SS8 or Fig. 31,
SS9). Remove the tramming control box from the
storage box. Connect the cable to one of the three
connectors. Press the RESET control (Fig. 33,
PB3).
While holding the tramming control box, slowly
move the controllers FIG. 33, VD1 and VD2: left
lever for left track, right lever for right track, away
from you for forward, toward you for reverse travel.
34-3 and 34-4) are turned on.
Read start up instructions on the attached Caterpillar Engine manual.
Make sure that the three emergency stop pushbuttons (Fig. 30, PB1 , Fig. 31. PB2 and Fig. 33,
PB2) are not pushed in.
Rotate the key (Fig. 21, SS16) to the start position. If the engine does not start within 20 seconds,
release the key and await the cooling of starter motor (at least 2 minutes).
Release the key as soon as the diesel engine is
running.
Engine oil and hydraulic pressures must reach
nominal values within 5 seconds. Adjust engine
speed with the control (Fig. 28, SS00; Fig. 30, SS00
or Fig. 31, SS9) .
Idle the engine for 5 minutes and run with reduced load until the water temperature reaches
60°C [140°F] and the hydraulic oil reaches 40°C
[104°F].
The electric system can be damaged seriously, if
the engine is started without the batteries connected. The engine must not run with disconnected
batteries.
DANGER
MOVING PARTS. Danger of entanglement. Keep body and clothing away.
4.8.10 ANCHOR THE MACHINE
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Page 23
Keep personnel at a safe distance
4.8.8 THRUST FRAME ANGLE
while driving tie down stakes, they
The thrust frame has two independent movepresent a danger of crushing.
ments. It can be tilted for changing the drilling
angle using the control (Fig. 31, SS22) and can be
4.8.10.2 OTHER METHODS OF ANCHORING
advanced or retracted (forward or rearward).
THE DRILL
In
especially
soft soils or sand, it may be neces4.8.9 THRUST FRAME EXTENSION
To advance or retract the frame, set the switch sary to use an earth anchor in addition to the tie
down stakes.
(Fig. 31, SS45) to DRILL position.
In hard or rocky soil it may be necessary to cut
Operate the Thrust/Pullback control (Fig. 30, PD2)
to position the carriage at the Carriage Lock (Fig. openings in the earth to accept the H-beams. Some
26). Swing the Lock Plate (Fig. 26-1) into the soils require the use of a pneumatic drill or other
socket on the carriage and rotate the toggle bar to equipment.
hold the Lock Plate in position.
In this positon, operation of the Thrust/Pullback 4.8.10.3 POUR A CONCRETE ANCHOR
In some soils, it will not be possible to install Hcontrol (Fig. 30, PD2) will extend or retract the
beams.
After selecting the launch point, the driller
thrust frame. Extend the thrust frame until the front
may use conventional excavating techniques to
foot contacts the ground.
DANGER
4.8.10.1 PLACING THE TIE DOWN STAKES
The tie down stakes are intended to prevent the
movement of the drill as it thrusts pipe into the
soil, or pulls on a backreamer or the product.
Placing the tie down augers requires another person in addition to the drill operator. While the second person holds the stake in position, the driller
drives the stake into the ground using a hydraulic
4.8.7 POSITIONING THE FRONT STABILIZ- stake driver.
ERS (JACKS)
As an alternative, the stakes can by pushed into
Use the controls (Fig. 31, SS18) to select the front the soil by carefully using the bucket of a backhoe
stabilizers. Use the controls (Fig. 31, SS20 and or excavator to exert downward force on the top
SS21) lower the stabilizers to contact the ground. of the stake.
Remove the pendant control from the storage box
and connect it at the base of the crane. While the
driller operates the crane controls, the second person detaches the hook block from its rest. Movement of the right front jack will move the base of
the crane, so be sure to unhook the crane from its
rest before moving the front jacks.
To activate the crane, connect the remote control
cable to the electric socket at the base of the crane.
Set the engine throttle (Fig. 30, SS8) to high. Operate the crane using the controls, (Fig. 27).
4.8.6 POSITION THE CRANE
present a danger of crushing.
Install the locking bolt through the holes drilled
of the drill when making the pilot bore. Do not use
the rear thrust stabilizers to level the drill. Do not in the thrust frame and the thrust frame support.
use the rear thrust stabilizers to lift the tracks off This will prevent the thrust frame from sliding on
the frame support.
the ground.
Rotate the toggle bar away from the Lock Plate.
DANGER
Swing the lock plate (Fig. 26-1) away the socket
Keep personnel at a safe distance
on the carriage. Drilling operations are done with
while lowering stabilizers, they
the lock plate away from the carriage.
Page 24
4.9.1 DEEP CROSSINGS - THE SETUP
A drilled crossing can be set up in several different ways. One method is to drill in a constant arc
or semi circle (see Fig. 44). The other method
would be to enter a hole at a downward angle. The
drill string is then directed into a horizontal position and advanced for the distance required to clear
the obstruction. The drill string would then be directed at an upward angle to the exit point A crossing is determined by its depth, starting point and
finishing point.
Once these criteria are determined, a set back distance is calculated for an entering and exiting point
to and from the intended line. A general rule of
thumb is that a drill string can bend at the rate of
30.5 m of radius per 2.5 cm of drilling pipe diameter. (Example: the minimum bend radius of a pipe
9.85 cm in diameter is approximately 120 m). [In
the English system a drill string can bend at the
rate of 100 ft of radius per 1 inch of drilling pipe
diameter. (Example: the minimum bend radius of
a pipe 3-7/8 inches in diameter is approximately
crossings, (4.5 m[15 ft] or more). The second category will be shallow crossings (4.5 m [15 ft] or
less). In both categories, the basic drilling methods are the same. The differences are in the manner of guidance and locating the drill string head.
Consult the manufacturer of the locating system
for exact operating instructions.
The directional drill provides the means for rotating, advancing and retracting the drill string. Depending on the specific project, a certain drill string
diameter is selected. Selection of drill string diameter or capacity is largely dependent on the
length of the crossing and the anticipated thrust
and pullback required for the finished product line.
At the leading end of the drill string, a cutting head
is attached (see Fig. 15-1). The cutting head is usually equipped with nozzles which direct drilling
fluid to the soil formation. While the cutting head
is being rotated into the ground, drilling fluid is
pumped through the drill string and passes through
the nozzles in the head to carry cuttings back to
the surface. The drilling fluid is also used as a lubricant to reduce friction and heat between the rotating parts and the ground.
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Directional drilling is the process of directing a
string of small pipe, known as a drill string, under
an obstacle, attach a cable or larger pipe line, and
pull it back to the starting point. Various factors
should be taken into account such as: 1) Hole size,
2) Required curvature, 3) Hole length, 4) Geology, 5) Minimum ground coverage, 6) Survey technique, 7) Magnetic bearing, 8) Drilling fluids, 9)
Entrance angle, 10) Exit angle, 11) Drill pipe, 12)
Drilling machine, 13) Preplotting chart, and 14)
General working area.
There are two categories. The first will be deep
4.9 DRILLING PROCESS
4.8.11 EXCAVATE THE ENTRY PIT
The drill should be anchored to the earth before
excavating the entry pit. Use earthmoving equipment to excavate the entry pit in front of the drill.
The pit is used to catch and retain drilling fluid
that returns from the bore. Many drillers excavate
a smaller pit to one side of the entry pit and connect the two pits together with a shallow channel.
Fluid returns enter the larger pit and overflow into
the smaller pit. During this process many of the
solids returning from the bore settle to the bottom
of the larger pit and do not have to be handled by
the fluid recycling equipment.
4.8.10.4 CONSTRUCT A “DEAD MAN”
ANCHOR
Construct a “dead man” anchor by excavating and
back filling. One effective method is to use sheet
piling and a steel beam. The sheet piling is placed
vertically in the excavation in front in front of the
drill. A steel beam is placed horizontally in front
of the sheet piling. A heavy chain or cable is attached between the steel beam and the front foot
of the drill. The excavated soil is replaced and compacted over the sheet piling and steel beam. This
arrangement prevents the drill from moving backward when thrusting the drill string into the earth.
See Fig. 37.
create a pit which can be filled with concrete. You
may consider placing beams or fasteners into the
wet concrete and attach the front foot of the drill
by fasteners or welding.
Page 25
A backreamer is a cutting head with its cutters
facing the drill string. Its purpose is to clear a path
for the product line being installed (Fig. 15-3 &
15-4). Directly behind the backreamer (away from
the drill pipe) a bearing swivel is installed. The
bearing swivel is to attach to a cap that has been
installed on the product line. The purpose of the
bearing swivel is to prevnt the product line from
rotating as the reamer and drill pipe rotate. As the
product line is pulled into the hole, the drill string
is rotated and drilling fluid is pumped in to maintain the integrity of the hole.
A rule of thumb states that the back ream diameter should be at least 1.5x the diameter of the product line.
In cases where the product line or bundle of lines
are larger than the pilot hole, an oversized
backreamer will be required. When backreaming
for product line installation, a slightly larger hole
WARNING
A wrench on rotating drill pipe can seriously injure or kill. Do not break out
tool joints with pipe wrenches
DANGER
MOVING PARTS. Pinch point. Keep
body and clothing away.
DANGER
ROTATING PIPE. Danger of entanglement. Keep body and clothing away.
compares the information to a plotted chart. If there
is any deviation from the intended line, the operator makes the steering corrections. Once the first
section is buried, the drill section is uncoupled from
the drill spindle and another section of drill pipe is
added. For each section of drill pipe installed, an
additional length of connector wire is also installed,
crimped and insulated to complete the circuit for
the survey probe.
The sequence continues until the pilot hole is
completed. By the time the pilot hole is completed,
the product line should have been prepared to be
pulled back. For pulling back a product line or lines,
first the cutting head is removed and a backreamer
is installed in its place.
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
4.9.3 DEEP CROSSINGS - DRILLING
METHOD
When drilling begins, the drilling fluid (mud)
pump is turned on and the cutting head is rotated
into the ground. As the first section is being buried, the operator monitors the head location and
4.9.2 DEEP CROSSINGS - STEERING SYSTEM
While the hole is being drilled, the drill string is
rotated along with the cutting head as a single section. When steering adjustments are required, the
drill string is not rotated, however, the cutting head
offset is rotated toward the desired direction of
travel and the drill string is advanced forward without rotation. The eccentric location of the cutting
head relative to the center line of the drill string
creates a wedge type effect when pushed without
rotation. This causes the drill string to deflect in
the desired direction.
The locating probe transmits the orientation of
the cutter head relative to the face of a clock (Fig.
18). Once the orientation is determined, the driller
rotates the drill pipe to the desired location. This is
confirmed by the locating instrument. The drill
string is then rotated to resume cutting. This process is repeated as many times as necessary to assure proper location of the cutting head as it
progresses along the desired path.
380 ft).]
Once the project is established and the entering
and exit points are known, the process can begin.
The drill rig is set up and the drill thrust frame is
set to the required angle. This is from 10 to 18
degrees, depending on the characteristics of the
crossing. The initial pipe section and cutting head
are set into the wrench. (Note: While the setup and
drilling is proceeding, a second operation should
be started to prepare the product line for installation). The first piece of drill pipe is made out of an
nonmagnetic material to eliminate any interference
to the survey probe. This first section is setup to
mount the cutting head and the survey probe for
guidance. Before the drilling process begins, a
magnetic bearing is selected for the desired direction of travel. The survey probe is calibrated to
this bearing and installed in the first section.
Page 26
4.9.6 DRILLING FLUID - THE PROCESS
Drilling fluid (mud) consists of water or water
with additives. Products such as bentonite and polymer can be very helpful for horizontal boring, Optimum delivery of drilling fluid to soil is critical
for minimizing operating pressures and torque.
There are several key factors which must be considered to maximize your production: 1) hole size,
2) boring rate, and 3) fluid injection rate. These
three factors can be used to calculate a fluid-tosoil injection rate in volume of fluid to volume of
soil removed. The amount of fluid required to make
the soil flow out the hole is dependent on the type
and amount of clays in the soil.
4.9.5 APPLICATION OF DRILLING FLUID TO
HORIZONTAL BORING
When using high productivity drills as large as
the DD-100 or DD-140B, a fluid recycling system
is strongly recommended. Drilling operations
might require fluid quantities of 1135 to 2270 L/
minute (300 to 600 GPM). Simply mixing fluid in
these quantities presents a challenge. A recycling
system enables the driller to reclaim most of the
drilling fluid for re-use, and minimizes the amount
of fresh water required for mixing. The recycling
system removes solids from the drilling fluid and
usually includes a high pressure pump (mud pump)
to send the fluid through the drill pipe into the bore.
Controls for an American Directional Drill recycling system fit in the control console next to the
drill controls (see Fig. 29-3).
The primary functions of a drilling fluid (mud)
in horizontal boring are: 1) to reduce torque associated with sticky soil conditions, 2) to aid removal
of solids from the freshly cut hole by a flushing
action, and 3) to help stabilize the soil. Water is
the major component of drilling fluids used in horizontal boring. Materials added to water to produce
a drilling fluid are bentonite and polymer. Factors
which are very important to drilling fluid quality
are: 1) water quality, 2) formulation of the products and mixing order, and 3) adequate mixing of
the products.
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
WARNING
A wrench on rotating drill pipe can seriously injure or kill. Do not break out
tool joints with pipe wrenches
DANGER
MOVING PARTS. Pinch point. Keep
body and clothing away.
DANGER
ROTATING PIPE. Danger of entanglement. Keep body and clothing away.
4.9.4 SHALLOW CROSSINGS - THE PROCESS
The DD-100 and DD-140B are not normally used
in shallow drilling (4.5 m [15 ft] or less).
than the product line is required so that the drilling
fluid can remove the cuttings. The amount of
overcut is largely dependent upon soil conditions
and the type of crossing or obstacle. In cases where
the ground conditions are soft and basically
unsupporting, use a barrel reamer. This is a tool
with radial or coned-shaped ends, which when
pulled and rotated through the ground, compacts
the soil in the hole to maintain its integrity. The
bearing swivel is installed behind the barrel reamer.
Drilling in hard soil or rock requires a downhole
motor (see Fig. 16). Downhole motors are designed
and built in various diameters and torque ratings
to accommodate most drilling applications.
Downhole motors are used where high cutter bit
speed is desired. In most applications the motors
are used in combination with the bent sub for steering purposes. Several manufacturers have combination systems for sale or lease.
In cases where the hole must be maintained or
blowouts must be prevented, use of a wash pipe is
recommended. A wash pipe can be installed when
backreaming or directly over the drill string. The
use of a wash pipe provides a maintained annular
area so the drilling fluid can remove the cuttings
and spoil material without increasing downhole
mud pressures and the probability of a frac-out (inadvertent return of fluid).
4.9.9 WATER QUALITY
Hard water (contains calcium and/or magnesium)
or salty water is detrimental to bentonite and polymer. If you notice severe thickening or separation
of bentonite or polymer at the bottom of the mixing tank, then you probably have a water quality
problem. If your makeup water is salty, replace it
with fresh water. If your water source is hard treat
with soda ash (sodium carbonate, Na2CO3) at a rate
from 0.25 kg to 1 kg per 380 litres [0.5 to 2.0 lb
per 100 gallons] or adjust the pH to 9.5. Soda ash
precipitates out calcium in the make-up water as
insoluble calcium carbonate, making it harmless.
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Page 27
4.9.10 MUD MIXING
Adequate mixing is essential for preparing either
bentonite or bentonite/polymer slurries. The mixing system must incorporate increased velocity by
pipe diameter reduction. Bentonite powder is added
4.9.8 FLUID DISPOSAL
Disposal of drilling fluid wastes should be cov- through the hopper portion of the jet mixer. Liquid
ered in construction permits. Although drilling fluid emulsion polymers should be mixed by recirculatadditives such as bentonite and polymer are not ing through a jet.
considered hazardous wastes, local regulations
concerning fluid disposal vary. While it is impor- 4.10ADDING AND REMOVING PIPE
tant to apply enough fluid to minimize operating
The crane is intended only for handling pipe and
torque, overuse of drilling fluid will increase costs
tooling. Do not use the crane for maintenance on
of bentonite and disposal fees.
For instance, reaming a 355 mm diameter hole other machines (such as tire lifting).
When the crane is not being used, disconnect
and using 3.8 litres of fluid per 3.8 litres of soil, a
bore 30.5 m long would require approximately the control cable and store it in a safe dry location.
3028 litres of fluid for 3028 litres of soil excavated. The control is not weather proof.
The crane is equipped with an “anti-two block”
The total waste generated is 6056 litres of a soil
safety
device. Do not disable this device. Do not
and water mixture. Depending on the amount of
material displaced from the drilled hole, it could use the safety device as a shut off when lifting a
be necessary to dig a pit of an additional 5.6 cubic load.
The crane has one power extension section on
metres volume just to accommodate the waste from
the drilled hole. [Using the English system, ream- the boom, and one manual pull out section. When
ing a 14 inch diameter hole and using 1 gallon of the boom sections are extended, the load on the
fluid per 1 gallon of soil, a bore 100 feet long would crane must be reduced according to the load chart
require approximately 800 gallons of fluid for 800 (Attachment 4, Crane Owners Manual). Also, as
gallons of soil excavated. The total waste gener- the crane boom approaches horizontal, the load on
ated is 1600 gallons of soil and water. Depending the crane must be reduced according to the load
on the amount of material displaced from the drilled chart.
hole, it could be necessary to dig a pit of an additional 200 cubic feet volume just to accommodate
the waste from the drilled hole.
4.9.7 CALCULATION OF VOLUME OF
FLUID TO VOLUME OF SOIL
The three pieces of information needed to calculate gallons of fluid to gallons of soil at a given
boring rate are: 1) hole volume, per unit of length.,
2) boring rate, in length/minute, and 3) pump rate
in volume/minute. From this information, the volume can be calculated (see Fig. 43).
Some soils may require more fluid, others less.
If you are at the maximum mud pump output and
encounter excess torque, then you can reduce the
rate of advance and vary your pump rate to produce minimum torque to optimize progress. Some
soils will be easier to drill if polymer is added to
the drilling fluid. Bentonite suppliers can offer
guidance concerning the use of bentonite and polymer products.
Page 28
4.10.2.1 THE ROTARY BRAKE
The operation of a mud motor induces an unwanted backward rotation into the drill string. The
rotary brake is used to lock the rotary spindle and
prevent it from turning backward. Activate the rotary brake with the control (Fig. 30, SS11). Unlock the rotary brake before attempting to steer the
mud motor.
4.10.2 USING A MUD MOTOR
A mud motor will be longer than the combination of the sonde housing and cutting head. The
mud motor also normally requires the use of a nonmagnetic pipe section which fits between the mud
motor and the first section of drill pipe. The locating sonde or other instrument is located inside this
non-magnetic section.
The use of a mud motor will normally require
excavation of a pit in front of the drill. The pit
should allow the cutting bit to enter the far vertical
wall of the pit. Mud motors vary somewhat in design. Follow the manufacturer’s instructions with
respect to installation of the cutting bit, and adjustment of the mud motor and non-magnetic section to calibrate the locating instrument.
DANGER
A wrench on rotating drill pipe can seriously injure or kill. Do not break out
tool joints with pipe wrenches
threads. Be sure to coat the pipe threads with thread
joint compound.
If the sonde and cutting head is very long, it may
be necessary to tilt the thrust frame or excavate a
pit in front of the drill.
Tighten pipe joints to the pipe manufacturer’s
specifications. You can set a limit on the rotary
torque at the spindle by observing the pressure on
the rotary torque gauge (Fig.30, GAGE2F) and
using the chart to convert the pressure to rotary
torque. Turn the control (Fig. 29-4) to adjust the
maximum pressure on the gauge. Avoid over-tightening the pipe threads to reduce problems when
loosening the threads.
Using suitable tools, tighten the cutting head and
sonde housing to the pipe.
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
4.10.1 ADDING PIPE (FIRST SECTION)
Coat the threads on the rotary spindle with special thread lubricant. Move the carriage to the rear
of the thrust frame using control (Fig. 30, PD2).
Using the crane and a pipe tongs, lift one section
of pipe from storage and place it over the thrust
frame.
Raise the pipe supports using the controls (Fig.
30, SS15 and SS16). Lower the pipe into the pipe
supports.
Using PD2, advance the carriage until its threads
contact the box of the pipe section. Using PD1,
rotate the spindle until the threads tighten.
Be sure to coat the pipe threads (pin end) with
thread joint compound. Advancing the carriage,
slide the first section of pipe through the wrenches
for installation of the sonde housing and cutter
head.
Lower the pipe supports, using the controls (Fig.
30, SS15 and SS16)
Following manufacturer’s instructions, resupply
the locating sonde with fresh batteries and calibrate the locating receiver. Put the sonde into a
sonde housing and hand fit it to a cutting head.
Hand-fit the sonde housing and cutting head to the
DANGER
MOVING PARTS. Pinch point. Install
the fender beneath the pipe loader.
Keep body and clothing away. Do not
allow personnel inside the fender
while the pipe loader is operating.
DANGER
MOVING PARTS. Pinch point. Keep
body and clothing away.
DANGER
ROTATING PARTS. Danger of entanglement. Keep body and clothing
away.
DANGER
Do not walk or stand under a suspended load. Retract the boom completely before transporting the drill. Do
not allow the crane to contact overhead electric wires.
Page 29
Position the spindle in the breakout wrench. Close
the jaws using VD8. Loosen the threaded joint at
the spindle by moving control VD6, activating the
breakout wrench. Then return the breakout wrench
to its original position.
Rotate the spindle in the breakout direction and
loosen the upper threaded joint to the spindle by
operating control PD1. This will require only 2 to
3 revolutions.
With the spindle threads loose but still engaged,
move the carriage toward the rear of the thrust
frame. Observe the mechanical pointer fixed to the
thrust frame near the wrenches. Move the carriage
toward the rear of the thrust frame until the shoulder of the pipe pin is aligned with the pointer. This
is the proper position to remove the pipe with the
loader arm.
NOTICE
Because Range 2 pipe sections can
vary in length, the wrenches on the
DD-100 and DD-140 are adjustable to
align the wrenches with the tool joints.
Position the wrenches forward and
rearward along the thrust frame, using the control (Fig. 30, SS17).
4.10.5 REMOVING PIPE
Using movement of the carriage (control PD2),
pull pipe back from the hole until the joint between
the spindle and the pipe is aligned in the jaws of
the wrench. The lower section of pipe should be
held by the fixed clamp, (control VD8). Make sure
the carriage is pulled back so that the sliding rotary box has moved forward. The sliding rotary
box must have room to move rearward as the pipe
threads disengage.
Use the carriage to push the section of pipe until
its pin end engages the box of the previous section
of pipe. Rotate the spindle slowly using control
PD1 and engage the new pipe threads with the previous section of pipe. Using the control (Fig. 30,
VD8) release the jaws of the fixed wrench.
Add additional sections of pipe to the drill string
repeating the instructions above.
Continue to add sections of pipe to complete the
pilot bore. Make steering corrections as necessary.
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
4.10.4 ADDING PIPE (ADDITIONAL SECTIONS)
Drill the first section of pipe, sonde housing and
cutter head into the earth until the spindle is just
about to enter the breakout wrench. The box end
of the pipe should be located between the jaws of
the fixed wrench.
Grip the first section of pipe tightly in the fixed
wrench, using control (Fig. 30, VD8). Loosen the
threads on the spindle by rotating spindle using
control (Fig. 30. PD8). Break out the joint, leaving the first section of pipe secure in the fixed
wrench.
Coat the spindle threads with thread joint compound. Move the carriage to the rear of the thrust
frame using control PD2.
Bring another section of pipe into position over
the thrust frame, following the instructions above.
Make up the joint between the spindle threads and
the new section of pipe. Rotate the spindle slowly
using control PD1, and advance the carriage toward the pipe, making sure the spindle and pipe
box are aligned.
Coat the pipe threads with lubricant. Rotate the
spindle slowly using control PD1 and engage the
new pipe threads with the previous section. As the
threads begin to tighten, apply pressure to the end
of the pipe with the carriage spindle.
4.10.3 INSTALLING A WIRELINE GUIDANCE INSTRUMENT
Several suppliers sell and lease a magnetic survey system which provide information to the drill
operator such as drill head rotation, drill head angle
and magnetic bearing. This information is relayed
to the operator by means of probe installed directly
behind the cutting head in the first section of the
drill pipe. The data is usually transmitted to the
surface via a single conductor wire. Most of the
units are provided with a surface processor for
computing the information.
The wireline guidance instrument is housed in a
special section of drill pipe. Some housings are
made of a non-magnetic alloy. It is necessary to
calibrate the guidance instrument and “time” it to
the drill string to get accurate readings. Follow the
manufacturer’s instructions.
DANGER
Drilling fluid under pressure can cause
personal injury. Stay away from the jet.
4.11 START OF THE DRILLING OPERATION
Confirm that the machine is in the drilling position, otherwise find this position and move the machine. The drill pipe should be positioned longitudinally along the intended bore path.
Anchor the machine.
Connect the mud mixing equipment(sold separately) to the drilling rig by means of a flexible
hose. The connection is alongside the thrust frame.
Following manufacturer’s instructions, operate
the transfer pump on the mud recycling system to
ensure an adequate supply of drilling fluid to the
mud pump on the DD-100 AND DD-140. It is normal for drilling fluid to escape from the cutting
head even if the mud pump is not operating.
With the drill properly positioned along the intended bore path, and with the front foot anchored
securely, activate the mud pump.
A strong jet of drilling fluid will escape from the
cutting head.
Control mud flow with the optional controls (Fig.
29-3)
4.10.7.1 LIMITING THRUST AND
PULLBACK FORCE
The maximum thrust and pullback force can be
set by turning the knobs (Fig. 29-5 and 29-6). This
can prevent applying too much force and damaging a down hole motor. It can also help the drill
operator regulate the rate of advance of the cutter
head or the retraction of a back reamer.
Page 30
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
4.10.6.1 LIMITING ROTARY TORQUE
The maximum rotary torque force can be set by
turning the knob (Fig. 29-4). This can prevent apUsing the control lever (Fig. 30, PD1), advance
plying too much force and damaging the pipe the carriage to thrust the cutting head into the earth.
threads.
Depending on the desired bore path, it is the
driller’s decision whether to advance the head with
4.10.7 CALCULATING THRUST AND PULL or without rotation.
BACK FORCE
When the length of pipe has been nearly thrust
Thrust and pullback force can be calculated by through the fixed wrench, align the joints in the
comparing the reading on the gauges (Fig. 30, pipe between the wrench and the breakout wrench.
GAGE2A and GAGE2B) to the table (Fig. 38 and Operation of the breakout wrench will loosen the
40). Example: 1,400 psi indicated on the DD-100 threads, assisted by rotation of the spindle in the
gauge provides a thrust/pullback force of 8,876 lb clockwise direction.
(High range) or 27, 221 lb (Low range).
4.10.6 CALCULATING ROTARY TORQUE
FORCE
Rotary torque force can be learned by comparing the reading on the gauge (Fig.30, GAGE2F) to
the table (Fig. 39). Example: 2,500 psi indicated
on the DD-100 gauge provides a torque of 3,538
ft-lb (High range) or 11,189 ft-lb (Low range).
Place the pipe sections in an area where they will
not interfere with the movements of the drilling
crew.
DANGER
Do not walk or stand under a suspended load. Do not allow the lifting
mechanism to contact overhead electric wires.
Using control PD2, move the carriage toward the
wrenches. Pause and apply thread joint compound
to the spindle threads. Move the spindle threads
into the box of the pipe still held in the fixed
wrench. Make sure the sliding rotary box has
moved to the rear of the carriage. Use control PD1
to rotate the spindle in the makeup direction until
the threads have completely engaged.
Observe the pressure on the gauge (Fig. 30,
GAGE2F). Compare the presssure reading to the
conversion chart (Fig. 39 or 41) to find makeup
torque. Avoid overtightening the threads, which can
shorten pipe life and make breakout difficult. Correct makeup torque values are supplied by the pipe
manufacturer.
WARNING
A wrench on rotating drill pipe can seriously injure or kill. Do not break out
tool joints with pipe wrenches.
WARNING
Do not attempt to bypass the es!lok®
system Operation of the drill with the
es!lok disabled can result in injury or
death.
DANGER
Unexpected movement or rotation of
the drill string can cause death or serious injury. American Directional
Drills come equipped with the es!lok®
exit side lockout system. Use the
es!lok ® system to disable the drill
while changing tooling. Instructions
for operating the es!lok® system are
found in a separate manual REFER
TO: Attachment 3, Es!lok® Operator’s
Manual.
4.13 START OF THE PULLBACK OPERATIONS
After the completion of the pilot bore, the operator must decide whether to enlarge the bore by
reaming. Factors include the soil conditions, length
of the bore, and the flexibility of the pipe or cable
being installed.
If reaming is required, remove the cutting head
from the drill pipe using suitable tools.
batteries and store the sonde in a safe container.
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Page 31
To pre-ream the pilot bore, install the reamer in
place of the cutting head. When all personnel are
clear, re-enable the es!lok® system, and rotate the
drill string. Use of drilling fluid as with the cutting
head will remove soil debris and will lubricate and
cool the reamer.
DANGER
Continue to withdraw sections of pipe from the
A wrench on rotating drill pipe can sepilot bore until the reamer has reached the entry
riously injure or kill. Do not break out
point.
tool joints with pipe wrenches.
Some drillers add sections of drill pipe behind
the reamer as it passes through the pilot bore. This
Completely clean the cutter head. Remove the ensures that the driller will have access to the pilot
sonde instrument from the housing. Remove the bore even in case of some collapse of the surround-
DANGER
Drilling operations may require construction of an exit-side pit. The pit
must be constructed following Federal
and local laws. Unsafe pit construction may cause death or serious injury.
4.12 END OF DRILLING OPERATIONS
Maintain good verbal contact with the personnel
at the exit point. Make sure everyone is clear of
the exiting pipe. Notify the driller and activate the
es!lok® system. Using suitable tools, remove the
cutter head and sonde housing. Separate the cutter
head from the sonde housing.
DANGER
Keep personnel away from the rotating parts.
When the spindle has come loose from the length
of pipe, apply thread joint compound to the spindle.
Retract the carriage to the rear of the thrust frame.
Operate the crane to position another section of
pipe between the spindle and the female thread (the
box) of the previous pipe.
Apply thread lubricant to the pin of the new pipe.
Slowly advance the spindle into the box of the
new pipe, then allow the pipe to slide over the pipe
supports until the pin of the new pipe contacts the
box of the previous pipe. Slowly rotate the spindle
and advance the carriage until the threads of the
two pipes engage and tighten. Tightening must be
done with rotation of the spindle. The breakout
wrench on the DD-100 and DD-140 is not designed
to tighten.
Release the jaws of the fixed wrench and advance
the pipe into the bore path as before.
Repeat this sequence to complete the pilot bore.
Steering corrections depend on the type of cutting head in use.
4.16EMERGENCY STOP
4.15 SWITCHING OFF THE ENGINE
Position all the controls in the OFF or NEUTRAL
position.
Reduce the engine rpm to minimum (Fig. 30,
SS18). Wait 5 minutes for the engine to cool.
Switch off the engine by pushing the Emergency
Stop button (Fig. 30, PB2).
WARNING
A crushed or damaged tramming control could result in unexpected movement of the machine. Unexpected
movement can cause death or serious
injury; Always replace the tramming
control into its holder.
Page 32
During drilling, it is absolutely necessary to monitor instruments and functions regularly.
In case of anomaly, act immediately, by modifying the adjustments or stopping operation.
4.18 CHECKS DURING OPERATION
REFER TO: Paragraph 4.7.1. STARTING THE
ENGINE.
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
WARNING
Do not sit or stand on machine while
tramming. Unexpected movement can
cause death or serious injury. Use remote tramming control box only while
standing at ground level with good
visibility.
4.14.1 REMOVING THE TIE DOWN STAKES
Using the EMERGENCY STOP push-buttons
Remove the tie down stakes from the front foot. (red) it is possible to stop every function of the
Do not attempt to remove the tie down stakes by machine immediately by switching off the diesel
raising the machine’s front foot. Remove the tie engine.
down stakes from the work area and store them.
Location of the 3 emergency stop push-buttons:
-On the set-up control panel on the right side of
DANGER
the machine (Fig. 31, PB1).
MOVING PARTS. Pinch point. Keep
-On the tramming control switch box (Fig. 33,
body and clothing away.
PB2) accessible from the ground.
-On the main control console (Fig. 30, PB0).
4.14.2 CLEAN UP
When one of emergency stop push-button is
Position the carriage at the midpoint of the thrust
pushed, the diesel engine switches off immediately.
frame as an aid to balance the machine. Remove
the mud supply hose from the mud pump. Put the 4.17 START AFTER AN EMERGENCY STOP
switch (Fig. 31, SS4) in the TRAVEL position. ReTo re-start the machine after an emergency stop,
tract the rear thrust stabilizers. Remove all tools find and remove the reason for the emergency. Then
and loose objects from the area and put them into use the following procedure:
storage. Before tramming away from the entry
Rotate the ignition key to switch the OFF posipoint, position the thrust frame into the travel po- tion (Fig. 31, SS3). Position all the controls in the
sition (see Paragraph 3.2.2). Using the tramming OFF or NEUTRAL position.
control box, slowly back the machine away from
Identify the emergency push-button used for the
the entry point. Wash mud, drilling fluid and soil stop and lift it.
off the machine before transporting it.
Start up the machine with the normal procedure.
4.14 END OF PULLBACK OPERATIONS
The pullback operation is complete when the pipe
or cable has been installed and pulled back to the
entry opening.
Using suitable tools, remove the swivel, reamer,
and pulling eye. Leave the pipe or cable exposed
according to the requirements of the installation.
ing soil.
The operator may be able to complete reaming
and pullback in a single operation. In that case, a
heavy duty swivel is connected to the far side of
the swivel. A suitable pulling eye is connected both
to the swivel and to the pipe or cable to be installed.
Page 33
Read and follow the test and set up instructions
in the ZAP ALERT® operator’s manual (AttachRefer to the Safety Awareness Program in this manual before attempting to operate this machine.
CAUTION
It is the operator’s responsibility to
stop the machine for any abnormal
value indicated by the instruments.
Read and understand the ZAP ALERT®
operator’s manual (Attachment 3).
A priority list of instruments can be the follow- 4.20ES!LOK® LOCKOUT
ing:
WARNING
-Engine rpm (Fig. 30, TACH)
Read
and
understand
the instructions
-Engine Throttle (Fig. 30, SS8)
®
in the es!lok operator’s manual, At-Thrust pressure (Fig. 30, GAGE2A)
tachment 3).
-Pullback pressure (Fig. 30, GAGE2B
-Rotary hydraulic pressure
WARNING
(Fig. 30, GAGE2F)
Do not attempt to bypass the es!lok®
-Hydraulic oil filter lights
system. Operation of the drill with the
(Fig. 30, LT2)
es!lok disabled can result in injury or
The driller should also make periodic inspections
death.
of the engine instruments (Fig. 28):
-Voltmeter (Fig 28-1)
The es!lok® exit side lockout must be manually
-Engine water temperature (Fig. 28-2)
engaged by the drill operator and by the Compe-Engine oil pressure (Fig. 28-3)
tent Person on the exit side crew. The drill operator pushes the reset switch on the receiver box
4.19 NORMAL OPERATING RANGES OF INmounted to the left of the control console (Fig. 29STRUMENTS
1 ). The Competent Person enables operation by
-Engine oil pressure normal value is 2.8 bar [40
pressing the start button on the es!lok® unit worn
psi]
on the belt. The normal indication is a green light
-Engine coolant temperature normal range is
on the receiver box and a flashing green light on
71°C to 96°C [160°F to 205°F] maximum 88°C
the unit worn on the belt. In case of any fault, the
[190°F]
thrust and rotation functions of the drill will stop,
-Hydraulic oil temperature normal range is 38°C
and will not operate until both persons have reset
to 60°C at an ambient temperature of 5°C to 27°C
their respective devices.
[100°F to 140°F at an ambient temperature from
40°F to 80°F]
4.20.1 START AFTER USE OF ES!LOK®
-Volt meter 12.8 to 13.5 volts
The normal use of the es!lok® is to provide safety
-Engine rpm (Fig. 30, TACH). Do not exceed
to the exit side crew while they are in contact with
2600 rpm
the drill pipe and tooling. After notifying the drill
-Rotary speed (Fig. 30, DM1) according to soil
operator by radio or other signal, the Competent
conditions, normal range (DD-100: 0-100 rpm;
Person presses the red STOP button on the belt
DD-140B: 0-95 rpm)
unit. A red light will be seen on the receiver box,
The correct operation of the battery charging cirreminding the drill operator that a lockout is uncuit is indicated by the voltmeter with the indicaderway. Only when it is safe to do so, the Competor between 12.8 and 13.5 volts. When the engine
tent Person will notify the drill operator to reset
is running, if the indicator is below 12.8v it indithe receiver. The Competent Person also resets the
cates an anomaly. Check the system.
belt unit by pressing the START button. Normal
Hydraulic oil red alarm lights indicate a need for
functions are restored to the drill.
maintenance when the system is at normal operating pressure and at normal temperature. In case 4.21 USE OF ZAP ALERT®
these lights remain on when 40°C [104°F] temperature is reached, replace the filters.
WARNING
4.22.2 STARTING THE ENGINE (with the machine kept warm through pre-heaters)
REFER TO: Attachment 1 3126 or 3306 Caterpillar Diesel Engines.
Idle the engine.
Wait until the engine has reached the operating
temperature before moving.
Wait for the hydraulic oil to reach the temperature of +30°C [86°F] before operating the controls.
Check that the filter pilot lights filters are switched
off before movement.
Disconnect the cable of preheaters from the electric supply before putting the machine to work.
WARNING
Pre-heating device operates on high
voltage (110 volts or 220 volts AC).
Connect to a circuit equipped with a
ground fault interrupter (GFI). Protect
the electric cables from contact with
water or other liquids.
The customer must specify which voltage range
the heater will be connected to. In this way it is
possible to start the diesel engine even at ambient
temperatures between -40 and -15°C [-40°F to
+5°F], it is advisable to use pre-heaters in case it
goes under 0°C [32°F]. Connect the cable of
preheater to the electric supply.
Page 34
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
WARNING
Make sure all the controls are in the
NEUTRAL or OFF position before
starting the engine.
4.22.3 STARTING THE ENGINE (in case the
preheaters are not connected while stopped)
In case of long stops with ambient temperatures
between -40°C and -15°C [-40°F to +5°F] without
the preheaters connected, before starting the enCAUTION
gine.
Failure to observe starting instrucIdle the engine.
tions can cause damage to the hyWait until the engine has reached operating temdraulic circuit and to the diesel engine.
perature before moving.
Wait until the hydraulic oil has reached the tem4.22.1 PRE-HEATING DEVICES
perature of +30°C [86°F] before moving the conDuring normal operation, the machine is able to
trols.
keep the temperatures of the oils within the limits
allowed. In case of stop it is necessary to supply
4.22.4 PROTECTING THE FLUID COURSE
power for keeping the temperatures inside the dieFROM FREEZING
sel engine. This is made by connecting the relevant
Whenever drilling is stopped and the ambient
plug of the pre-heating device to an electric supply rated at 1 kW at 110/220V 50/60Hz monophase. temperature is expected to reach 0°C [32°F] or
Only the machines especially arranged at the factory can work under ambient temperatures between
-40°C and -15°C [-40°F to +5°F]. This is due to a
particular choice of materials (rubber, gaskets, oils,
grease) so that the components do not suffer from
the cold and do not age quickly. Some machines
are equipped with a preheater device to keep the
minimum temperature needed for starting the diesel engine.
It is necessary to carefully follow the specifications of oils and cooling liquids for the diesel engine, that must guarantee suitable protection at the
minimum temperature.
REFER TO: Attachment 1, Caterpillar 3126 or
3306 Diesel Engines.
4.22OPERATION UNDER AMBIENT TEMPERATURES BETWEEN -40 & -15°C
[-40°F to +5°F]
4.21.1 START AFTER USE OF ZAP ALERT®
Make sure that the drill and associated equipment
are no longer energized. Retest and set up the ZAP
ALERT® as before.
ment 4). The ZAP ALERT® is intended to warn
the crew if the drill and associated equipment become energized. It is critical to take proper action
after striking a buried cable. Taking the wrong action can cause death or severe injury.
Page 35
NOTICE
Refer to the table (Fig. 45) for approved
replacement fluids
Every day before use and at least every 10 hours,
inspect and perform maintenance on the machine
according to the procedures indicated in Section
5.
5.3 SCHEDULED INSPECTION AND MAINTENANCE
5.2.2 FREQUENCY OF INSPECTIONS
Periodical inspections give the operator a simple
identification and solution of the problems. It is
advisable to carry out the inspections more frequently when working in difficult soil conditions.
At every inspection/maintenance schedule all previous inspections must be carried out. For example,
at 250 working hours, also perform the items listed
in daily and weekly schedules.
NOTICE
For any operation which is not described in this manual or for extra information please contact AMERICAN
AUGERS or the nearest dealer directly.
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
DANGER
Make sure that personnel keep a safe
distance during maintenance and control operations.
WARNING
Do not carry out welding near the
tanks and inflammable liquids.
Hydraulic oil, gearboxes oil, diesel engine oil,
pins and bearings grease, diesel engine cooling liquid, batteries liquid, fuel: handle with care.
Engines, muffler, gearboxes and hydraulic system, can reach very high temperature. Do not attempt maintenance immediately after stopping the
work until after the parts are cool.
WARNING
Carry out maintenance when the machine is off. Before operating, clean
the machine and lock movable parts.
For maintenance to be carried out with
running machine, follow instructions
in Chapter 4 USE.
5.1 DANGEROUS ZONES—SAFE DISTANCES
5. MAINTENANCE
to concerns about spills. Use special
antifreeze fluid which is classified as
“non-toxic.”
can be drained by breaking the tool joint nearest
the wrenches and by opening the small valve be- 5.2.1 QUALIFICATION OF THE TECHNICIAN
The technician in charge must be trained to know
hind the hammer union where the mud supply hose
the operation and handling of the machine, to verify
is connected.
that there are no functioning faults, to carry out
maintenance with suitable equipment and protecCAUTION
tion, and to inform the responsible qualified perFreezing water can do severe damage
sonnel about special repairs that cannot be made
to the mud pump and other parts of
by himself (example: adjustment of Caterpillar
the fluid course. Do not use engine
engine, welding, etc).
antifreeze fluid in the mud pump due
below, it is necessary to protect the fluid course 5.2 ORDINARY, PERIODICAL AND PREVENTIVE
MAINTENANCE
(path of mud flow) from freezing.
This section includes all the necessary operations
for maintenance by the drill operator (example:
4.22.4.1 DRAIN THE FLUID COURSE
The fluid course on the DD-100 and DD-140B greasing, adding oil, etc).
NOTICE
At every inspection all the inspections
with previous schedules must be carried out.
5.3.1.6After Each Job
Thoroughly wash and drain mud system of all cuttings and packed bentonite.
Check track adjustment. Tighten if needed, see
manual.
5.3.1.5Yearly (or 1000 hours)
Perform daily, weekly, monthly and six month
maintenance items, plus:
Replace engine coolant or submit sample for analysis.
Change engine fuel filters.
Change all hydraulic filter elements or when indicated by red lights.
Remove and replace all gearbox oil, or submit
sample for analysis. Includes:
-Rotary gearbox
-Carriage drive gearboxes
-Track drive gearboxes (2)
-Hydraulic pump drive gearbox
Change hydraulic system oil, or submit sample for
analysis.
Page 36
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
5.3.1.4 Six Months (or 500 hours)
Perform daily, weekly and monthly maintenance
items, plus:
Change air filter elements.
Grease fittings must be kept clean so
that contamination is not forced inside. Replace damaged fittings.
5.3.1.2 Weekly (or 50 hours)
Perform daily maintenance items, plus:
Carriage planetary gearbox lube levels. Remove 5.3.2 EMERGENCY STOP
“level check” plug. Fill to lower edge of opening.
Verify that the 3 emergency stop push-buttons of
Pump drive gearbox. Remove dipstick. Add oil to the machine are operating.
mark shown on dipstick.
Track drive gearbox. Remove “level check” plug. 5.3.3 GREASING
Fill to lower edge of opening.
The points listed below must be lubricated daily
(where not otherwise specified, 2 grease pumps
5.3.1.3 Monthly (or 250 hours)
are enough). Use Shell Retinax LC, which is suitPerform daily and weekly maintenance items, plus: able for most temperatures When working in very
Drain and replace engine lube oil and crankcase high or low temperature consult the factory.
filter.
Check battery water level.
5.3.3.1GREASE POINTS (LIST)
Clean or change primary air filter element.
Inspect engine coolant level.
NOTICE
5.3.1.1 Daily (or 10 hours)
Engine crankcase lube oil level.
Engine coolant level.
Hydraulic tank oil sight glass level (3/4 full).
Fuel level.
Rotary box lube level sight glass (3/4 full).
Look around rig and mud system for signs of fuel,
coolant, hydraulic leaks. Check hydraulic fittings
visually.
Grease carriage cam followers.
Grease wrench and die holder slides.
Grease hinge pin bosses.
Check crane pins and retainers.
Check track tension.
NOTICE
The procedures must be carried out
as indicated in the maintenance section of the manual for the operator. For
maintenance on the diesel engine
REFER TO: Attachment 1, 3126 or 3306
Caterpillar Diesel Engines.
5.3.1 MAINTENANCE SCHEDULES OF DIRECTIONAL DRILL MODEL DD-100 AND DD140
WARNING
Hydraulic oil may be under high pressure. Release pressure before opening the system.
NOTICE
Very small amounts of contamination
of hydraulic oil can damage the system.
5.3.8 HYDRAULIC OIL CIRCUIT
Page 37
CAUTION
Hydraulic circuit can be damaged irreparably if start up procedure is not
followed correctly.
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
5.3.7 FUEL
Use only clean fuel of the proper grade.
After every refuelling, lock the tank.
Discharge water and deposits from the fuel tanks.
For temperatures lower than 0°C [32°F] use winter fuel in order to avoid the stoppage of filters for
deposits of wax.
WARNING
Support the thrust frame with a strong
support before draining the hydraulic
filters. Do not start up the engine until
personnel have moved away from the
area.
page indicator (Fig. 42-2) signals the need to clean
or replace the filter. In extremely dusty conditions, 5.3.8.1 PROCEDURE FOR REPLACEMENT
OF FILTERS (500 HOURS or when
the maintenance of engine air filter should be increased. Use the procedures indicated in Attach- indicated by lights)
ment 1, 3126 or 3306 Caterpillar Diesel Engines.
Check that the level of the radiator coolant is at
maximum and that there is no contamination. Add
coolant if the level is low. Consult Attachment 1,
Check the level in the tank using the transparent
3126 or 3306 Caterpillar Diesel Engines for the
specifications about coolant and cooling system. gauge mounted on it. If the level is too low, add oil
as far as the mark indicates the level.
The level must be checked when the oil is cold,
5.3.6 AIR FILTERS
Do not clean the air cleaner unless the instrument with all cylinders retracted.
After refilling, lock the tank cap.
shows a need for service. At each inspection of the
Check the condition of the pipes and hoses and
air cleaner also inspect the rubber evacuator valve
(Fig. 42-1). Check that in the air cleaner pipes there replace damaged ones.
Identify and eliminate the losses immediately:
are no deposits, if so clean them. The primary filter can be cleaned and reused up to 6 times. The losses of hydraulic system under pressure get alsecondary filter must not be used again. A stop- ways worse.
WARNING
Before checking or changing coolant
wait for the engine to cool.
5.3.5 ENGINE COOLANT
WARNING
Before changing oil wait for the engine
to cool.
WARNING
5.3.4 ENGINE OIL
Before changing fuel filters wait for the
Consult the CATERPILLAR operating and mainengine to cool.
tenance manual. Check that the engine oil is at the
max. level and that there is no contamination,
Replace the diesel fuel filters every 500 hours or
which could lead to change, filter and oil prematurely. Typical contamination is: oil discoloration, earlier if necessary.
Use the procedures indicated in Attachment 1, 3126
water or engine coolant in the oil, etc.
or 3306 Caterpillar Diesel Engines.
Page 38
5.3.9.4 CARRIAGE ROTARY GEAR BOX,
LEVEL CHECK
After unscrewing a level plug , a small quantity
of oil will escape. As soon as this happens inspect
the oil in order to verify that there is no contamination which requires an unscheduled replacement.
5.3.9.3 CARRIAGE ROTARY GEARBOX
Inspect the gearbox in order to discover leaks. In
case of a small loss, fill the gearbox to the correct
level.
Replace the oil in the gearboxes and in the pump
drive every 500 hours and whenever contamination occurs.
5.3.9.2 HYDRAULIC PUMP DRIVE, FILLING
PROCEDURE
For filling use the elbows where breather pipe is
positioned
Remove the breather pipes
Top up with suitable oil until it comes out the
level hole.
For draining the oil remove the plug in the bottom of the gearbox. Catch the oil in a suitable container. Dispose of used oil in a lawful manner.
5.3.9.1 PUMP DRIVE, LEVEL CHECK
For controlling the oil level in the pump drive
use the dipstick (rod) accessible from the engine
door. The correct level must be between the two
lines marked on the rod.
5.3.9 GEARBOXES AND PUMP DRIVE
Inspect the gearbox in order to discover leaks. In
case of a small loss, fill the gearbox to the correct
level.
Replace the oil in the gearboxes and in the pump
drive every 500 hours and whenever contamination occurs.
After unscrewing a level plug, a small quantity
of oil will escape. As soon as this happens inspect
the oil in order to verify that there is no contamination which requires an unscheduled replacement.
CAUTION
Check levels only when gearboxes are
cold.
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Wipe the inner part of the tank with lint free cloths.
Reassemble the suction filter.
Put silicone on inspection cover and reassemble.
Tighten bolts of the cover.
Refill with hydraulic oil (REFER TO: Fig. 45,
Approved Replacement Fluids). Do not mix hydraulic oils produced by different companies due
to the possibility of reactions among the oils.
A transparent gauge is mounted on the tank in
order to allow quick checks of oil levels. The oil
level in the tank can vary considerably according
to the effect of temperature (hot oil increases the
volume) and to the position of hydraulic cylinders.
Overfilling can cause oil to come out of the tank.
WARNING
Do not use inflammable solvents, near
fire, sparks or other ignition sources.
5.3.8.2 PROCEDURE FOR THE REPLACE–
MENT OF HYDRAULIC OIL
(every 500 hours)
Drain hydraulic oil from the tank in a container
suitable for transport or elimination.
All parts must be cleaned.
Remove the hydraulic tank inspection cover and
remove any deposit of old gaskets.
Keep all the bolts together.
Remove the suction filter in the tank.
Clean suction filter, breather pipe, and magnetic
cap with a lint free cloth and clean oil.
To replace oil filters:
1. Place a container under the filters to catch the
oil. Oil from nearby hoses will also drain out.
2. Use a wrench to loosen and remove the outer
container.
3. Remove and replace the filter element.
4. Replace the outer container.
5. Run the engine at low speed and operate the
rotary.
6. Confirm proper oil level in the tank.
7. Run the engine at high speed for 5 minutes.
8. Shut off the engine and inspect for leaks.
5.3.12 RADIATOR
This category includes the engine radiator and
hydraulic oil radiator. Check that there are no obstructions. Clean the obstructions in order to allow the correct air flow and cooling. Cooling capacity of heat exchangers of the machine is greatly
reduced by deposit of foreign material such as dust
layers, oil layers, leaves, grass and other material
which can obstruct air flow. Correct any problem
immediately.
Welding must be done with the battery switches
(Fig. 34-3 and 34-4) in OFF position (switched off).
The ground wire must be connected directly to
the component where the welding is made. Failure to follow the above instructions could damage
electric and hydraulic components, cylinders, gears
and bearings, due to internal arcing.
Disconnect ground terminal first.
Reconnect ground terminal last.
CAUTION
Disconnect all wires to battery equalizer before welding on machine. Failure to do so may result in damage to
battery equalizer and batteries.
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Page 39
5.3.9.8 TRACK DRIVE GEARBOXES,
FILLING PROCEDURE
Position the level plugs as described in 5.3.9.7,
above. Remove both plugs.
Top up with suitable oil until it comes out the
level hole at the 10:00 clock position.
For draining the oil remove the plug in the bot- 5.3.13 HYDRAULIC PISTON RODS
Check that the rods are not damaged, and that
tom of the gearbox. Catch the oil in a suitable conthey do not have losses of oil.
tainer. Dispose of old oil in a lawful manner.
Clean if necessary. If this is not done, the shaft
seals can fail.
5.3.10 TRACK TENSION
Track tension is maintained by adding grease
5.3.14 CLEANING
through a special fitting, one on each track.
Clean all the marking plates as well as all lighting devices installed. Do not direct spray of water
inside the muffler, or the air filter, against electric
components and control panels, on caps and open
5.3.9.7 TRACK DRIVE GEARBOXES,
LEVEL CHECK
There are two check plugs on each track drive
gearbox. Move the machine to position the level
plugs. One plug must be at 12:00 o’clock. The other
plug will be positioned counterclockwise at the
10:00 o’clock position. Remove the plug at the
10:00 position After unscrewing the level plug , a
small quantity of oil will escape. As soon as this
happens inspect the oil in order to verify that there
is no contamination which requires an unscheduled replacement
5.3.9.6 TRACK DRIVE GEARBOXES
Inspect the gearbox in order to discover leaks. In
case of a small loss, fill the gearbox to the correct
level.
Replace the oil in the gearboxes and in the pump
drive every 500 hours and whenever contamination occurs.
dures is not covered under warranty.
5.3.9.5 CARRIAGE ROTARY GEAR BOX,
5.3.11 WELDING
FILLING PROCEDURE
CAUTION
Top up with suitable oil until it comes out the
Failure to follow welding procedure
level hole
can cause damage to electric and
For draining the oil remove the plug in the botmechanical components. Damage to
tom of the gearbox. Catch the oil in a suitable concomponents due to improper procetainer. Dispose of old oil in a lawful manner.
Page 40
as working lights and radios, which are much less
expensive than similar items manufactured for 24
volt systems. When the 12 volt loads require power
the battery equalizer assures that the current is taken
equally from both batteries. This equalization extends battery life.
The battery equalizer system used on the DD100 and DD-140B includes a system monitor
which also operates status/warning lamps.
Under normal conditions the battery equalizer
system does not require periodic service.
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Check the level of the electrolyte and add liquid
if the level is too low. Check the battery cables
and verify that there are no abrasions or indentations; if necessary, replace the battery cables. Check
that the battery terminals are not corroded, otherwise clean and replace them. The voltage of the
battery is 12 volts.
WARNING
Machine batteries contain acid. Use
proper precautions and follow the instructions listed above.
5.4.5 BATTERIES
5.4.4 GAUGES AND INSTRUMENTS
Wipe the faces of gauges with a cloth moistened
with water. Replace cracked or missing glass.
Fluid-filled (shock resistant) gauges should be replaced if the glass is cracked.
tanks. Do not use acid or abrasive solutions. For
Do not start the engine without batteries or disthe control panels use only a damp cloth or com- connect them with the engine running. This can
pressed air (max. 2 bar [30 psi]).
damage the electric system.
The batteries contain sulfuric acid. Protect eyes,
5.4 OTHER CHECKS AND MAINTENANCE
face and hands during maintenance work. Do not
(50 HOURS)
pour battery acid on clothes, skin or eyes. If the
At the beginning of every week or after every 50 acid reaches the skin, flood with water. If the acid
operating hours, inspect the following items, in reaches the eyes, wash with water plentifully and
addition to any scheduled maintenance.
go to the doctor immediately. In case of ingestion
drink water or milk and go to the doctor immedi5.4.1 BOLTS AND NUTS
ately.
Inspect for any loose or missing bolts and nuts.
Batteries can produce explosive gas. Do not
Tighten loose bolts and nuts. Replace missing bolts smoke near a battery: keep away inflammable
and nuts.
source, sparks or flames. Charge the batteries only
in good ventilated areas.
5.4.2 PIPES AND HOSES
Clean corrosion marks on battery terminals, if
Inspect pipes for leaks. Replace leaking pipes. any. A paste make of sodium bicarbonate and waInspect hoses for leaks and for damage to the out- ter is normally enough to clean terminals and batside surface due to abrasion.
tery box. After cleaning, rinse thoroughly with
clean water. Coat the terminals with grease in or5.4.3 LEAKS
der to prevent future corrosion.
Inspect the machine for leaks of gear oil, hydraulic oil, engine coolant and fuel. Big leaks should 5.4.5.1 BATTERY EQUALIZER
be repaired. Small leaks should be wiped clean and
The battery equalizer is a highly reliable method
the relevant part watched closely for oil level. Note of obtaining a 12 volt DC power source from a 24
that allowing oil or other fluids to leak into the volt DC electrical system. Availability of 12 volt
environment might be unlawful.
power permits the use of 12 volt equipment such
Fill the cooling system with antifreeze.
REFER TO: Attachment 1, Caterpillar Diesel Engines
WARNING
Wait for the engine to cool.
5.6.2 COOLING SYSTEM
Check that belts have the right tension. If they
have loosened, put them under tension. Replace
belts if they are worn over the limits.
REFER TO: Attachment 1, 3126 OR 3306 Caterpillar Diesel Engines.
WARNING
Wait for the engine to cool.
5.6.1 ENGINE BELTS
5.6 OTHER INSPECTION AND MAINTENANCE
(EVERY 500 HOURS)
5.5.4 TRACK TENSION
Track tension is maintained by adding grease
through a special fitting on each track.
Page 41
5.6.4 ELECTRIC SYSTEM
Inspect all the cables and wires for cracks, broken connections and loosened attachments. Repair
or replace damaged parts. REFER TO: Figs. 5052 and 58-61.
Every 600 hours clean the engine breather pipe.
Clean it more often when operating in dusty conditions. REFER TO: Attachment 1, 3126 OR 3306
Caterpillar Diesel Engines.
WARNING
Wait for the engine to as cool.
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Check that there are no obstructions or deposits
accumulated. Clean the breather pipes in case of
obstructions. We recommend using an oil solvent
(diesel fuel is OK).
Flywheel gearbox (1)
Hydraulic tank (1)
Fuel tank (1)
WARNING
Do not use inflammable solvents, near
fire, sparks or other inflammable
sources. Before starting the operation
wait until all the machine units (engine, etc.) are cool.
5.5.3 BREATHER PIPES
5.5.2 UNDERCARRIAGE ROLLERS
Replace the rollers in case of damage, flat spots,
etc.
5.5.1 MOTOR MOUNTS AND RADIATORS
Check the rubber for wear. If the rubber parts are
worn replace them.
5.6.3 ENGINE OIL BREATHER PIPE
Check and/or effect the maintenance of the machine every 250 hours of engine operation as follows: (this control must be carried out together with
the daily and weekly controls mentioned previously).
5.5 OTHER INSPECTIONS AND
MAINTENANCE (EVERY 250 HOURS)
DANGER
Remove pipe and pipe basket from the
machine before performing maintenance. The max. weight of the machine on the undercarriage system
can be in excess of 26,300 kg [58,000
lb]. Before starting any maintenance
on the undercarriage, the machine
must be properly supported vertically.
The vertical support must include a
locking system that cannot be inadvertently released allowing the machine to fall down. Failure to use this
procedure could cause serious injury
or death of the operators.
5.4.6 UNDERCARRIAGE
technical assistance service.
Switching on of one or more lights (Fig. 30, LT2)
indicates the restriction of the filters. Under conditions of extreme cold it is possible that these
lights switch on when the machine is started and
then switch off by increasing of hydraulic oil temperature. This is normal, but do not operate the
machine with one of these lights on in order to
avoid serious damage to the hydraulic system.
Page 42
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Replace the coolant at 1200 hours or 24 months.
7. DEMOLITION
Follow carefully the instructions indicated in Attachment 1, 3126 OR 3306 Caterpillar Diesel En- 7.1 MACHINE DEACTIVATION
gines.
For demolition of the machine, apply to authorized centers only. The elimination of waste mate6. DIAGNOSTIC
rials must be carried out in conformity with the
laws in force in the country of destination.
6.1 OPERATING FAULTS
Place the machine in a site having the features
described in Paragraph 3.1 STORAGE. The site
6.1.1 CLOGGED AIR FILTER
must be inaccessible to non-authorized personnel.
Visibility of the red marker (Fig. 42-2) indicates The movable parts must be positioned in the same
that the air filter is clogged with dust. This causes way followed for transport (REFER TO: Chapter
a high decrease of engine efficiency and can cause 3. STORAGE AND TRANSPORT).
serious damage to inner mechanical parts. Clean
Place oils and fuel not used in sealed containers.
or replace filter elements.
Remove the batteries and place them in a dry and
inaccessible site.
6.1.2 ENGINE OIL PRESSURE ALARM
Normally the same centers which sell batteries also
In case of low engine oil pressure an automatic collect old batteries.
device stops the engine. Check for low oil level or
For oils, apply to the suppliers. Furthermore in
other fault. If necessary, contact American Augers Italy there is the “Association of Used Oils” which
WARNING
Wait for the engine to cool.
5.8.1 ENGINE COOLING SYSTEM
5.8 INSPECTIONS AND MAINTENANCE
EVERY 24 MONTHS
6.1.4 ROTARY AND CARRIAGE DO NOT OPERATE
Add rust inhibitor to the engine cooling system
Activation of the es!lok® belt unit by the Compeevery 600 hours or 12 months. REFER TO Attach- tent Person or loss of signal will lock out the roment 1, 3126 or 3306 Caterpillar Diesel Engines tary and carriage function. REFER TO: Attachment
3 ES!LOK® Operation and Maintenance Instruc5.7.3 EMERGENCY STOP
tion Manual.
Verify the perfect operation of both emergency
stop controls.
6.1.5 CLOGGED OIL FILTER
WARNING
Wait for the engine to cool.
6.1.3 ENGINE COOLANT TEMPERATURE
5.7.1 ENGINE FUEL FILTERS
ALARM
REFER TO Attachment 1, 3126 or 3306 CaterpilIn case of high temperature an automatic device
lar Diesel Engines
stops the engine. Once suitable operating temperature has been reached again, the engine can be
5.7.2 ENGINE COOLING SYSTEM
started. If necessary, contact American Augers technical assistance service.
5.7 OTHER CHECKS (EVERY 1000 HOURS OR
EVERY YEAR)
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
NOTICE
The machine is made with some nonbiodegradable materials. Take the
machine to an authorized place for
elimination of these materials.
Corners of sharp steel parts are dangerous.
Keep the machine in a site inaccessible to people
except those in charge with dismantling.
7.2 RESIDUAL RISKS
NOTICE
American Augers declines any responsibility in case of recycling or reusing of parts of the machine.
NOTICE
Take used liquids to an authorized recycling center.
has been established for law. It is always available
for the elimination of oils not used.
For the elimination, material of different nature
must be separated and sent to authorized collecting sites.
Page 43
Page 44
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
This page was left blank intentionally.
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Not required in North America
Fig. 1 Declaration of EC Conformity
Page 45
Page 46
WARRANTY
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
The Manufacturer warrants its products to be free from defects in material and workmanship for
a period of six months from the date of shipment from the factory. The Manufacturer shall not be
responsible for any damage resulting to or caused by its products by reason of installation, improper
storage, unauthorized service, alteration of products, neglect or abuse or the use of the product in a
manner inconsistent with its design. This warranty does not extend to any component parts not manufactured by Manufacturer; however, Manufacturer’s warranty herein shall not limit any warranties
made by manufacturers of component parts which may extend to Buyer.
THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES AND NO REPRESENTATIONS, GUARANTEES, OR WARRANTIES, EXPRESS OR IMPLIED, (INCLUDING,
BUT NOT LIMITED TO, A WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE,) ARE MADE BY MANUFACTURER IN CONNECTION WITH THE
MANUFACTURE OR SALE OF ITS PRODUCTS. NO EMPLOYEE, DISTRIBUTOR, OR REPRESENTATIVE IS AUTHORIZED TO CHANGE THIS WARRANTY IN ANY WAY OR GRANT
ANY OTHER WARRANTY ON BEHALF OF THE MANUFACTURER.
Claims for defects in material and workmanship shall be made in writing to Manufacturer within
ten days of discovery of defect. Manufacturer may either send a service representative or have the
product returned to its factory at Buyer’s expense for inspection. If judged by Manufacturer to be
defective in material or workmanship, the product will be replaced or repaired at the option of the
Manufacturer, free from all charges except authorized transportation.
THE REMEDIES OF BUYER SET FORTH HEREIN ARE EXCLUSIVE AND ARE IN LIEU
OF ALL OTHER REMEDIES. THE LIABILITY OF MANUFACTURER WHETHER IN CONTRACT, TORT, UNDER ANY WARRANTY, OR OTHERWISE SHALL NOT EXTEND BEYOND
ITS OBLIGATION TO REPAIR OR REPLACE, AT ITS OPTION, ANY PRODUCT OR PART
FOUND BY MANUFACTURER TO BE DEFECTIVE IN MATERIAL OR WORKMANSHIP.
MANUFACTURER SHALL NOT BE LIABLE FOR COST OF INSTALLATION AND/OR REMOVAL OR BE RESPONSIBLE FOR DIRECT, INDIRECT, SPECIAL OR CONSEQUENTIAL
DAMAGES OF ANY NATURE. UNDER NO CIRCUMSTANCES SHALL MANUFACTURER
BE LIABLE FOR LOSS OF ANTICIPATED PROFITS.
Fig. 2 Warranty Certificate
Do not break out tool
joints with pipe wrenches.
WARNING
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Use only suitable equipment to break out tool joints.
A wrench on rotating drill
pipe can seriously injure
or kill.
Fig. 4 Pipe Wrench Warning
construction, protection, barricades, traffic control, installation and type of ladders used in the
pit and personal safety equipment. American
Augers recommends that the owner become familiar with the requirements of 29CFR1910. Information can be obtained from your Regional
Department of Labor Office.
Use the es!lok® exit side lockout
system to prevent inadvertent
movement or rotation of the drill
pipe and tooling.
Drilling operations may require construction
of a pit to receive the cutter or mud motor on the
exit side of the crossing.
It is the responsibility of the owner to make a
safe pit that is in accordance with the rules set
forth in the (OSHA) Code of Federal Regulations 29. There are specific requirements for pit
Fig. 3 Exit Pit Warning
Page 47
Page 48
Return Mud Pit
Erect safety barrier 8m (25 ft) beyond machine.
Make sure grounding stake is properly installed.
Keep spectators away.
Electrical Hazard
! WARNING
Directional Drill
Electrical Bonding Cable
Ground (earth)
Ground (earth)
Mud Mixer/Cleaner
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Electrical Bonding Cable (not supplied) electrically bonds
mud mixer/cleaner to drill (to maintain equal electrical
potential in event of an electric strike.)
8m (25 ft)
8m (25 ft)
Fig. 5 Electrical Hazard Warning
8NP41296
8NP41297
Proposition 65 Warning
CAUTION
8NP41209
8NP47274
8NP47274
Refer to operator’s manual.
Disconnect ground terminal first.
Reconnect ground terminal last.
Disconnect all wires to battery
equalizer before welding on machine. Failure to do so may result
in damage to battery equalizer
and batteries.
!
8NP41209
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth
defects and other reproductive harm
8NP41271
15GB7119
15GB7113
8NP41204
8NP41283
8NP41117
8NP41285
Page 49
15GB7118
8NP41206
FILLED WITH OIL __/__/__
8NP41104
HYDRAULIC OIL
8NP41105
DIESEL FUEL
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
8NP41199
8NP41199
BEFORE OPERATING
RIGHT JACKUNHOOK BLOCK &
RAISE
CRANE FROM REST
& UNHOOK
DRILLERS CONSOLE
ARM CHAIN
CAUTION
15GB7116
8NP41101
15GB7155
CALIFORNIA
8NP41103
8NP41102
15GB7116-1
15GB7112
Fig. 6 Machine Labels
Page 50
8NP41102
8NP41103
15GB7116-1
15GB7116-1
8NP41101
8NP41101
8NP41204
8NP41204
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
8NP41102
8NP41117
15GB7116-1
Fig. 7 Placement of Labels
8NP41103
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Fig. 8 Placement of Labels
15GB7116-1
8NP41297
15GB7116
15GB7118
15GB7113
15GB7116
15GB7155
8NP41209
8NP41271
8NP41285
8NP47274
15GB7113 8NP41206 15GB7155 15GB7119
15GB7116
15GB7116
Page 51
Page 52
Chains
Platform
Spreader bar
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Fig. 10 Lifting The Drill
Fig. 9 Transporting The Drill
Fig. 12
11 ft 6 in
(3511 mm)
30 ft 3 in (9246 mm)
18°
18°
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
DD-100 Max. Drill Angle (18°)
26 ft 3 in (8000 mm)
Machine Transport Width: 7 ft 11 in (2413 mm)
64 mm)
44 ft 6 in (135
DD-100 Transport Position
18 ft 3 in (5563 mm)
Fig. 11
Page 53
10 ft 1 in (3073 mm)
Page 54
Fig. 14
Fig. 13
26 ft 11 in (8204 mm)
783mm)
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
DD-140B Max. Drill Angle (18°)
18°
Machine Transport Width: 8 ft 4-3/4 in (2559 mm)
48 ft 6 in (14,
29 ft 9.6 in (9,085 mm)
DD-140B Transport Position
13 ft 1 in (3988 mm)
16 ft 6 in (5944 mm)
Transmission section
Fig. 15-8 - Pullback swivel
Cutting bit
Page 55
Fig. 15-9 - Product line
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Power section
Fig. 16 Down Hole (Mud) Motor
Blade reamer
Fig. 15-5 - Pullback eye
Fig. 15-4 - Blade reamer
Fig. 15-6 - Duct puller
Fig. 15-2 - Sonde housing
Fig. 15-3 - Barrel reamer
Fig. 15-1 - Cutting head
Fig. 14-5 - Drill string
Fig. 15 Tooling
Page 56
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Fig. 18 Clock face display on three brands of receivers
With cutter head positioned as shown, and thrust without rotation,
bore moves in direction of arrow. Clock face will be represented on
locating receiver.
Fig. 17 Steering
9
6
12
3
Fig. 21 Handrails
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Fig. 20 Hose Carrier Hold-Down
Fig. 19 Tramming
Page 57
Page 58
22-1
Fig. 23 Extending Console
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
24-1
Fig. 24 Storage Box (typ.)
Fig. 22 Console Lock Chain
26-1
27-1
Fig. 27 Hand Rails
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Fig. 26 Carriage Lock
Fig. 25 Positioning Crane
27-2
Page 59
28-8
28-9
28-1
Page 60
29-1
29-3
28-7
28-3
RPM
29-4
28-4
29-5
29-6
28-6
28-5
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
29-2
HIGH
THROTTLE
LOW
28-2
Instruments & Controls (Engine Panel)
Fig. 29 Control Console (General Arrangement)
Fig. 28
VD7
SS15
PB3
VD8
LT2
SS16
LT2
GAGE2E
LT2
LT3
LT2
SS11
DM1
TACH
GAGE2F
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Page 61
PD1
SS17
SS12
GAGE2D
PD2
VD6
SS14
GAGE2C
POT1
SS7
GAGE2B
SS13
SS8
SS5
PB2
GAGE2A
LT3
Fig. 30 Control Console
Page 62
FU3
FU2
FU1
SS20
SS18
PG3
32-3
SS21
32-4
SS3
SS4
32-5
PB1
SS22
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
32-2
32-1
Fig. 32 Crane Controls
PG4
Fig. 31 Setup Control Panel
SS6
SS9
PB4
PB3
VD2
PB2
34-4
34-3
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
34-2
34-1
Fig. 34 Battery Switches and Battery Equalizer (DD-140B shown, DD-100 similar)
VD1
SS17
Fig. 33 Instruments & Controls (Tramming Control)
Page 63
Page 64
27-2
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Fig. 36 Tie Down Stakes
Fig. 35 Pipe Support
Entry Pit
Steel Beam
Chain or Cable
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Sheet Piling
Fig. 37 Buried Anchor
Page 65
GAUGE
PRESSURE
PSI
900
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2000
2100
2200
2300
2400
2500
LOW
HIGH
RANGE
RANGE
FORCE (LBS) FORCE (LBS)
13610
4388
16332
5265
19054
6143
21777
7020
24499
7898
27221
8876
29943
9653
32665
10531
35387
11408
38109
12286
40831
13163
43553
14041
46275
14918
48997
15796
51719
16674
54441
17551
57163
18429
GAUGE
PRESSURE
PSI
2600
2700
2800
2900
3000
3100
3200
3300
3400
3500
3600
3700
3800
3900
4000
4100
LOW
HIGH
RANGE
RANGE
FORCE (LBS) FORCE (LBS)
59886
19306
62608
20184
65330
21061
68052
21939
70774
22817
73496
23694
76218
24572
78940
25449
81662
26327
84384
27204
87106
28082
89828
28959
92550
29837
95272
30715
97995
31592
100717
32470
Table To Convert PSI Reading (Fig. 30-GAGE2A & 2B) to Thrust/Pullback Force
(DD-100)
Page 66
GAUGE
PSI
500
600
700
800
900
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2000
2100
2200
2300
GAUGE
PSI
2400
2500
2600
2700
2800
2900
3000
3100
3200
3300
3400
3500
3600
3700
3800
3900
4000
4100
4200
LOW RANGE
HIGH RANGE
FORCE (FT-LB) FORCE (FT-LB)
10656
3369
11189
3538
11722
3706
12255
3875
12788
4043
13321
4212
13853
4380
14386
4549
14919
4717
15452
4886
15985
5054
16518
5222
17050
5391
17583
5559
18116
5728
18649
5896
19182
6065
19714
6233
20247
6402
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
LOW RANGE
HIGH RANGE
FORCE (FT-LB) FORCE (FT-LB)
533
168
1066
337
1598
505
2131
674
2664
842
3197
1011
3730
1179
4263
1348
4795
1516
5328
1685
5861
1853
6394
2022
6927
2190
7460
2359
7992
2527
8525
2695
9058
2864
9591
3032
10124
3201
Fig. 39 Table To Convert PSI Reading(Fig. 30-GAGE2F) to Rotary Torque (DD-100)
Fig. 38
GAUGE
FORCE
PRESSURE
(LBS)
PSI
1ST GEAR
2000
66332
2100
70478
2200
74624
2300
78770
2400
82916
2500
87061
2600
91207
2700
95353
2800
99499
2900
103644
3000
107790
3100
111936
3200
116082
3300
120228
3400
124373
FORCE
FORCE
(LBS)
(LBS)
2ND GEAR 3RD GEAR
39715
13097
42197
13915
44679
14734
47161
15552
49643
16371
52125
17189
54607
18008
57090
18826
59572
19645
62054
20463
4536
21282
67018
22100
69500
22919
71983
23738
74465
24556
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Page 67
IST GEAR 2ND GEAR 3RD GEAR
GAUGE FORCE
FORCE
FORCE
PSI
(FT-LBS)
(FT-LBS)
(FT-LBS)
2000
66332
39715
13097
2100
70478
42197
13915
2200
74624
44679
14734
2300
78770
47161
5552
2400
82916
49643
16371
2500
87061
52125
17189
2600
91207
54607
18008
2700
95353
57090
18826
2800
99499
59572
19645
2900
103644
62054
20463
3000
107790
64536
21282
3100
111936
67018
22100
3200
116082
69500
22919
3300
120228
71983
23738
3400
124373
74465
24556
Table To Convert PSI Reading (Fig. 30-gage2f) to Rotary Torque (DD-140B)
IST GEAR 2ND GEAR 3RD GEAR
GAUGE FORCE
FORCE
FORCE
PSI
(FT-LBS)
(FT-LBS)
(FT-LBS)
500
4146
2482
819
600
8292
4964
1637
700
12437
7446
2456
800
16583
9929
3274
900
20729
12411
4093
1000
24875
14893
4911
1100
29020
17375
5730
1200
33166
19857
6548
1300
37312
22339
7367
1400
41458
24822
8185
1500
45604
27304
9004
1600
49749
29786
9822
1700
53895
32268
10641
1800
58041
34750
11459
1900
62187
37232
12278
Fig. 41
FORCE
FORCE
(LBS)
(LBS)
2ND GEAR 3RD GEAR
2482
819
4964
1637
7446
2456
9929
3274
12411
4093
14893
4911
17375
5730
19857
6548
22339
7367
24822
8185
27304
9004
29786
9822
32268
641
34750
11459
37232
12278
Table To Convert PSI Reading (Fig.30-GAGE2A & 2B) to Thrust/Pullback Force
(DD-140B)
GAUGE
FORCE
PRESSURE
(LBS)
PSI
1ST GEAR
500
4146
600
8292
700
12437
800
16583
900
20729
1000
24875
1100
29020
1200
33166
1300
37312
1400
41458
1500
45604
1600
49749
1700
53895
1800
58041
1900
62187
Fig. 40
=
(
Page 68
42-2
)
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
800 gallons of soil plus an additional 800 gallons of fluid or
a total of 1600 gallons per 100 feet of bore. This volume
would require a returns pit of approx. 6x6x6 feet. If you have
reached maximum mud pump rate and still need to reduce
torque, reduce the bore rate (in feet/minute).
x Bore rate, Ft/min
Flow Rate, Gal/Minute
Hole Dia. (inches2) , Gal/ft
24.5
Use this formula to calculate a fluid-to-soil injection rate, to
make soil fluid enough to flow out of the bore. As much as
two gallons of fluid per gallon of soil could be required to
minimize torque. Example: backreaming a 14-inch diameter
hole= 8 gallons of soil per foot of bore. Progressing at 0.8 ft/
min=6.4 gallons of soil per minute. Depending on soil type
you might have to pump 6 gallons of fluid per minute. Therefore, one hundred feet of bore would generate approximtely
Gallons Water
Gallons Soil
Fig. 43 Volume Of Soil Formula
42-1
Fig. 42 Air Cleaner
si
radiu
ter
Steer down-horizontal-steer up bore
Constant arc bore
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Minim
um
cm
r 2.5
s 30.
5m
pe
Fig. 44 Steering Radius
iame
of pip
ed
Page 69
Page 70
Daily
or 10 hrs
Weekly
or 50 hrs
Monthly
6 Months
or 250 hrs or 500 hrs
Yearly
or 1000 hrs
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Engine crankcase oil
Engine coolant level
Hydraulic oil level
Fuel level
Rotary box oil level
Inspect for leaks
Grease
Check track tension
Carriage planetary gear box oil
Hydraulic pump gearbox
Track drive gearboxes
Replace engine oil & filter
Battery water level
Clean or replace air filter
Test engine coolant
Change engine fuel filters
Change hydraulic oil filters
Change oil all gearboxes
Change hydraulic oil
Replace engine coolant
Check track tension
Fig. 46 Maintenance Schedule
To order fluids from other suppliers, consult the AA Lubrication Specifications
After
each job
Engine Oil ............................................... Shell Rotella™ T ...................................... AA Spec 401
Hydraulic Oil ........................................... Shell Tellus™ T46 .................................... AA Spec 202
Pump Drive Oil ....................................... Shell Spirax S™ 80W140 ........................ AA Spec 102
Rotary Drive Oil ...................................... Shell Spirax S™ 80W140 ........................ AA Spec 102
Rotary Gearbox ...................................... Shell Spirax S™ 80W140 ........................ AA Spec 102
Carriage Drive Oil ................................... Shell Spirax S™ 80W140 ........................ AA Spec 102
Track Drive Oil ....................................... Shell Spirax S™ 80W140 ........................ AA Spec 102
Grease ................................................... Shell Retinax™ LC-2 ............................... AA Spec 301
Mud Swivel Grease ................................ Shell Retinax™ LC-2 ............................... AA Spec 301
Slip Sub Grease ..................................... Jet Lube Kopr Kote ................................. AA Spec 302
Engine Antifreeze ................................... Shellzone™ 60%, Water 40% .................. AA Spec 601
WaterCourse Antifreeze ......................... Pitt-Penn RV Antifreeze .......................... AA Spec 603
Fig. 45 Approved Replacement Fluids
(Ambient temperature = -18°C to 44°C [0°F to 110°F])
Consult factory for specification at low temperature
Fig. 47 DD-100 Hydraulic Schematic (1 of 3)
Page 71
Fig. 48 DD-100 Hydraulic Schematic (2 of 3)
Page 72
Fig. 49 DD-100 Hydraulic Schematic (3 of 3)
Page 73
Fig. 50 DD-100 ELECTRIC Schematic (1 of 3)
Page 74
Fig. 51 DD-100 ELECTRIC Schematic (2 of 3)
Page 79
75
Fig. 52 DD-100 ELECTRIC Schematic (3 of 3)
Page 76
Fig. 53 DD-140B Hydraulic Schematic (1 of 4)
Page 77
Fig. 55 DD-140B Hydraulic Schematic (2 of 4)
Page 78
Fig. 56 DD-140B Hydraulic Schematic (3 of 4)
Page 79
Fig. 57 DD-140B Hydraulic Schematic (4 of 4)
Page 80
Fig. 58 DD-140B Electric Schematic (1 of 4)
Page 81
Fig. 59 DD-140B Electric Schematic (2 of 4)
Page 82
Fig. 60 DD-140B Electric Schematic (3 of 4)
Page 83
Fig. 61 DD-140B Electric Schematic (4 of 4)
Page 84
This page left blank intentionally
Page 85
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Battery Equalizer
Thrust Frame
Crane
Undercarriage
Breakout Wrench
Front Stabilizer (Jack)
Carriage
Rear Thrust Stabilizer (Jack)
Hose Carrier
Front Foot
Fixed Wrench
Fig. 62 Machine Nomenclature
Page 87
71
American Augers, Inc.
135 U.S. Rt. 42 • P.O. Box 814 • West Salem, Ohio 44287 USA
Phone 419-869-7107 • 800-324-4930 • Fax 419-869-7425
www.americanaugers.com
Due to continuing product improvement, specifications are subject to change without notice.
Part Number: DD100140BOOK-01 November 2001