Joystick de Taladro Electrónico

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 direc-
tional 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 experi-
enced 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 pro- operation of the DD-100™ and DD-140™ directional
vide a full line of modern equipment for the trenchless drills. Specifications are subject to change without no-
excavation construction industry. The company is or- tice or obligation to retrofit units already in the field.
ganized in three product divisions to serve the full range This manual will be constantly updated to remain cur-
of trenchless technology. American Directional Drill rent with new operations. Please call if there are areas
is the division producing the leading line of Horizon- requiring further explanation or instruction. Material
tal Directional Drills. We are proud of our equipment contained herein may not be reproduced in whole or in
and the job it can do. We encourage you to call us for part without the express written permission of Ameri-
any and all of your drilling needs. can Augers Inc., the Innovative Leader in the Trenchless
Every effort has been made to cover adequately the 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.
TABLE OF CONTENTS
1.11.1 CONVENTIONS OF TERMINOLOGY
1.11.2 TYPOGRAPHIC CONVENTIONS
1. GENERAL INFORMATION
2. DESCRIPTION
1.1 USE AND MAINTENANCE MANUAL 2.1 PARTS OF THE MACHINE
1.1.1 DATA OF MANUAL 2.2 DESCRIPTION OF THE MACHINE
1.1.2 CONTENTS OF MANUAL 2.2.1 THRUST FRAME
1.1.3 WHO SHOULD USE THIS MANUAL 2.2.2 CARRIAGE
1.1.3.1 TRANSPORTER 2.2.3 REAR THRUST STABILIZERS
1.1.3.2 USER 2.2.4 FRONT STABILIZERS
1.1.3.3 MAINTENANCE TECHNICIAN 2.2.5 FIXED WRENCH
1.1.4 OWNERSHIP OF INFORMATION 2.2.6 BREAKOUT WRENCH
1.2 MANUFACTURER IDENTIFICATION DATA 2.2.7 MUD
1.3 MACHINE IDENTIFICATION DATA
2.2.8 MUD PUMP
1.4 DECLARATION OF EC CONFORMITY
1.5 GENERAL INFORMATION ON SAFETY 2.2.9 TIE DOWN SYSTEM
1.5.1 SAFETY STANDARD 2.2.10 DRILL PIPE
1.5.1.1. SAFETY AWARENESS 2.2.11 ES!LOK®
PROGRAM 2.2.12 ZAP ALERT®
1.5.2 QUALIFICATION OF PERSONNEL 2.2.13 UNDERCARRIAGE
1.5.3 USE OF PERSONAL PROTECTIVE 2.2.14 CRANE
EQUIPMENT 2.3 PURPOSE OF THE MACHINE
2.4 STRUCTURE
1.5.4 DANGEROUS ZONES—SAFE DIS- 2.5 TECHNICAL SPECIFICATIONS
TANCES 2.5.1 GENERAL FEATURES (DD-100)
1.6 LEGAL VALUE OF THE MANUAL
2.5.2 GENERAL FEATURES
1.7 USES ALLOWED
(DD-140B)
1.7.1 FEATURES OF THE SOIL TO BE
2.5.3 DIESEL ENGINE (DD-100)
DRILLED
2.5.4 DIESEL ENGINE (DD-140B)
1.7.1.1 TYPES OF SOIL
2.5.5 ELECTRICAL SYSTEM
1.7.1.2 GROUND LEVELING
2.5.6 HYDRAULIC SYSTEM (DD-100)
1.7.1.3 AMBIENT CONDITIONS
2.5.7 HYDRAULIC SYSTEM (DD-140B)
1.7.2 FEATURES OF TRANSPORT
2.5.8 PERFORMANCE AS SUPPLIED
1.7.3 MACHINE HANDLING
(DD-100)
PROCEDURES
2.5.9 PERFORMANCE AS SUPPLIED
1.7.3.1 TRANSPORT
(DD-140B)
1.7.3.2 USE
2.5.10 VIBRATION
1.7.3.3 MAINTENANCE
1.8 USES NOT ALLOWED 2.5.11 NOISE
1.9 WARRANTY 2.6 RESPONSIBILITY
1.9.1 GENERAL CONDITIONS 3. STORAGE AND TRANSPORT
3.1 STORAGE
1.9.2 LIMITATIONS OF WARRANTY
3.1.1 MINIMUM STORAGE SPACE
1.9.3 WARRANTY CERTIFICATE
REQUIRED
1.9.4 REQUEST FOR SERVICE
3.1.1.1 PROTECTION WHILE IN
SUPPORT
STORAGE
1.9.5 WARRANTY AND SERVICE FOR
3.1.2 STORAGE SITE ENVIRONMENT
CATERPILLAR ENGINE
1.10 SERVICE AGREEMENT 3.1.3 PROCEDURES OF STORAGE
1.11 CONVENTIONS 3.1.3.1 DRAIN OR PROTECT FLUID
COURSE
Refer to the Safety Awareness Program in this manual before attempting to operate this machine. Page 3
3.2 TRANSPORT GENERAL ARRANGEMENT
3.2.1 PRELIMINARY OPERATIONS FOR 4.6.2.3 CONTROL CONSOLE
LOADING THE MACHINE FOR 4.6.2.4 SET-UP CONTROL PANEL
TRANSPORTATION 4.6.2.5 CRANE PENDANT CONTROL
3.2.2 PROCEDURES OF POSITIONING 4.6.2.6 TRAMMING CONTROL
3.2.3 TRANSPORTATION 4.6.2.7 BATTERY SWITCHES AND
3.2.4 LOADING OF THE MACHINE FOR BATTERY EQUALIZER
TRANSPORTATION 4.6.3 ES!LOK® LOCKOUT SYSTEM
3.2.5 TRANSPORT CONDITIONS 4.6.4 ZAP ALERT™ SYSTEM
3.2.6 UNLOADING OPERATIONS 4.7 OPERATION
3.3 LIFTING THE MACHINE 4.7.1 STARTING THE ENGINE
4. USE 4.7.2 MOVEMENT OF THE MACHINE
4.1 WORKING SITE PHYSICAL FEATURES 4.8 SET-UP
4.1.1 MINIMUM SPACE REQUIRED 4.8.1 POSITION THE DRILL
4.1.2 GROUND LEVELING 4.8.2 EXTEND THE DRILLER’S CONSOLE
4.1.3 TYPE OF GROUND 4.8.3 REMOVE HOSE CARRIER HOLD-DOWN
4.1.4 LIGHTING 4.8.4 INSTALL HANDRAILS
4.1.5 OPERATING TEMPERATURES 4.8.5 POSITION REAR THRUST STABILIZERS
4.1.6 RELATIVE HUMIDITY 4.8.6 POSITION THE CRANE
4.1.7 MAXIMUM ALTITUDE 4.8.7 POSITION THE FRONT STABILIZERS
4.1.8 ATMOSPHERIC CONDITIONS 4.8.8 THRUST FRAME ANGLE
4.2 FUNCTION OF THE MACHINE
4.8.9 THRUST FRAME EXTENSION
4.2.1 NORMAL OPERATION
4.8.10 ANCHOR THE MACHINE
4.3 DANGEROUS ZONES—SAFE DISTANCES
4.8.10.1 PLACING THE TIE DOWN STAKES
4.3.1 DANGEROUS PARTS AND
4.8.10.2 OTHER METHODS OF ANCHORING
DESCRIPTION OF THE RISK
4.8.10.3 POUR A CONCRETE ANCHOR
4.3.1.1 TIE DOWN
4.8.10.4 CONSTRUCT A “DEAD MAN”
4.3.1.2 REAR THRUST STABILIZERS
ANCHOR
4.3.1.3 FRONT STABILIZERS
4.8.11 EXCAVATE THE ENTRY PIT
4.3.1.4 CARRIAGE
4.3.1.5 WRENCH ASSEMBLY 4.9 DRILLING PROCESS
4.3.1.6 CUTTING HEAD 4.9.1 DEEP CROSSINGS- THE SET UP
4.3.1.7 DRILL PIPE 4.9.2 DEEP CROSSINGS - STEERING
4.3.1.8 MUD SYSTEM SYSTEM
4.3.1.9 REAMING TOOLS 4.9.3 DEEP CROSSINGS - DRILLING
4.3.1.10 DIESEL ENGINE AND MUFFLER METHOD
4.3.1.11 PERSONAL PROTECTIVE 4.9.4 SHALLOW CROSSINGS -THE
EQUIPMENT PROCESS
4.4 QUALIFICATION OF THE OPERATOR
4.9.5 APPLICATION OF DRILLING FLUID
4.5 POSITION OF THE OPERATOR
4.6 CONTROLS AND INSTRUMENTS TO HORIZONTAL BORING
4.6.1 CONTROLS 4.9.6 DRILLING FLUID - THE PROCESS
4.6.1.1 TRAMMING CONTROL 4.9.7 CALCULATION OF VOLUME OF
4.6.1.2 EMERGENCY STOP PUSH BUTTONS FLUID TO VOLUME OF SOIL
4.6.2 INSTRUMENTS (LIST) 4.9.8 FLUID DISPOSAL
4.6.2.1 ENGINE PANEL 4.9.9 WATER QUALITY
4.6.2.2 CONTROL PANEL 4.9.10 MUD MIXING
4.10 HANDLING PIPE 5.2.2 FREQUENCY OF INSPECTIONS
4.10.1 ADDING PIPE (FIRST SECTION) 5.3 SCHEDULED INSPECTION AND
4.10.2 INSTALLING A WIRELINE GUIDANCE MAINTENANCE
INSTRUMENT 5.3.1 MAINTENANCE SCHEDULES OF
4.10.3 USING A MUD MOTOR DIRECTIONAL DRILL MODEL DD-100
4.10.4 ADDING PIPE (ADDITIONAL AND DD-140
SECTIONS) 5.3.1.1 DAILY (OR 10 HOURS)
4.10.5 REMOVING PIPE 5.3.1.2 WEEKLY (OR 50 HOURS)
4.10.6 CALCULATING ROTARY TORQUE 5.3.1.3 MONTHLY (OR 250 HOURS)
FORCE 5.3.1.4 SIX MONTHS (OR 500 HOURS)
4.10.6.1 LIMITING ROTARY TORQUE 5.3.1.5 YEARLY (OR 1000 HOURS)
4.10.7 CALCULATING THRUST AND 5.3.1.6 AFTER EACH JOB
PULLBACK FORCE 5.3.2 EMERGENCY STOP
4.10.7.1 LIMITING THRUST AND 5.3.3 GREASING
PULLBACK FORCE 5.3.3.1 GREASE POINTS (LIST)
4.11 START OF THE DRILLING OPERATION 5.3.4 ENGINE OIL
4.12 END OF DRILLING OPERATIONS 5.3.5 ENGINE COOLANT
4.13 START OF PULLBACK OPERATIONS 5.3.6 AIR FILTERS
4.14 END OF PULLBACK OPERATIONS
5.3.7 FUEL
4.14.1 REMOVING TIE DOWN
5.3.8 HYDRAULIC OIL CIRCUIT
STAKES
5.3.8.1 PROCEDURE FOR REPLACEMENT OF
4.14.2 CLEAN UP
4.15 SWITCHING OFF THE ENGINE FILTERS
4.16 EMERGENCY STOP 5.3.8.2 PROCEDURE FOR REPLACEMENT
4.17 START AFTER AN EMERGENCY STOP OF HYD. OIL
4.18 CHECKS DURING OPERATION 5.3.9 GEARBOXES AND PUMP DRIVE
4.19 NORMAL OPERATING RANGES OF
INSTRUMENTS 5.3.9.1 PUMP DRIVE, LEVEL CHECK
4.20 ES!LOK® LOCKOUT SYSTEM 5.3.9.2 HYD. PUMP DRIVE, FILLING
4.20.1 START AFTER USE OF ES!LOK® PROCEDURE
4.21 USE OF ZAP ALERT® 5.3.9.3 CARRIAGE ROTARY GEAR BOX
4.21.1 START AFTER USE OF ZAP 5.3.9.4 CARRIAGE ROTARY GEAR BOX,
ALERT™ CHECK LEVEL
4.22 OPERATION WITH AMBIENT 5.3.9.5 CARRIAGE ROTARY GEAR BOX,
TEMPERATURES BETWEEN
-40 & -15°C FILLING PROCEDURE
4.22.1 PRE-HEATING DEVICES 5.3.9.6 TRACK DRIVE GEAR BOXES
4.22.2 STARTING THE ENGINE (with the 5.3.9.7 TRACK DRIVE GEAR BOXES,
machine kept warm through pre-heaters) LEVEL CHECK
4.22.3 STARTING THE ENGINE (without use of 5.3.9.8 TRACK DRIVE GEAR BOXES,
preheaters) FILLING PROCEDURE
4.22.4 PROTECTING THE FLUID COURSE 5.3.10 TRACK TENSION
FROM FREEZING 5.3.11 WELDING
4.22.4.1 DRAIN THE FLUID COURSE 5.3.12 RADIATOR
5. MAINTENANCE 5.3.13 HYDRAULIC PISTON RODS
5.1 DANGEROUS ZONES—SAFE DISTANCES 5.3.14 CLEANING
5.2 ORDINARY, PERIODICAL AND 5.4 OTHER INSPECTION AND
PREVENTIVE MAINTENANCE MAINTENANCE (50 HOURS)
5.2.1 QUALIFICATION OF THE TECHNICIAN 5.4.1 BOLTS AND NUTS
5.4.2 PIPES AND HOSES Fig. 6 Machine Labels
5.4.3 LEAKS Fig. 7 Placement of Labels, 1 of 2
5.4.4 GAUGES AND INSTRUMENTS Fig. 8 Placement of Labels, 2 of 2
5.4.5 BATTERIES Fig. 9 Transporting The Drill
5.4.5.1 BATTERY EQUALIZER Fig. 10 Lifting The Drill
5.4.6 UNDERCARRIAGE Fig. 11 Transport Dimensions DD-100
5.5 OTHER INSPECTIONS AND Fig. 12 Max. Drill Angle Dimensions DD-100
MAINTENANCE (EVERY 250 HOURS) Fig. 13 Transport Dimensions DD-140B
5.5.1 MOTOR MOUNTS AND RADIATORS
Fig. 14 Max. Drill Angle Dimensions DD-140B
5.5.2 UNDERCARRIAGE ROLLERS
Fig. 15 Tooling
5.5.3 BREATHER PIPES
Fig. 16 Down Hole (Mud) Motor
5.5.4 TRACK TENSION
Fig. 17 Steering
5.6 OTHER CHECKS & MAINTENANCE
(EVERY 500 HOURS) Fig. 18 Clock Face Display
5.6.1 ENGINE BELTS Fig. 19 Tramming
5.6.2 COOLING SYSTEM Fig. 20 Hose Carrier Hold Down
5.6.3 ENGINE OIL BREATHER PIPE Fig. 21 Hand Rails
5.6.4 ELECTRIC SYSTEM Fig. 22 Console Lock Chain
5.7 OTHER CHECKS (EVERY 1000 HOURS Fig. 23 Extending Console
OR EVERY YEAR) Fig. 24 Storage Box
5.7.1 ENGINE FUEL FILTERS Fig. 25 Positioning Crane
5.7.2 ENGINE COOLING SYSTEM Fig. 26 Carriage Lock
5.7.3 EMERGENCY STOP Fig. 27 Hand Rail Installation
5.7.4 HYDRAULIC OIL AND FILTERS OF Fig. 28 Engine Panel
HYDRAULIC SYSTEM Fig. 29 Control Console General Arrangement
5.8 INSPECTIONS AND MAINTENANCE Fig. 30 Instruments—Control Console
EVERY 24 MONTHS
Fig. 31 Setup Controls
5.8.1 ENGINE STOP
Fig. 32 Crane Controls
5.8.2 ENGINE COOLING SYSTEM
5.9 OTHER CHECKS (EVERY 2000 HOURS) Fig. 33 Tramming Control
6. DIAGNOSTIC Fig. 34 Battery Switch & Equalizer
6.1 OPERATING FAULTS Fig. 35 Pipe Support
6.1.1 CLOGGED AIR FILTER Fig. 36 Tiedown Stakes
6.1.2 ENGINE OIL PRESSURE ALARM Fig. 37 Buried Anchor
6.1.3 ENGINE COOLANT TEMPERATURE Fig. 38 Thrust Conversion Table-DD-100
ALARM Fig. 39 Torque Conversion Table-DD-100
6.1.4 ROTARY AND CARRIAGE DO NOT Fig. 40 Thrust Conversion Table-DD-140B
OPERATE Fig. 41 Torque Conversion Table-DD-140B
6.1.5 CLOGGED OIL FILTER(S) Fig. 42 Air Cleaner
7. DEMOLITION Fig. 43 Volume of Soil Formula
7.1 MACHINE DEACTIVATION Fig. 44 Steering Radius
7.2 RESIDUAL RISKS Fig. 45 Approved Replacement Fluids
Fig. 46 Maintenance Schedule
Fig. 1 Declaration of EC Conformity
Fig. 47-49 Hydraulic Schematics—DD-100
Fig. 2 Warranty Certificate
Fig. 50-52 Electrical Schematics—DD-100
Fig. 3 Exit Pit Warning
Fig. 53-57 Hydraulic Schematics—DD-140B
Fig. 4 Pipe Wrench Warning
Fig. 58-61 Electrical Schematics—DD-140B
Fig. 5 Electrical Hazard Warning
Fig. 62 Machine Nomenclature manual for any other subsequent training. The au-
thorized dealer is always available for any further
Attachment 1 Cat 3126 or 3306 Diesel Engines. information or instruction. The user must read and
Attachment 2 Es!lok® Operator’s Manual follow the manual.
Attachment 3 Zap-Alert Instructions
Attachment 4 Crane Operator’s Manual 1.1.3.3 MAINTENANCE TECHNICIAN
Attachment 5 Battery Equalizer Instructions The technician in charge of maintenance must get
acquainted with operation and handling of the
1. GENERAL INFORMATION machine, he must be able to check that there are
no faults in order to carry out maintenance work
1.1 USE AND MAINTENANCE MANUAL with adequate equipment and protection. In case
the technician is not qualified, he must inform a
1.1.1 DATA OF MANUAL qualified person so that skilled personnel are called
TITLE: Operation & Safety Instruction Manual, for special work (example: adjustment of Cater-
Model DD-100 AND DD-140 Horizontal Direc- pillar engine, welding, etc.). The technician must
tional Drill read and follow the manual.
EDITION: 2001
Part number: DD100140BOOK-01 1.1.4 OWNERSHIP OF INFORMATION
American Augers, Inc. reserves all rights to the
1.1.2 CONTENTS OF MANUAL information in this manual.
Chapter 1 General Information The manual cannot be reproduced or photocop-
Chapter 2 Description ied in part on in whole without previous written
Chapter 3 Storage and Transport authorization from American Augers, Inc. The use
Chapter 4 Use of the manual is restricted to the customer who
Chapter 5 Maintenance received it and only for purposes of installation,
Chapter 6 Diagnostic use and maintenance of the relevant machine.
Chapter 7 Demolition American Augers declares that the information
contained in this manual fits the technical and
1.1.3 WHO SHOULD USE THIS MANUAL safety specifications of the machine. American
Augers disclaims responsibility for direct or indi-
1.1.3.1 TRANSPORTER rect damages to persons or property caused when
The transporter is not authorized to handle the the manual or the machine are used in in violation
machine nor start the engine. Only trained person- of the information contained herein.
nel having a written authorization are allowed to The information contained in the manual refers
load and unload the machine from the transport only to the machine mentioned in Paragraph 1.3.
vehicle (see: USER). Relevant parts of the manual IDENTIFICATION DATA OF THE MACHINE.
are in Chapter 3 Storage and Transport. American Augers reserves the right to modify or
improve the manual and the machines without no-
1.1.3.2 USER tice.
At consignment of the machine, a technician ei- 1.2 MANUFACTURER IDENTIFICATION DATA
ther from the authorized dealer or from American AMERICAN AUGERS, INC.
Augers is available for training one or more op- 135 U.S. Rt. 42, P.O. Box 814
erators. Only trained personnel are qualified to op- West Salem, Ohio 44287 USA
erate and maintain the machine. Tel. 419-869-7107 • Fax 419-869-7425
We recommend following the procedure of the
acceptance and test-run certificate, which must al-
ways come with the machine together with the
1.3 MACHINE IDENTIFICATION DATA
Type: Directional Drill This is the safety alert symbol. This symbol is
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 informa-
tion 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 Declara- indicates an imminently hazardous
tion of EC Conformity. situation which, if not avoided, will
result in death or serious personal in-
1.5 GENERAL INFORMATION ON SAFETY jury.
WARNING
1.5.1 SAFETY STANDARD indicates a potential hazard or unsafe
In designing and construction of the machine, situation which, if not avoided, could
standards have been adopted in order to satisfy es- result in death or serious personal in-
sential safety requirements with subsequent modi- jury.
fications under applicable directives. In particu- CAUTION
lar, suitable measures to prevent risks for opera- indicates a potential hazard or unsafe
tors during transport, use, maintenance and demo- practice, which if not avoided may re-
lition of the machine have been completed. The sult in minor personal injury or prod-
complete documentation of the measures adopted uct or property damage.
for safety purposes is contained in the technical
file of the machine, registered by the manufacturer. If you are the owner, operator, or the helper us-
The detailed analysis of risks carried out by the ing an American Directional Drill, it is important
manufacturer are intended to eliminate most of the that you recognize that your drill is a powerful piece
risks connected with the conditions of use of the of construction equipment. (IT MUST BE OPER-
machine, both foreseen and reasonably foreseeable. ATED WITH RESPECT AND CAUTION.)
The manufacturer recommends that the user care- All operators or trainees must carefully read and
fully follows instructions, procedures and advice thoroughly understand this Operation Manual be-
contained in the manual and the laws in force on fore starting or using this machine. Thorough train-
the work site, as well as the use of all protective ing of both operators and helpers is essential for
equipment, both integrated in the machine and the safe operation of this equipment. Never allow
personal protective equipment. inexperienced personnel to operate or work near
the machine unless they are carefully supervised
1.5.1.1. SAFETY AWARENESS PROGRAM during training. In the United States, workplace
Understanding Operation Safety safety is regulated by the Occupational Health and
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. Infor-
counter problems not addressed in this manual. mation can be obtained from your Regional U.S.
BE AWARE OF SAFETY INFORMATION. Department of Labor Office.
Please note the limited warranty included in this
manual. If you have questions on the warranty or
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 in-
The 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.
they are placed on the DD-100 AND
DD-140. These hazard alert signs are
1.5.4 DANGEROUS ZONES—SAFE DIS-
placed on the machine to inform your
operator and other personnel of po- TANCES
tential hazards that exist while these Any zone inside or near the machine where the
machines are in operation. These presence of a person means a risk for his health
signs must be kept clean and legible. and security.
Replacement signs are available from All the areas concerned with handling of parts or
American Augers. machine.
During transport, keep a distance of at least 2 m
NOTICE (6.5 feet) away from the drill.
American Augers disclaims any re- While drilling, some drilling fluid can be sprayed
sponsibility for damages to persons
from the cutting head.
or property caused by operation in
In addition, in case of striking a buried electric
violation of safety advice contained in
the manual. cable, the earth around the drill can become elec-
. trically charged. Keep spectators at least 8 m (25
1.5.2 QUALIFICATION OF PERSONNEL ft) from the drill and associated equipment.
If skilled personnel operate the machine accord- During maintenance, use adequate supports be-
ing to the advice and instructions supplied in the fore releasing bolts, pins, valves, pipes and pis-
manual, the machine will operate safely. All the tons.
operations of transport, use and maintenance must Safety distances during transport: 2 m (6.5 ft)
be carried out only by skilled and authorized per- Safety during self-moving: 2 m
sonnel, after studying and understanding the in- Safety distances during use: 8 m (25 ft)
structions supplied by the manual. Safety distances during maintenance: 8 m
1.6 LEGAL ASPECT OF THE MANUAL

NOTICE
American Augers disclaims any re-
sponsibility for damages to persons NOTICE
or property caused by the operation American Augers disclaims any re-
of the machine by untrained person- sponsibility for damages to persons
nel. or property caused by the operation
of the machine in violation of the in-
structions contained in this manual
1.5.3 USE OF PERSONAL PROTECTIVE
EQUIPMENT 1.7 USES ALLOWED
Work allowed:
WARNING Installation of drill pipe into the earth. Rotation
If personal protective equipment is not
of drill pipe. Use of bentonite fluid to create the
used, serious injury or death of per-
pilot bore. Removal of drill pipe from the earth.
sonnel can occur.
Use of bentonite fluid to back ream the bore. Pull-
The operator and all other personnel on the ing a reamer through the pilot bore. Pulling prod-
worksite must use proper protective equipment uct pipe or cable through the bore.
1.7.1 FEATURES OF THE SOIL TO BE 1.7.3.2 USE
DRILLED When the machine is used, only one operator is
allowed to operate the drilling functions for safety
1.7.1.1 TYPE OF GROUND reasons. Other trained personnel may work near
The machine is suitable for working in the follow- the drill if they are wearing personal protective
ing types of soil: equipment.
-Sand -Gravel -Loam -Clay -Shale -Rock
1.7.3.3 MAINTENANCE
1.7.1.2 GROUND LEVELLING During maintenance with the machine running,
Max. transversal inclination (lateral) :10° only one qualified technician is allowed to operate
Max. longitudinal inclination (frontal): 15° the controls for safety reasons.
Max. height the machine will climb:150mm (6 in.) For maintenance operations with the machine off,
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
[5°F and 105°F] (with oils and coolants recom- The machine is not designed and built for any
mended). For temperature lower than 0°C [32°F] uses not specified in Paragraph 1.7. USES AL-
REFER TO Paragraph 4.21. OPERATION WITH LOWED.
TEMPERATURES BETWEEN -40°C AND -15°C In particular the uses not allowed are the follow-
[-40°F AND +5°F]. For temperatures not included ing:
in this range, get in touch with American Augers. 1) Drilling on sandy, collapsing or incoherent
Relative humidity allowed during work: 100% ground. 2) Drilling on boggy ground or with too
Max. altitude: 2000 m [6500 ft] above sea level much water that compromises the grip or the sup-
Atmospheric conditions must allow adequate vis- port of the tracks. 3) Use of the machine for pull-
ibility 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.
lightning is present. 5) Use of the machine in explosive and/or inflam-
mable area. 6) Use the front foot to lift the tie down
1.7.2 FEATURES OF TRANSPORT stakes out of the earth. 7) Any time when there are
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
onto the trailer deck. present within the dangerous zones indicated in
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
TRANSPORT CAUTION
If the drill exceeds overall dimensions allowed, It is the responsibility of the user to
decide whether to use the drill in con-
it is necessary to flag it according to the Highway
ditions which can cause excessive
laws of the countries involved in the transport.
wear or damage to the machine.
1.7.3 MACHINE HANDLING PROCEDURES CAUTION

Stop working when any situations
1.7.3.1 TRANSPORT compromise the safety of the opera-
When the machine is loaded on a trailer, only one tor or the integrity of the machine.
operator is allowed to operate the tramming con-
trols for safety reasons.
NOTICE warranty is valid worldwide. Only Caterpillar deal-
American Augers does not bear any ers are authorized to perform repairs under war-
responsibility for damages caused by ranty and supply service and spare parts.
the incorrect use of the machine, nor
for wear and damage caused by the 1.10 SERVICE AGREEMENT
particular quality of the drilled mate- Contact the local dealer.
rial.
NOTICE
1.9 WARRANTY
This manual must be kept for the
whole lifetime of the machine so that
1.9.1 GENERAL CONDITIONS it can be easily found if needed. If the
Any warranty is subject to the conditions speci- machine is sold, the manual must be
fied in the warranty certificate. provided to the new owner.
Except for the specified exclusions and limita-
tion, the warranty certificate covers all the mate- 1.11 CONVENTIONS
rial supplied for a period of 6 months beginning
from the shipping date. 1.11.1 CONVENTIONS OF TERMINOLOGY
Extensions can be granted only by the President As the directional drill is not a conventional con-
of American Augers and must be signed and en- struction machine we list some terms normally used
closed with the certificate consigned at the time of in the text with their description.
sale. FRONT is the end with the wrenchs and foot.
No extension can be granted after sale. LEFT or RIGHT as seen standing behind the ma-
chine facing FRONT. The operator’s console is on
1.9.2 LIMITATIONS OF WARRANTY the RIGHT side.
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/manufac- In 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:
ognized by the same suppliers/manufacturers. In NOTICE
particular the warranty on the Caterpillar engine is Notices, cautions and warnings in-
supplied by the Caterpillar dealer in the area where cluding important information are set
the drill is sold. apart from the text.
1.9.3 WARRANTY CERTIFICATE REFER TO: Safety Awareness Program, Paragraph

See Fig. 2. 1.5.1.1.
1.9.4 REQUEST FOR SERVICE SUPPORT 2. DESCRIPTION

For any request of service support in or out of
2.1 PARTS OF THE MACHINE
the warranty period, contact your authorized dealer.
The machine consists of the following assemblies
Have available model number, serial number of
(REFER TO: Fig. 47 & 48).
the machine and working hours indicated on the
instrument (Fig. 30, TACH). 2.2 DESCRIPTION OF THE DIRECTIONAL DRILL
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 prob-
lems related to Caterpillar engine. The Caterpillar
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
2.2.2 CARRIAGE which imparts thrust and pull- 2.3 PURPOSE OF THE MACHINE
back force, and rotary motion to the drill pipe The directional drill is designed for the produc-
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
ward when thrusting blade or with hard metal teeth and is able to re-
move soil. The result is a bore with circular sec-
2.2.4 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 cut-
the crane ting head is advanced by connecting it to sections
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
joints water, bentonite and other substances, which is
forced into the drill pipe by the mud pump.
2.2.6 BREAKOUT WRENCH a moveable wrench The actual bore dimension cannot be guaranteed
that applies enough force to loosen pipe joints for each bore. For example: depending on soil con-
ditions and the size of the pipe or cable to be in-
2.2.7 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
conditions. requires additional special accessories which are
not supplied and must be ordered separately.
2.2.8 MUD PUMP a pump separate from the ma-
chine that forces drill fluid through the drill pipe. NOTICE
American Augers disclaims any re-
sponsibility for differences in dimen-
2.2.9 TIE DOWN SYSTEM H-beam stakes which
sions between theoretical and actual
are driven through the front foot to anchor the drill
bores.
to the earth.
2.4 STRUCTURE
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 cut-
ting head. ting head into the soil is determined by the length
and depth of the bore, in consideration of the al-
2.2.11 ES!LOK® an exit side lockout system that lowable bending of the drill pipe.
is capable of disabling the rotation and linear move- The drill is anchored in place using the tie down
ment of the drill pipe. system and by positioning the rear thrust stabiliz-
ers. 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 opera-
2.2.13 UNDERCARRIAGE tracks and associated tion of the carriage. It is possible to steer the cut-
parts for support and movement of the machine. ting head as it passes through the soil. By know-
ing the orientation of the cutting head, the opera- length: 14783 mm [48 ft 6 inches]
tor can rotate the drill pipe to correct the path of
the bore. By continuously rotating the pipe, the Dimensions in transport position:
cutting head advances without steering. The drill height: 3988 mm [13 ft 1 inch]
pipe and its joints have been designed to withstand width: 2559 mm [8 ft 4-3/4 inches]
a certain amount of bending. length: 14783 mm [48 ft 6 inches]
It is customary and desirable for the drilling fluid
to return to the surface at the entry point. This fluid *add 1524 mm (60 inches) when console is in
carries all the soil removed in the production of working position
the bore. A pit may be dug adjacent to the entry REFER TO: Figs. 13, 14
point of the cutting head to store the returning drill-
ing fluid. 2.5.3 DIESEL ENGINE (DD-100)
The operator is seated to permit good visibility Fuel: diesel fuel
of the operation of the drill and various gauges that Piston displacement: 7.2 L [442 cu. inch]
indicate performance. It is possible to control all Power: 194 kW (260 HP)
the functions by means of electric or hydraulic Fuel tank capacity: 568 L [150 U.S. Gallons]
controls under complete safety conditions for the Hours of operation per tankful: approx. 10 hours
operator. REFER TO: Attachment 1, Caterpillar 3126 Die-
sel Engines.
2.5 TECHNICAL SPECIFICATIONS
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 Die-
height: 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
Voltage: 24 volt DC start and run; 12 volt acces-
Dimensions in transport position: sory
height: 3073 mm [10 ft 1 inch] REFER TO: Figs. 50-52 and 58-61
width: 2413 mm [7 ft 11 inches]
length: 13564 mm [44 ft 6 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]
Open loop: 345 bar [5000 psi]
Dimensions in working position, 18° drill angle: Max. temperature allowed for hydraulic oil is 80°C
height: 5944 mm [16 ft 6 inches] [175 °F].
width*: 2559 mm [8 ft 4-3/4 inches]
2.5.8 PERFORMANCE AS SUPPLIED (DD-100) 3. STORAGE AND TRANSPORT
Max. carriage speed: 30 m/min (100 FPM)
Rotary speed: 0—110 rpm 3.1 STORAGE
Drill angle: 10°-18°
3.1.1 MINIMUM STORAGE SPACE RE-
2.5.9 PERFORMANCE AS SUPPLIED (DD- QUIRED (TRANSPORT POSITION)
140B) DD-100: level 3 x 15 m, height 3 m [118 x 590
Max. carriage speed: 29 m/min (95 FPM) inches, height 118 inches].
Rotary speed: 0—95 rpm DD-140B: level 3 x 15 m, height 3.2 m [118 x 590
Drill angle: 10°-18° inches, height 126 inches].
2.5.10 VIBRATION
Vibration is an indication of incorrect operation, 3.1.1.1 PROTECTION WHILE IN STORAGE:
such as advancing the drill pipe too rapidly. If the machine has been lubricated it can be stored
in an exposed area up to 30 days. For storage peri-
CAUTION ods more than 30 days place it in a covered and
Stop work in case of vibration, which dry area. Level the storage site so that the tracks
could compromise the safety of the are fully supported.
operator or the integrity of the ma- DD-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 mini-
mum safety distance (8 m [25 feet] from the near- 3.1.2 STORAGE SITE ENVIRONMEN T
est point of the machine) must wear adequate hear- Temperature 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 Caterpil-
DANGER lar manual and follow the instructions for storage
The noise generated by the machine of the engine. Verify that there is no water or drill-
may cause injury to personnel. Ob- ing fluid in the drilling fluid course and no water
serve the national laws in force about
in the diesel fuel and hydraulic oil tanks.
the protection from risks caused by
noise.
3.1.3 PROCEDURES OF STORAGE
2.6 RESPONSIBILITY • Clean all mud and other foreign materials off the
machine.
NOTICE • Position the machine on a level surface. Position
American Augers disclaims any re- the carriage in the center of the thrust frame. Raise
sponsibility for inconvenience, faults the front foot by retracting the thrust frame.
or malfunctioning of the machine in • Switch off electric system by turning the battery
circumstances where procedures switches at the battery box.
identified in paragraph 4.18 are not fol- • Lubricate the entire machine according to the
lowed. daily schedule. Coat all exposed hydraulic cylin-
der 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, con-
sult and follow the instructions of storage for Cat-
erpillar engine (mentioned in the relevant mainte-
nance manual), disconnect batteries and store them WARNING
separately at temperatures above 0°C (32°F). Before loading the machine on a
Eliminate sediment and water from the tanks (die- trailer, follow the instructions supplied
sel fuel and oil), top up all the gearboxes and the in this manual carefully.
hydraulic oil tank.
• For periods longer than 30 days, disconnect the 3.2.2 PROCEDURES OF POSITIONING
es!lok® battery charger located inside the storage Position the thrust frame in order to obtain a mini-
box (Fig. 24-1). This charger is not affected by the mum overall dimension.
battery switch. If left connected it could discharge Remove the tie-down stakes from the front foot
the machine batteries. and store them in a safe location. Make sure to
retract the thrust frame and raise the rear thrust
NOTICE stabilizers.
Before putting the machine back in Position the carriage as far forward on the thrust
service reconnect the es!lok® battery frame as possible.
charger to either a 12 v DC or 24 v DC
supply and recharge the es!lok® bat- 3.2.3 TRANSPORTATION
teries. Make sure the es!lok® batteries Considering dimensions, weight and shape of the
are charged before attempting to put machine, the transporter is responsible for using
the machine back into service.
the proper method of transport in conformity with
local regulations. Detailed information on the ma-
The machine must be kept away from salty or chine features are in: Chapter 1 GENERAL IN-
acid 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.
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: Para- Make sure that all personnel keep a
graph 4.23.4, PROTECTING THE FLUID safe distance while loading the ma-
COURSE FROM FREEZING chine for transportation. Start up and
handle the machine according to Para-
3.2 TRANSPORT graph 4.7. OPERATION. Use the teth-
ered tramming controls and stay clear
WARNING of the machine. Always use low speed
Transport of the machine must be car- for loading and move the controls deli-
ried out by trained and authorized per- cately.
sonnel only, after learning the infor-
mation supplied in the manual. WARNING
Do not sit or stand on the machine
3.2.1 PRELIMINARY OPERATIONS FOR while tramming. Unexpected move-
LOADING THE MACHINE FOR TRANSPOR- ment can cause death or serious in-
TATION jury. Use remote tramming control
Clean the machine by using a water spray. only, while standing at ground level
with good visibility.
CAUTION
Don’t direct water spray inside the
Start the engine.
muffler, or the air filter, against elec- Remove the locking bolt from the thrust frame
tric components or control panels. and the thrust frame support.
Operate the Thrust/Pullback control (Fig. 30, 3.2.6 UNLOADING OPERATIONS
PD2) to position the carriage at the Carriage Lock
(Fig. 26). Swing the Lock Plate (Fig. 26-1) into WARNING
the socket on the carriage and rotate the toggle bar Make sure that all personnel keep a
to hold the Lock Plate in position. safe distance when unloading the
Operate the Thrust/Pullback control (Fig. 30, machine after transportation. Check
PD2) to position the thrust frame in the transport that the machine lost no liquids dur-
ing transport or storage, in particular
position.
check if there is the proper amount of
Raise the front jacks.Retract the front jacks to-
hydraulic oil in the tank.
ward the center line of the machine.
Gather the control hoses and stow them on the
Switch ON the battery master switches (Fig. 34-
deck of the drill.
3 and 34-4).
Push the console support arm to its storage posi-
Insert the ignition key in the control panel (Fig.
tion and anchor it with the chain (Fig. 22-1).
31, SS3).
Rotate the crane boom towards the rear of the
Make sure three emergency stop push buttons are
machine and lower the boom onto the crane rest.
UP (Fig. 30, PB2; Fig. 31, PB1 and Fig. 33, PB2).
Tie off the hook block (Fig. 25).
Start the engine by rotating the switch clockwise
Remove the handrails from the walkway and
(Fig. 31, SS6).
store them on the machine (Fig. 21).
Always use low speed for shifting and move the
Install the hose carrier hold down (Fig. 20).
controls delicately.
Tilt the thrust frame of the machine as necessary
Raise the front foot by tilting the thrust frame
in order to avoid the front end dragging the ramps
(Fig. 31, SS22).
or trailer deck while loading or unloading.
Raise the rear thrust stabilizers by selecting
Connect the tramming control box (Fig. 19).
REAR (Fig 31, SS18) then operate SS20 and SS21.
There are three connections, one on each side and
Connect the tethered tramming controls (Fig. 33).
one at the rear, so the operator can have the best
Press the RESET button (Fig. 33, PB3). Propel the
possible visibility.
machine using controls VD1 and VD2 and stay
Proceed slowly when passing the edge of the
clear of the machine . The tether is long enough
trailer as the machine could swing, when chang-
for the operator to walk along either side the ma-
ing the inclination. chine for good visibility. There are three connec-
After reaching the final position on the trailer, tors for the tether—one on each side of the drill
make sure that the front foot is lowered totally. and one on the back.
Lower the rear thrust stabilizers (see Fig. 47) and
make sure the machine is switched off. WARNING
Do not sit or stand on machine while
tramming. Unexpected movement can
cause death or serious injury. Use re-
3.2.5 TRANSPORT CONDITIONS mote tramming control box only while
Anchor the machine. standing at ground level with good
Remove the ignition key from the control panel visibility.
(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.
WARNING 150mm [6 inches] high. Otherwise level the site
A crushed or damaged tramming con- using earthmoving equipment.
trol could result in unexpected move-
ment of the machine. Unexpected 4.1.3 TYPE OF GROUND
movement can cause death or serious The machine is designed to work on clay, asphalt,
injury; Always replace the tramming
cement, rock and normal soil. It is not suitable to
control into its holder.
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 AL-
make sure that the front foot does not drag on the
LOWED and Paragraph 1.8 USES NOT AL-
ground.
LOWED.
Proceed slowly when passing the edge of the
trailer as the machine could swing, when chang-
4.1.4 LIGHTING
ing the inclination.
There has to be enough light to guarantee good
3.3 LIFTING THE MACHINE
visibility of all the movable parts. It may be nec-
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.
adequate capacity for weight. Position the machine
on the flat rack according to paragraph 3.2.4 above. 4.1.5 OPERATING TEMPERATURE: between -
Switch off the engine. 15°C and +40°C [+5°F and 105°F] (with oils and
Use chains to anchor the machine to the flat rack. coolants recommended).
Attach the lifting lines to the flat rack, not to the For temperature lower than 0°C [32°F] use win-
machine. Use spreader bars to ensure that the lift- ter fuel for easier starting and in order to avoid the
ing lines do not come in contact with the machine stoppage of filters from deposits of wax. Make sure
(Fig.10). that all the liquids have suitable features. REFER
TO: Chapter 5 MAINTENANCE.
4. USE For temperature included between -40°C and -
15°C [-40°F and +5°F] REFER TO: Paragraph 4.22
4.1 WORKING SITE PHYSICAL FEATURES OPERATION UNDER AMBIENT TEMPERA-
TURES BETWEEN -40°C AND -15°C [-40°F
4.1.1 MINIMUM SPACE REQUIRED AND +5°F].
In working position 2.5 m [8 feet] width and at
least 15 m [50 feet] length. Height required for 4.1.6 RELATIVE HUMIDITY ALLOWED during
working on flat ground: 8 m [26 feet] (to allow the work: 100%
adding or removing pipe ). Additional clear dis-
tance must be maintained between the crane and 4.1.7 MAX. ALTITUDE: 2000 m [6500 ft] above
any overhead electric wires. These dimensions do sea level.
not allow for storage of pipe or tooling nor the set
up and operation of a mud plant. In addition, mark 4.1.8 ATMOSPHERIC CONDITIONS: they must
off a safety zone 8 m [25 ft] in each direction from allow adequate visibility within the safety area. It
the machine and prevent spectators from entering is inadvisable to use the machine during rain where
this zone. lightning is present.
4.1.2 GROUND LEVELING

The machine is able to operate on surfaces with a
max. lateral inclination of 10°, slope in the run-
ning direction up to 15° and to cross steps up to
4.2 FUNCTION OF THE MACHINE [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 produc-
part has to be considered dangerous.
tion of a bore under the earth with a system more
efficient than conventional excavating and resto-
4.3.1 DANGEROUS PARTS AND DESCRIP-
ration 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 H-
a bore with circular section ready for positioning
beams that are heavy and present a danger of pinch-
pipe 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 ex-
sections of drill pipe which are added by the op-
tending 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 re-
backward 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 con-
4.3.1.5 WRENCH ASSEMBLY presents the dan-
ditions and the size of the pipe or cable to be in-
ger 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 move-
requires 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 dan-
ger of becoming entangled.
4.2.1 NORMAL OPERATION
The operator has manual control over the rota-
4.3.1.7 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 care-
carriage, flow and volume of mud, and operation
lessly, can fall or swing. While being forced into
of the fixed wrench and breakout wrench. The op-
the earth the drill pipe is exposed and may be in
erator also has manual control over the movements
rotation, presenting a danger of becoming en-
of the pipe loader. In addition the operator has
tangled.
manual control over the angle of the thrust frame.

4.3.1.8 MUD SYSTEM presents a danger of high
The machine is designed to be operated by one pressure fluid spray
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.
4.3.1.10 DIESEL ENGINE AND MUFFLER WARNING
produce high temperatures. Danger of burns. Do not sit or stand on machine while
Before approaching always wait until: tramming. Unexpected movement can
-the machine is motionless cause death or serious injury. Use re-
-the engine is off mote tramming control box only while
standing at ground level with good vis-
-the movable parts are on the ground or in rest
ibility.
position
-the hot parts have cooled.
WARNING
A crushed or damaged tramming con-
4.3.1.11 PERSONAL PROTECTIVE trol could result in unexpected move-
EQUIPMENT ment of the machine. Unexpected
Always wear suitable personal protective equip- movement can cause death or serious
ment: injury; Always replace the tramming
-protection for hearing control into its holder.
-safety shoes
-helmet WARNING
-safety glasses Before leaving the console, make sure
REFER TO: Paragraph 1.5.4 DANGEROUS that all the controls are in OFF or NEU-
ZONES—SAFE DISTANCES TRAL position.
4.6 CONTROLS AND INSTRUMENTS

WARNING
When using the machine, make sure
that all personnel keep a safe distance 4.6.1 CONTROLS
(8 m [25 ft] in every direction). Use The drilling functions are controlled by levers and
adequate protective equipment for any switches mounted on an extendable console. As
operation to be done near the ma- an option, the controls can be located inside a
chine. See Fig. 5. 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 cor-
the 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 con- NOTICE
sole. Additional workers will assist with loading The switch must be in the SET-UP po-
and 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 4.6.2.3Fig. 30—Control Console
A crushed or damaged tramming con- LT3 Panel Light
trol could result in unexpected move- GAGE2A Pullback Pressure
ment of the machine. Unexpected GAGE2B Thrust Pressure
movement can cause death or serious GAGE2C Makeup Pressure
injury. Always replace the tramming
GAGE2D Rotating Clamp Pressure
GAGE2E Fixed Clamp Pressure
GAGE2F Rotary Pressure
4.6.1.2 EMERGENCY STOP PUSH-BUTTONS
SS7 Work Lights ON/OFF
One red emergency stop push-button is positioned
SS14 Crane Power ON/OFF
on the tramming control switch box, a second is
SS12 Auxiliary ON/OFF
located on the setup panel on the right side. A third
PB3 Horn
is located at the control console. These push-but-
LT2 Service Filters Warning LIghts
tons stop the diesel engine and consequently all
PB3 Emergency Stop
the functions of the machine.
SS5 Reset/Start Engine
After an emergency stop, reset it by lifting the
SS8 Throttle
push-button before attempting to restart the engine.
TACH Engine Speed (RPM)
There are also reset buttons on near the Emergency
DM1 Rotary Speed Digital Display
Stop buttons, (Fig. 30, SS5; Fig. 31, SS6; Fig. 33,
SS11 Rotary Brake FREE/LOCK
PB3).
SS13 Carriage Speed HIGH/LOW
POT1 Rotary Speed Limit
NOTICE
It is not possible to restart the engine PD2 Carriage Push/Pullback
if any emergency stop push-button is VD6 Wrench MAKEUP/BREAKOUT
on (down). VD7 Rotary Clamp GRIP/RELEASE
VD8 Fixed Clamp GRIP/RELEASE
4.6.2 INSTRUMENTS AND CONTROLS (LIST) PD1 Rotary MAKEUP/BREAKOUT
REFER TO: Figs. 28—34 SS17 Wrench Travel
FORWARD/REVERSE
4.6.2.1Fig. 28—Engine Panel SS15 Upper Pipe Support
Fig. 28—1 Voltmeter RAISE/LOWER
Fig. 28—2 Engine Coolant Temperature SS16 Lower Pipe Support
Fig. 28—3 Engine Oil Pressure RAISE/LOWER
Fig. 28—4 Service Meter
Fig. 28—5 Engine Start Switch 4.6.2.4 Fig. 31—Set-up Control Panel
Fig. 28—6 Digital Engine Speed (RPM) SS18 Jacks FRONT/REAR
Fig. 28—7 Starting Aid SS21 Right Jack RAISE/LOWER
Fig. 28—8 Throttle SS4 Mode TRAVEL/DRILL
Fig. 28—9 Emergency Stop SS22 Boom Foot UP/DOWN
SS20 Left Jack RAISE/LOWER
4.6.2.2Fig. 29—Controls General Arrangement PB4 Horn
Fig. 29-1 Es!lok® Receiver FU1 Fuse
Fig. 29-2 Control Console FU2 Fuse
Fig. 29-3 Recycling System (Optional) FU3 Fuse
Fig. 29-4 Limit Rotary Force SS9 Throttle SLOW/FAST
Fig. 29-5 Limit Pullback SS6 Reset/Start Engine
Fig. 29-6 Limit Thrust PG4 Elec. Jack Guidance Signal (+)
PG3 Elec. Jack Guidance Signal (-)
SS3 Key Switch OFF/ON WARNING
PB1 Emergency Stop A wrench on rotating drill pipe can se-
riously injure or kill. Do not break out
4.6.2.5 Fig. 32—Crane Pendant Control tool joints with pipe wrenches.
32-1 Power OFF/ON
32-2 Lift Load 4.6.4 ZAP ALERT™
32-3 Boom Extend Retract Accidental contact with an underground electri-
32-4 Winch RAISE/LOWER fied wire can cause death or serious injury to the
32-5 Rotate CLOCKWISE/ drilling crew from electric shock. Crew personnel
CONTER-CLOCKWISE should wear personal protective equipment. It is
essential that the crew is aware if the drill and re-
4.6.2.6 Fig. 33—Tramming Control lated equipment become energized. The ZAP
SS17 Travel Speed FAST/SLOW ALERT® device senses the difference in electric
PB2 Emergency Stop potential (voltage) between the drill rig and earth
VD1 Left Track FORWARD/REVERSE ground and sounds an alarm. REFER TO: Attach-
PB3 Reset ment 4, ZAP ALERT™ Manual.
VD2 Right Track FORWARD/REVERSE
4.7 OPERATION
4.6.2.7 Fig. 34—Battery Switches CAUTION
and Battery Equalizer Read instruction manual before oper-
34-1 Battery Equalizer ating (optional) engine preheater.
34-2 Battery Box Heater must be preheated up to 30
34-3 Battery Disconnect Switch seconds before engine cranking. Do
34-4 Battery Disconnect Switch not operate preheater for more than 3
minutes after engine starts.
WARNING
Make sure all the controls are in the WARNING
NEUTRAL or OFF position before Do not use starting fluid (ether). Im-
starting the engine. mediate engine damage and personal
injury may result.
WARNING
Replace any malfunctioning signalling CAUTION
instrument immediately. In case unusual noise, abnormal pres-
sure values, or if signal lights appear,
4.6.3 ES!LOK® LOCKOUT SYSTEM stop the engine immediately and carry
The exit side crew has to work in contact with out necessary repairs.
drill pipe and down hole tooling. Unexpected
movement or rotation of the drill pipe or tooling 4.7.1 STARTING THE ENGINE
can cause death or serious injury. The es!lok® exit REFER TO: Fig. 28—34
side lockout system (Fig. 29-1) allows the exit side REFER TO: Attachment 1, Caterpillar 3126 or
crew to lock out movement and rotation of the drill 3306 Diesel Engines.
pipe and tooling. REFER TO: Attachment 3,
For temperature included between -40°C and -
ES!LOK® Owner’s Manual.
15°C [-40°F and +5°F] REFER TO: Paragraph
4.23, OPERATION UNDER AMBIENT TEM-
WARNING
PERATURES BETWEEN -40°C AND -15°C [-
Do not attempt to bypass the es!lok®
40°F AND +5°F].
system Operation of the drill with the
es!lok disabled can result in injury or Make sure that the battery master switches (Fig.
death.
34-3 and 34-4) are turned on. WARNING
Read start up instructions on the attached Cater- A crushed or damaged tramming con-
pillar Engine manual. trol could result in unexpected move-
Make sure that the three emergency stop push- ment of the machine. Unexpected
buttons (Fig. 30, PB1 , Fig. 31. PB2 and Fig. 33, movement can cause death or serious
PB2) are not pushed in.
Rotate the key (Fig. 21, SS16) to the start posi-
tion. If the engine does not start within 20 seconds, 4.8 SET-UP
release the key and await the cooling of starter mo-
tor (at least 2 minutes). NOTICE
Release the key as soon as the diesel engine is Efficient set-up requires the driller
running. plus one additional person.
Engine oil and hydraulic pressures must reach
nominal values within 5 seconds. Adjust engine 4.8.1 POSITION THE DRILL
speed with the control (Fig. 28, SS00; Fig. 30, SS00 Using the tramming controls, move the drill and
or Fig. 31, SS9) . position it over the intended center line of the bore.
Idle the engine for 5 minutes and run with re- Using levers (Fig. 23-1 and 23-2), position the
duced load until the water temperature reaches thrust frame to the desired angle.
60°C [140°F] and the hydraulic oil reaches 40°C
[104°F]. 4.8.2 EXTEND THE DRILLER’S CONSOLE
The electric system can be damaged seriously, if The control console on the DD-100 AND DD-
the engine is started without the batteries con- 140 pivots from travel position and minimum ma-
nected. The engine must not run with disconnected chine width to drilling position. It is necessary to
batteries. move the console into the drilling position before
operation (See Fig. 22 and 23).
4.7.2 MOVEMENT OF THE MACHINE
Insure that all personnel and objects are clear from 4.8.3 REMOVE HOSE CARRIER HOLD DOWN
the intended path of travel. Place switch (Fig. 31, See Fig. 20.
SS4) in the TRAVEL mode. Adjust the engine
speed to low (Fig. 28-9; Fig. 30, SS8 or Fig. 31, 4.8.4 INSTALL HANDRAILS ON THE WALK-
SS9). Remove the tramming control box from the WAY
storage box. Connect the cable to one of the three Remove the handrails from the storage area on
connectors. Press the RESET control (Fig. 33, the drill. Install them in the sockets provided and
PB3). secure with a bolt and nut.
While holding the tramming control box, slowly
move the controllers FIG. 33, VD1 and VD2: left NOTICE
The handrail sections ARE NOT inter-
lever for left track, right lever for right track, away
changeable. Each section is marked
from you for forward, toward you for reverse travel.
with a numeral (Fig. 27-1) so you may
fit it into the matching socket (see Fig.
WARNING 27-2).
tramming. Unexpected movement can
4.8.5 POSITIONING REAR THRUST STABILIZERS
(JACKS)
mote tramming control box only while
standing at ground level with good Use the controls (Fig. 31, SS18) to select the rear
visibility. stabilizers. Use the controls (Fig. 31, SS20 and
SS21) lower the stabilizers to contact the ground.
The stabilizers are to resist the rearward movement
of the drill when making the pilot bore. Do not use Install the locking bolt through the holes drilled
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 ground. the frame support.
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.
present a danger of crushing.
4.8.10 ANCHOR THE MACHINE
4.8.6 POSITION THE CRANE
Remove the pendant control from the storage box DANGER
and connect it at the base of the crane. While the MOVING PARTS. Danger of entangle-
driller operates the crane controls, the second per- ment. Keep body and clothing away.
son detaches the hook block from its rest. Move-
ment of the right front jack will move the base of 4.8.10.1 PLACING THE TIE DOWN STAKES
the crane, so be sure to unhook the crane from its The tie down stakes are intended to prevent the
rest before moving the front jacks. movement of the drill as it thrusts pipe into the
To activate the crane, connect the remote control soil, or pulls on a backreamer or the product.
cable to the electric socket at the base of the crane. Placing the tie down augers requires another per-
Set the engine throttle (Fig. 30, SS8) to high. Op- son in addition to the drill operator. While the sec-
erate the crane using the controls, (Fig. 27). ond 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.
DANGER
4.8.8 THRUST FRAME ANGLE Keep personnel at a safe distance
The thrust frame has two independent move- while driving tie down stakes, they
ments. It can be tilted for changing the drilling present a danger of crushing.
angle using the control (Fig. 31, SS22) and can be
advanced or retracted (forward or rearward). 4.8.10.2 OTHER METHODS OF ANCHORING
THE DRILL
4.8.9 THRUST FRAME EXTENSION In especially soft soils or sand, it may be neces-
To advance or retract the frame, set the switch sary to use an earth anchor in addition to the tie
(Fig. 31, SS45) to DRILL position. down stakes.
Operate the Thrust/Pullback control (Fig. 30, PD2) In hard or rocky soil it may be necessary to cut
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
control (Fig. 30, PD2) will extend or retract the In some soils, it will not be possible to install H-
thrust frame. Extend the thrust frame until the front beams. After selecting the launch point, the driller
foot contacts the ground. may use conventional excavating techniques to
create a pit which can be filled with concrete. You crossings, (4.5 m[15 ft] or more). The second cat-
may consider placing beams or fasteners into the egory will be shallow crossings (4.5 m [15 ft] or
wet concrete and attach the front foot of the drill less). In both categories, the basic drilling meth-
by fasteners or welding. ods are the same. The differences are in the man-
ner of guidance and locating the drill string head.
4.8.10.4 CONSTRUCT A “DEAD MAN” Consult the manufacturer of the locating system
ANCHOR for exact operating instructions.
Construct a “dead man” anchor by excavating and The directional drill provides the means for ro-
back filling. One effective method is to use sheet tating, advancing and retracting the drill string. De-
piling and a steel beam. The sheet piling is placed pending on the specific project, a certain drill string
vertically in the excavation in front in front of the diameter is selected. Selection of drill string di-
drill. A steel beam is placed horizontally in front ameter or capacity is largely dependent on the
of the sheet piling. A heavy chain or cable is at- length of the crossing and the anticipated thrust
tached between the steel beam and the front foot and pullback required for the finished product line.
of the drill. The excavated soil is replaced and com- At the leading end of the drill string, a cutting head
pacted over the sheet piling and steel beam. This is attached (see Fig. 15-1). The cutting head is usu-
arrangement prevents the drill from moving back- ally equipped with nozzles which direct drilling
ward when thrusting the drill string into the earth. fluid to the soil formation. While the cutting head
See Fig. 37. is being rotated into the ground, drilling fluid is
pumped through the drill string and passes through
4.8.11 EXCAVATE THE ENTRY PIT the nozzles in the head to carry cuttings back to
The drill should be anchored to the earth before the surface. The drilling fluid is also used as a lu-
excavating the entry pit. Use earthmoving equip- bricant to reduce friction and heat between the ro-
ment to excavate the entry pit in front of the drill. tating parts and the ground.
The pit is used to catch and retain drilling fluid
that returns from the bore. Many drillers excavate 4.9.1 DEEP CROSSINGS - THE SETUP
a smaller pit to one side of the entry pit and con- A drilled crossing can be set up in several differ-
nect the two pits together with a shallow channel. ent ways. One method is to drill in a constant arc
Fluid returns enter the larger pit and overflow into or semi circle (see Fig. 44). The other method
the smaller pit. During this process many of the would be to enter a hole at a downward angle. The
solids returning from the bore settle to the bottom drill string is then directed into a horizontal posi-
of the larger pit and do not have to be handled by tion and advanced for the distance required to clear
the fluid recycling equipment. the obstruction. The drill string would then be di-
rected at an upward angle to the exit point A cross-
4.9 DRILLING PROCESS ing is determined by its depth, starting point and
Directional drilling is the process of directing a finishing point.
string of small pipe, known as a drill string, under Once these criteria are determined, a set back dis-
an obstacle, attach a cable or larger pipe line, and tance is calculated for an entering and exiting point
pull it back to the starting point. Various factors to and from the intended line. A general rule of
should be taken into account such as: 1) Hole size, thumb is that a drill string can bend at the rate of
2) Required curvature, 3) Hole length, 4) Geol- 30.5 m of radius per 2.5 cm of drilling pipe diam-
ogy, 5) Minimum ground coverage, 6) Survey tech- eter. (Example: the minimum bend radius of a pipe
nique, 7) Magnetic bearing, 8) Drilling fluids, 9) 9.85 cm in diameter is approximately 120 m). [In
Entrance angle, 10) Exit angle, 11) Drill pipe, 12) the English system a drill string can bend at the
Drilling machine, 13) Preplotting chart, and 14) rate of 100 ft of radius per 1 inch of drilling pipe
General working area. diameter. (Example: the minimum bend radius of
There are two categories. The first will be deep a pipe 3-7/8 inches in diameter is approximately
380 ft).] compares the information to a plotted chart. If there
Once the project is established and the entering is any deviation from the intended line, the opera-
and exit points are known, the process can begin. tor makes the steering corrections. Once the first
The drill rig is set up and the drill thrust frame is section is buried, the drill section is uncoupled from
set to the required angle. This is from 10 to 18 the drill spindle and another section of drill pipe is
degrees, depending on the characteristics of the added. For each section of drill pipe installed, an
crossing. The initial pipe section and cutting head additional length of connector wire is also installed,
are set into the wrench. (Note: While the setup and crimped and insulated to complete the circuit for
drilling is proceeding, a second operation should the survey probe.
be started to prepare the product line for installa- The sequence continues until the pilot hole is
tion). The first piece of drill pipe is made out of an completed. By the time the pilot hole is completed,
nonmagnetic material to eliminate any interference the product line should have been prepared to be
to the survey probe. This first section is setup to pulled back. For pulling back a product line or lines,
mount the cutting head and the survey probe for first the cutting head is removed and a backreamer
guidance. Before the drilling process begins, a is installed in its place.
magnetic bearing is selected for the desired direc-
tion of travel. The survey probe is calibrated to DANGER
this bearing and installed in the first section. ROTATING PIPE. Danger of entangle-
ment. Keep body and clothing away.
4.9.2 DEEP CROSSINGS - STEERING SYSTEM
While the hole is being drilled, the drill string is DANGER
rotated along with the cutting head as a single sec- MOVING PARTS. Pinch point. Keep
tion. When steering adjustments are required, the body and clothing away.
drill string is not rotated, however, the cutting head
WARNING
offset is rotated toward the desired direction of
A wrench on rotating drill pipe can se-
travel and the drill string is advanced forward with-
out rotation. The eccentric location of the cutting tool joints with pipe wrenches
head relative to the center line of the drill string
creates a wedge type effect when pushed without A backreamer is a cutting head with its cutters
rotation. This causes the drill string to deflect in facing the drill string. Its purpose is to clear a path
the desired direction. for the product line being installed (Fig. 15-3 &
The locating probe transmits the orientation of 15-4). Directly behind the backreamer (away from
the cutter head relative to the face of a clock (Fig. the drill pipe) a bearing swivel is installed. The
18). Once the orientation is determined, the driller bearing swivel is to attach to a cap that has been
rotates the drill pipe to the desired location. This is installed on the product line. The purpose of the
confirmed by the locating instrument. The drill bearing swivel is to prevnt the product line from
string is then rotated to resume cutting. This pro- rotating as the reamer and drill pipe rotate. As the
cess is repeated as many times as necessary to as- product line is pulled into the hole, the drill string
sure proper location of the cutting head as it is rotated and drilling fluid is pumped in to main-
progresses along the desired path. tain the integrity of the hole.
A rule of thumb states that the back ream diam-
4.9.3 DEEP CROSSINGS - DRILLING eter should be at least 1.5x the diameter of the prod-
METHOD uct line.
When drilling begins, the drilling fluid (mud) In cases where the product line or bundle of lines
pump is turned on and the cutting head is rotated are larger than the pilot hole, an oversized
into the ground. As the first section is being bur- backreamer will be required. When backreaming
ied, the operator monitors the head location and for product line installation, a slightly larger hole
than the product line is required so that the drilling 4.9.5 APPLICATION OF DRILLING FLUID TO
fluid can remove the cuttings. The amount of HORIZONTAL BORING
overcut is largely dependent upon soil conditions When using high productivity drills as large as
and the type of crossing or obstacle. In cases where the DD-100 or DD-140B, a fluid recycling system
the ground conditions are soft and basically is strongly recommended. Drilling operations
unsupporting, use a barrel reamer. This is a tool might require fluid quantities of 1135 to 2270 L/
with radial or coned-shaped ends, which when minute (300 to 600 GPM). Simply mixing fluid in
pulled and rotated through the ground, compacts these quantities presents a challenge. A recycling
the soil in the hole to maintain its integrity. The system enables the driller to reclaim most of the
bearing swivel is installed behind the barrel reamer. drilling fluid for re-use, and minimizes the amount
Drilling in hard soil or rock requires a downhole of fresh water required for mixing. The recycling
motor (see Fig. 16). Downhole motors are designed system removes solids from the drilling fluid and
and built in various diameters and torque ratings usually includes a high pressure pump (mud pump)
to accommodate most drilling applications. to send the fluid through the drill pipe into the bore.
Downhole motors are used where high cutter bit Controls for an American Directional Drill recy-
speed is desired. In most applications the motors cling system fit in the control console next to the
are used in combination with the bent sub for steer- drill controls (see Fig. 29-3).
ing purposes. Several manufacturers have combi- The primary functions of a drilling fluid (mud)
nation systems for sale or lease. in horizontal boring are: 1) to reduce torque asso-
In cases where the hole must be maintained or ciated with sticky soil conditions, 2) to aid removal
blowouts must be prevented, use of a wash pipe is of solids from the freshly cut hole by a flushing
recommended. A wash pipe can be installed when action, and 3) to help stabilize the soil. Water is
backreaming or directly over the drill string. The the major component of drilling fluids used in hori-
use of a wash pipe provides a maintained annular zontal boring. Materials added to water to produce
area so the drilling fluid can remove the cuttings a drilling fluid are bentonite and polymer. Factors
and spoil material without increasing downhole which are very important to drilling fluid quality
mud pressures and the probability of a frac-out (in- are: 1) water quality, 2) formulation of the prod-
advertent return of fluid). ucts and mixing order, and 3) adequate mixing of
the products.
4.9.4 SHALLOW CROSSINGS - THE PROCESS
The DD-100 and DD-140B are not normally used 4.9.6 DRILLING FLUID - THE PROCESS
in shallow drilling (4.5 m [15 ft] or less). Drilling fluid (mud) consists of water or water
with additives. Products such as bentonite and poly-
DANGER mer can be very helpful for horizontal boring, Op-
ROTATING PIPE. Danger of entangle- timum delivery of drilling fluid to soil is critical
ment. Keep body and clothing away. for minimizing operating pressures and torque.
There are several key factors which must be con-
DANGER sidered to maximize your production: 1) hole size,
MOVING PARTS. Pinch point. Keep 2) boring rate, and 3) fluid injection rate. These
body and clothing away. three factors can be used to calculate a fluid-to-
soil injection rate in volume of fluid to volume of
WARNING
soil removed. The amount of fluid required to make
A wrench on rotating drill pipe can se-
the soil flow out the hole is dependent on the type
tool joints with pipe wrenches and amount of clays in the soil.
4.9.7 CALCULATION OF VOLUME OF 4.9.9 WATER QUALITY
FLUID TO VOLUME OF SOIL Hard water (contains calcium and/or magnesium)
The three pieces of information needed to calcu- or salty water is detrimental to bentonite and poly-
late gallons of fluid to gallons of soil at a given mer. If you notice severe thickening or separation
boring rate are: 1) hole volume, per unit of length., of bentonite or polymer at the bottom of the mix-
2) boring rate, in length/minute, and 3) pump rate ing tank, then you probably have a water quality
in volume/minute. From this information, the vol- problem. If your makeup water is salty, replace it
ume can be calculated (see Fig. 43). with fresh water. If your water source is hard treat
Some soils may require more fluid, others less. with soda ash (sodium carbonate, Na2CO3) at a rate
If you are at the maximum mud pump output and from 0.25 kg to 1 kg per 380 litres [0.5 to 2.0 lb
encounter excess torque, then you can reduce the per 100 gallons] or adjust the pH to 9.5. Soda ash
rate of advance and vary your pump rate to pro- precipitates out calcium in the make-up water as
duce minimum torque to optimize progress. Some insoluble calcium carbonate, making it harmless.
soils will be easier to drill if polymer is added to
the drilling fluid. Bentonite suppliers can offer 4.9.10 MUD MIXING
guidance concerning the use of bentonite and poly- Adequate mixing is essential for preparing either
mer products. bentonite or bentonite/polymer slurries. The mix-
ing system must incorporate increased velocity by
4.9.8 FLUID DISPOSAL pipe diameter reduction. Bentonite powder is added
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 recirculat-
additives 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
torque, overuse of drilling fluid will increase costs The crane is intended only for handling pipe and
of bentonite and disposal fees. tooling. Do not use the crane for maintenance on
For instance, reaming a 355 mm diameter hole other machines (such as tire lifting).
and using 3.8 litres of fluid per 3.8 litres of soil, a When the crane is not being used, disconnect
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 total waste generated is 6056 litres of a soil The crane is equipped with an “anti-two block”
and water mixture. Depending on the amount of safety device. Do not disable this device. Do not
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.
metres volume just to accommodate the waste from The crane has one power extension section on
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 addi-
tional 200 cubic feet volume just to accommodate
the waste from the drilled hole.
DANGER threads. Be sure to coat the pipe threads with thread
Do not walk or stand under a sus- joint compound.
pended load. Retract the boom com- If the sonde and cutting head is very long, it may
pletely before transporting the drill. Do be necessary to tilt the thrust frame or excavate a
not allow the crane to contact over- pit in front of the drill.
head electric wires.
Tighten pipe joints to the pipe manufacturer’s
specifications. You can set a limit on the rotary
DANGER
torque at the spindle by observing the pressure on
ROTATING PARTS. Danger of en-
the rotary torque gauge (Fig.30, GAGE2F) and
tanglement. Keep body and clothing
away. using the chart to convert the pressure to rotary
torque. Turn the control (Fig. 29-4) to adjust the
DANGER maximum pressure on the gauge. Avoid over-tight-
MOVING PARTS. Pinch point. Keep ening the pipe threads to reduce problems when
body and clothing away. loosening the threads.
Using suitable tools, tighten the cutting head and
DANGER sonde housing to the pipe.
MOVING PARTS. Pinch point. Install
the fender beneath the pipe loader. DANGER
Keep body and clothing away. Do not A wrench on rotating drill pipe can se-
allow personnel inside the fender riously injure or kill. Do not break out
while the pipe loader is operating. tool joints with pipe wrenches
4.10.1 ADDING PIPE (FIRST SECTION) 4.10.2 USING A MUD MOTOR

Coat the threads on the rotary spindle with spe- A mud motor will be longer than the combina-
cial thread lubricant. Move the carriage to the rear tion of the sonde housing and cutting head. The
of the thrust frame using control (Fig. 30, PD2). mud motor also normally requires the use of a non-
Using the crane and a pipe tongs, lift one section magnetic pipe section which fits between the mud
of pipe from storage and place it over the thrust motor and the first section of drill pipe. The locat-
frame. ing sonde or other instrument is located inside this
Raise the pipe supports using the controls (Fig. non-magnetic section.
30, SS15 and SS16). Lower the pipe into the pipe The use of a mud motor will normally require
supports. excavation of a pit in front of the drill. The pit
Using PD2, advance the carriage until its threads should allow the cutting bit to enter the far vertical
contact the box of the pipe section. Using PD1, wall of the pit. Mud motors vary somewhat in de-
rotate the spindle until the threads tighten. sign. Follow the manufacturer’s instructions with
Be sure to coat the pipe threads (pin end) with respect to installation of the cutting bit, and ad-
thread joint compound. Advancing the carriage, justment of the mud motor and non-magnetic sec-
slide the first section of pipe through the wrenches tion to calibrate the locating instrument.
for installation of the sonde housing and cutter
head. 4.10.2.1 THE ROTARY BRAKE
Lower the pipe supports, using the controls (Fig. The operation of a mud motor induces an un-
30, SS15 and SS16) wanted backward rotation into the drill string. The
Following manufacturer’s instructions, resupply rotary brake is used to lock the rotary spindle and
the locating sonde with fresh batteries and cali- prevent it from turning backward. Activate the ro-
brate the locating receiver. Put the sonde into a tary brake with the control (Fig. 30, SS11). Un-
sonde housing and hand fit it to a cutting head. lock the rotary brake before attempting to steer the
Hand-fit the sonde housing and cutting head to the mud motor.
4.10.3 INSTALLING A WIRELINE GUID- Use the carriage to push the section of pipe until
ANCE INSTRUMENT its pin end engages the box of the previous section
Several suppliers sell and lease a magnetic sur- of pipe. Rotate the spindle slowly using control
vey system which provide information to the drill PD1 and engage the new pipe threads with the pre-
operator such as drill head rotation, drill head angle vious section of pipe. Using the control (Fig. 30,
and magnetic bearing. This information is relayed VD8) release the jaws of the fixed wrench.
to the operator by means of probe installed directly Add additional sections of pipe to the drill string
behind the cutting head in the first section of the repeating the instructions above.
drill pipe. The data is usually transmitted to the Continue to add sections of pipe to complete the
surface via a single conductor wire. Most of the pilot bore. Make steering corrections as necessary.
units are provided with a surface processor for
computing the information. 4.10.5 REMOVING PIPE
The wireline guidance instrument is housed in a Using movement of the carriage (control PD2),
special section of drill pipe. Some housings are pull pipe back from the hole until the joint between
made of a non-magnetic alloy. It is necessary to the spindle and the pipe is aligned in the jaws of
calibrate the guidance instrument and “time” it to the wrench. The lower section of pipe should be
the drill string to get accurate readings. Follow the held by the fixed clamp, (control VD8). Make sure
manufacturer’s instructions. the carriage is pulled back so that the sliding ro-
tary box has moved forward. The sliding rotary
4.10.4 ADDING PIPE (ADDITIONAL SEC- box must have room to move rearward as the pipe
TIONS) threads disengage.
Drill the first section of pipe, sonde housing and
cutter head into the earth until the spindle is just NOTICE
about to enter the breakout wrench. The box end Because Range 2 pipe sections can
of the pipe should be located between the jaws of vary in length, the wrenches on the
the fixed wrench. DD-100 and DD-140 are adjustable to
align the wrenches with the tool joints.
Grip the first section of pipe tightly in the fixed
Position the wrenches forward and
wrench, using control (Fig. 30, VD8). Loosen the
rearward along the thrust frame, us-
threads on the spindle by rotating spindle using ing the control (Fig. 30, SS17).
control (Fig. 30. PD8). Break out the joint, leav-
ing the first section of pipe secure in the fixed Position the spindle in the breakout wrench. Close
wrench. the jaws using VD8. Loosen the threaded joint at
Coat the spindle threads with thread joint com- the spindle by moving control VD6, activating the
pound. Move the carriage to the rear of the thrust breakout wrench. Then return the breakout wrench
frame using control PD2. to its original position.
Bring another section of pipe into position over Rotate the spindle in the breakout direction and
the thrust frame, following the instructions above. loosen the upper threaded joint to the spindle by
Make up the joint between the spindle threads and operating control PD1. This will require only 2 to
the new section of pipe. Rotate the spindle slowly 3 revolutions.
using control PD1, and advance the carriage to- With the spindle threads loose but still engaged,
ward the pipe, making sure the spindle and pipe move the carriage toward the rear of the thrust
box are aligned. frame. Observe the mechanical pointer fixed to the
Coat the pipe threads with lubricant. Rotate the thrust frame near the wrenches. Move the carriage
spindle slowly using control PD1 and engage the toward the rear of the thrust frame until the shoul-
new pipe threads with the previous section. As the der of the pipe pin is aligned with the pointer. This
threads begin to tighten, apply pressure to the end is the proper position to remove the pipe with the
of the pipe with the carriage spindle. loader arm.
Using control PD2, move the carriage toward the 4.10.7.1 LIMITING THRUST AND
wrenches. Pause and apply thread joint compound PULLBACK FORCE
to the spindle threads. Move the spindle threads The maximum thrust and pullback force can be
into the box of the pipe still held in the fixed set by turning the knobs (Fig. 29-5 and 29-6). This
wrench. Make sure the sliding rotary box has can prevent applying too much force and damag-
moved to the rear of the carriage. Use control PD1 ing a down hole motor. It can also help the drill
to rotate the spindle in the makeup direction until operator regulate the rate of advance of the cutter
the threads have completely engaged. head or the retraction of a back reamer.
Observe the pressure on the gauge (Fig. 30,
GAGE2F). Compare the presssure reading to the 4.11 START OF THE DRILLING OPERATION
conversion chart (Fig. 39 or 41) to find makeup Confirm that the machine is in the drilling posi-
torque. Avoid overtightening the threads, which can tion, otherwise find this position and move the ma-
shorten pipe life and make breakout difficult. Cor- chine. The drill pipe should be positioned longitu-
rect makeup torque values are supplied by the pipe dinally along the intended bore path.
manufacturer. Anchor the machine.
Connect the mud mixing equipment(sold sepa-
DANGER rately) to the drilling rig by means of a flexible
Do not walk or stand under a sus- hose. The connection is alongside the thrust frame.
pended load. Do not allow the lifting Following manufacturer’s instructions, operate
mechanism to contact overhead elec- the transfer pump on the mud recycling system to
tric wires. ensure an adequate supply of drilling fluid to the
mud pump on the DD-100 AND DD-140. It is nor-
Place the pipe sections in an area where they will mal for drilling fluid to escape from the cutting
not interfere with the movements of the drilling head even if the mud pump is not operating.
crew. With the drill properly positioned along the in-
tended bore path, and with the front foot anchored
4.10.6 CALCULATING ROTARY TORQUE securely, activate the mud pump.
FORCE A strong jet of drilling fluid will escape from the
Rotary torque force can be learned by compar- cutting head.
ing the reading on the gauge (Fig.30, GAGE2F) to Control mud flow with the optional controls (Fig.
the table (Fig. 39). Example: 2,500 psi indicated 29-3)
on the DD-100 gauge provides a torque of 3,538
ft-lb (High range) or 11,189 ft-lb (Low range). DANGER
Drilling fluid under pressure can cause
4.10.6.1 LIMITING ROTARY TORQUE personal injury. Stay away from the jet.
The maximum rotary torque force can be set by
turning the knob (Fig. 29-4). This can prevent ap- Using 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).
When the spindle has come loose from the length batteries and store the sonde in a safe container.
of pipe, apply thread joint compound to the spindle.
Retract the carriage to the rear of the thrust frame. 4.13 START OF THE PULLBACK OPERA-
Operate the crane to position another section of TIONS
pipe between the spindle and the female thread (the After the completion of the pilot bore, the opera-
box) of the previous pipe. tor must decide whether to enlarge the bore by
Apply thread lubricant to the pin of the new pipe. reaming. Factors include the soil conditions, length
Slowly advance the spindle into the box of the of the bore, and the flexibility of the pipe or cable
new pipe, then allow the pipe to slide over the pipe being installed.
supports until the pin of the new pipe contacts the If reaming is required, remove the cutting head
box of the previous pipe. Slowly rotate the spindle from the drill pipe using suitable tools.
and advance the carriage until the threads of the
two pipes engage and tighten. Tightening must be DANGER
done with rotation of the spindle. The breakout Unexpected movement or rotation of
wrench on the DD-100 and DD-140 is not designed the drill string can cause death or se-
to tighten. rious injury. American Directional
Release the jaws of the fixed wrench and advance Drills come equipped with the es!lok®
exit side lockout system. Use the
the pipe into the bore path as before.
es!lok ® system to disable the drill
Repeat this sequence to complete the pilot bore.
while changing tooling. Instructions
Steering corrections depend on the type of cut- for operating the es!lok® system are
ting head in use. found in a separate manual REFER
TO: Attachment 3, Es!lok® Operator’s
DANGER Manual.
Keep personnel away from the rotat-
ing parts. WARNING
4.12 END OF DRILLING OPERATIONS system Operation of the drill with the
Maintain good verbal contact with the personnel es!lok disabled can result in injury or
at the exit point. Make sure everyone is clear of death.
the exiting pipe. Notify the driller and activate the
es!lok® system. Using suitable tools, remove the WARNING
cutter head and sonde housing. Separate the cutter A wrench on rotating drill pipe can se-
head from the sonde housing.
tool joints with pipe wrenches.
DANGER
To pre-ream the pilot bore, install the reamer in
Drilling operations may require con-
struction of an exit-side pit. The pit place of the cutting head. When all personnel are
must be constructed following Federal clear, re-enable the es!lok® system, and rotate the
and local laws. Unsafe pit construc- drill string. Use of drilling fluid as with the cutting
tion may cause death or serious injury. 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 se- pilot 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-
ing soil. WARNING
The operator may be able to complete reaming A crushed or damaged tramming con-
and pullback in a single operation. In that case, a trol could result in unexpected move-
heavy duty swivel is connected to the far side of ment of the machine. Unexpected
the swivel. A suitable pulling eye is connected both movement can cause death or serious
to the swivel and to the pipe or cable to be installed.
4.15 SWITCHING OFF THE ENGINE

4.14 END OF PULLBACK OPERATIONS
Position all the controls in the OFF or NEUTRAL
The pullback operation is complete when the pipe
position.
or cable has been installed and pulled back to the
Reduce the engine rpm to minimum (Fig. 30,
entry opening.
SS18). Wait 5 minutes for the engine to cool.
Using suitable tools, remove the swivel, reamer,
Switch off the engine by pushing the Emergency
and pulling eye. Leave the pipe or cable exposed
Stop button (Fig. 30, PB2).
according to the requirements of the installation.
4.16EMERGENCY STOP
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. Re- To 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 posi-
point, 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.
REFER TO: Paragraph 4.7.1. STARTING THE
WARNING ENGINE.
tramming. Unexpected movement can 4.18 CHECKS DURING OPERATION
During drilling, it is absolutely necessary to moni-
mote tramming control box only while
tor instruments and functions regularly.
standing at ground level with good
visibility. In case of anomaly, act immediately, by modify-
ing the adjustments or stopping operation.
A priority list of instruments can be the follow- 4.20ES!LOK® LOCKOUT
ing:
-Engine rpm (Fig. 30, TACH) WARNING
-Engine Throttle (Fig. 30, SS8) Read and understand the instructions
®
-Thrust pressure (Fig. 30, GAGE2A) in the es!lok operator’s manual, At-
tachment 3).
-Pullback pressure (Fig. 30, GAGE2B
-Rotary hydraulic pressure
WARNING
(Fig. 30, GAGE2F)
-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 opera-
tor pushes the reset switch on the receiver box
4.19 NORMAL OPERATING RANGES OF IN- mounted to the left of the control console (Fig. 29-
STRUMENTS
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 cir-
reminding the drill operator that a lockout is un-
cuit is indicated by the voltmeter with the indica-
derway. Only when it is safe to do so, the Compe-
tor 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 indi-
the 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 operat-
ing pressure and at normal temperature. In case 4.21 USE OF ZAP ALERT®
these lights remain on when 40°C [104°F] tem-
perature is reached, replace the filters. WARNING
Read and understand the ZAP ALERT®
CAUTION operator’s manual (Attachment 3).
It is the operator’s responsibility to
stop the machine for any abnormal Read and follow the test and set up instructions
value indicated by the instruments.
in the ZAP ALERT® operator’s manual (Attach-
ment 4). The ZAP ALERT® is intended to warn The customer must specify which voltage range
the crew if the drill and associated equipment be- the heater will be connected to. In this way it is
come energized. It is critical to take proper action possible to start the diesel engine even at ambient
after striking a buried cable. Taking the wrong ac- temperatures between -40 and -15°C [-40°F to
tion can cause death or severe injury. +5°F], it is advisable to use pre-heaters in case it
goes under 0°C [32°F]. Connect the cable of
4.21.1 START AFTER USE OF ZAP ALERT® preheater to the electric supply.
Make sure that the drill and associated equipment
are no longer energized. Retest and set up the ZAP WARNING
ALERT® as before. Pre-heating device operates on high
voltage (110 volts or 220 volts AC).
4.22OPERATION UNDER AMBIENT TEMPERA- Connect to a circuit equipped with a
TURES BETWEEN -40 & -15°C ground fault interrupter (GFI). Protect
[-40°F to +5°F] the electric cables from contact with
Only the machines especially arranged at the fac- water or other liquids.
tory can work under ambient temperatures between
-40°C and -15°C [-40°F to +5°F]. This is due to a 4.22.2 STARTING THE ENGINE (with the ma-
particular choice of materials (rubber, gaskets, oils, chine kept warm through pre-heaters)
grease) so that the components do not suffer from REFER TO: Attachment 1 3126 or 3306 Caterpil-
the cold and do not age quickly. Some machines lar Diesel Engines.
are equipped with a preheater device to keep the Idle the engine.
minimum temperature needed for starting the die- Wait until the engine has reached the operating
sel engine. temperature before moving.
It is necessary to carefully follow the specifica- Wait for the hydraulic oil to reach the tempera-
tions of oils and cooling liquids for the diesel en- ture of +30°C [86°F] before operating the controls.
gine, that must guarantee suitable protection at the Check that the filter pilot lights filters are switched
minimum temperature. off before movement.
REFER TO: Attachment 1, Caterpillar 3126 or Disconnect the cable of preheaters from the elec-
3306 Diesel Engines. tric supply before putting the machine to work.
WARNING 4.22.3 STARTING THE ENGINE (in case the

Make sure all the controls are in the preheaters are not connected while stopped)
NEUTRAL or OFF position before In case of long stops with ambient temperatures
starting the engine. between -40°C and -15°C [-40°F to +5°F] without
the preheaters connected, before starting the en-
CAUTION gine.
Failure to observe starting instruc-
Idle the engine.
tions can cause damage to the hy-
Wait until the engine has reached operating tem-
draulic circuit and to the diesel engine.
perature before moving.
Wait until the hydraulic oil has reached the tem-
4.22.1 PRE-HEATING DEVICES
perature of +30°C [86°F] before moving the con-
During 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 die-
FROM 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 sup-
temperature is expected to reach 0°C [32°F] or
ply rated at 1 kW at 110/220V 50/60Hz monophase.
below, it is necessary to protect the fluid course 5.2 ORDINARY, PERIODICAL AND PREVENTIVE
(path of mud flow) from freezing. MAINTENANCE
This section includes all the necessary operations
4.22.4.1 DRAIN THE FLUID COURSE for maintenance by the drill operator (example:
The fluid course on the DD-100 and DD-140B greasing, adding oil, etc).
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
hind the hammer union where the mud supply hose The technician in charge must be trained to know
is connected. the operation and handling of the machine, to verify
that there are no functioning faults, to carry out
CAUTION maintenance with suitable equipment and protec-
Freezing water can do severe damage tion, and to inform the responsible qualified per-
to the mud pump and other parts of sonnel about special repairs that cannot be made
the fluid course. Do not use engine by himself (example: adjustment of Caterpillar
antifreeze fluid in the mud pump due engine, welding, etc).
to concerns about spills. Use special
antifreeze fluid which is classified as NOTICE
“non-toxic.” For any operation which is not de-
scribed in this manual or for extra in-
5. MAINTENANCE formation please contact AMERICAN
AUGERS or the nearest dealer directly.
5.2.2 FREQUENCY OF INSPECTIONS
WARNING Periodical inspections give the operator a simple
Carry out maintenance when the ma- identification and solution of the problems. It is
chine is off. Before operating, clean advisable to carry out the inspections more fre-
the machine and lock movable parts. quently when working in difficult soil conditions.
For maintenance to be carried out with At every inspection/maintenance schedule all pre-
running machine, follow instructions
vious inspections must be carried out. For example,
in Chapter 4 USE.
at 250 working hours, also perform the items listed
in daily and weekly schedules.
Hydraulic oil, gearboxes oil, diesel engine oil,
pins and bearings grease, diesel engine cooling liq- 5.3 SCHEDULED INSPECTION AND MAINTE-
uid, batteries liquid, fuel: handle with care. NANCE
Engines, muffler, gearboxes and hydraulic sys- Every day before use and at least every 10 hours,
tem, can reach very high temperature. Do not at- inspect and perform maintenance on the machine
tempt maintenance immediately after stopping the according to the procedures indicated in Section
work until after the parts are cool. 5.
NOTICE
WARNING Refer to the table (Fig. 45) for approved
Do not carry out welding near the replacement fluids
tanks and inflammable liquids.
DANGER
Make sure that personnel keep a safe
distance during maintenance and con-
trol operations.
5.3.1 MAINTENANCE SCHEDULES OF DI- Change engine fuel filters.
RECTIONAL DRILL MODEL DD-100 AND DD- Change all hydraulic filter elements or when indi-
140 cated by red lights.
Remove and replace all gearbox oil, or submit
NOTICE sample for analysis. Includes:
The procedures must be carried out -Rotary gearbox
as indicated in the maintenance sec- -Carriage drive gearboxes
tion of the manual for the operator. For -Track drive gearboxes (2)
maintenance on the diesel engine
-Hydraulic pump drive gearbox
REFER TO: Attachment 1, 3126 or 3306
Change hydraulic system oil, or submit sample for
Caterpillar Diesel Engines.
analysis.
5.3.1.1 Daily (or 10 hours)
5.3.1.5Yearly (or 1000 hours)
Engine crankcase lube oil level.
Engine coolant level. Perform daily, weekly, monthly and six month
maintenance items, plus:
Hydraulic tank oil sight glass level (3/4 full).
Replace engine coolant or submit sample for analy-
Fuel level.
sis.
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 5.3.1.6After Each Job
visually. Thoroughly wash and drain mud system of all cut-
tings and packed bentonite.
Grease carriage cam followers.
Check track adjustment. Tighten if needed, see
Grease wrench and die holder slides.
manual.
Grease hinge pin bosses.
Check crane pins and retainers.
NOTICE
Check track tension.
At every inspection all the inspections
with previous schedules must be car-
5.3.1.2 Weekly (or 50 hours) ried out.
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 suit-
Perform 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
Grease fittings must be kept clean so
5.3.1.4 Six Months (or 500 hours) that contamination is not forced in-
Perform daily, weekly and monthly maintenance side. Replace damaged fittings.
items, plus:
Change air filter elements.
5.3.4 ENGINE OIL WARNING
Consult the CATERPILLAR operating and main- Before changing fuel filters wait for the
tenance manual. Check that the engine oil is at the engine to cool.
max. level and that there is no contamination,
which could lead to change, filter and oil prema- Replace the diesel fuel filters every 500 hours or
turely. Typical contamination is: oil discoloration, earlier if necessary.
water or engine coolant in the oil, etc. Use the procedures indicated in Attachment 1, 3126
or 3306 Caterpillar Diesel Engines.
WARNING
Before changing oil wait for the engine 5.3.8 HYDRAULIC OIL CIRCUIT
to cool.
NOTICE
5.3.5 ENGINE COOLANT Very small amounts of contamination
of hydraulic oil can damage the sys-
WARNING tem.
Before checking or changing coolant
wait for the engine to cool. WARNING
Hydraulic oil may be under high pres-
Check that the level of the radiator coolant is at sure. Release pressure before open-
maximum and that there is no contamination. Add ing the system.
coolant if the level is low. Consult Attachment 1,
3126 or 3306 Caterpillar Diesel Engines for the Check the level in the tank using the transparent
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.
5.3.6 AIR FILTERS The level must be checked when the oil is cold,
Do not clean the air cleaner unless the instrument with all cylinders retracted.
shows a need for service. At each inspection of the After refilling, lock the tank cap.
air cleaner also inspect the rubber evacuator valve Check the condition of the pipes and hoses and
(Fig. 42-1). Check that in the air cleaner pipes there replace damaged ones.
are no deposits, if so clean them. The primary fil- Identify and eliminate the losses immediately:
ter can be cleaned and reused up to 6 times. The losses of hydraulic system under pressure get al-
secondary filter must not be used again. A stop- ways worse.
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
the maintenance of engine air filter should be in- OF FILTERS (500 HOURS or when
creased. Use the procedures indicated in Attach- indicated by lights)
ment 1, 3126 or 3306 Caterpillar Diesel Engines.
WARNING
Support the thrust frame with a strong
5.3.7 FUEL
support before draining the hydraulic
Use only clean fuel of the proper grade. filters. Do not start up the engine until
After every refuelling, lock the tank. personnel have moved away from the
Discharge water and deposits from the fuel tanks. area.
For temperatures lower than 0°C [32°F] use win-
ter fuel in order to avoid the stoppage of filters for CAUTION
deposits of wax. Hydraulic circuit can be damaged ir-
reparably if start up procedure is not
followed correctly.
To replace oil filters: CAUTION
1. Place a container under the filters to catch the Check levels only when gearboxes are
oil. Oil from nearby hoses will also drain out. cold.
2. Use a wrench to loosen and remove the outer
container. 5.3.9 GEARBOXES AND PUMP DRIVE
3. Remove and replace the filter element. Inspect the gearbox in order to discover leaks. In
4. Replace the outer container. case of a small loss, fill the gearbox to the correct
5. Run the engine at low speed and operate the level.
rotary. Replace the oil in the gearboxes and in the pump
6. Confirm proper oil level in the tank. drive every 500 hours and whenever contamina-
7. Run the engine at high speed for 5 minutes. tion occurs.
8. Shut off the engine and inspect for leaks. After unscrewing a level plug, a small quantity
of oil will escape. As soon as this happens inspect
5.3.8.2 PROCEDURE FOR THE REPLACE– the oil in order to verify that there is no contami-
MENT OF HYDRAULIC OIL nation which requires an unscheduled replacement.
(every 500 hours)
Drain hydraulic oil from the tank in a container 5.3.9.1 PUMP DRIVE, LEVEL CHECK
suitable for transport or elimination. For controlling the oil level in the pump drive
All parts must be cleaned. use the dipstick (rod) accessible from the engine
Remove the hydraulic tank inspection cover and door. The correct level must be between the two
remove any deposit of old gaskets. lines marked on the rod.
Keep all the bolts together.
Remove the suction filter in the tank. 5.3.9.2 HYDRAULIC PUMP DRIVE, FILLING
Clean suction filter, breather pipe, and magnetic PROCEDURE
cap with a lint free cloth and clean oil. For filling use the elbows where breather pipe is
positioned
WARNING Remove the breather pipes
Do not use inflammable solvents, near Top up with suitable oil until it comes out the
fire, sparks or other ignition sources. level hole.
For draining the oil remove the plug in the bot-
Wipe the inner part of the tank with lint free cloths. tom of the gearbox. Catch the oil in a suitable con-
Reassemble the suction filter. tainer. Dispose of used oil in a lawful manner.
Put silicone on inspection cover and reassemble.
Tighten bolts of the cover. 5.3.9.3 CARRIAGE ROTARY GEARBOX
Refill with hydraulic oil (REFER TO: Fig. 45, Inspect the gearbox in order to discover leaks. In
Approved Replacement Fluids). Do not mix hy- case of a small loss, fill the gearbox to the correct
draulic oils produced by different companies due level.
to the possibility of reactions among the oils. Replace the oil in the gearboxes and in the pump
A transparent gauge is mounted on the tank in drive every 500 hours and whenever contamina-
order to allow quick checks of oil levels. The oil tion occurs.
level in the tank can vary considerably according
to the effect of temperature (hot oil increases the 5.3.9.4 CARRIAGE ROTARY GEAR BOX,
volume) and to the position of hydraulic cylinders. LEVEL CHECK
Overfilling can cause oil to come out of the tank. 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 contami-
nation which requires an unscheduled replacement.
5.3.9.5 CARRIAGE ROTARY GEAR BOX, 5.3.11 WELDING
FILLING PROCEDURE
Top up with suitable oil until it comes out the CAUTION
level hole Failure to follow welding procedure
For draining the oil remove the plug in the bot- can cause damage to electric and
tom of the gearbox. Catch the oil in a suitable con- mechanical components. Damage to
tainer. Dispose of old oil in a lawful manner. components due to improper proce-
dures is not covered under warranty.
CAUTION
5.3.9.6 TRACK DRIVE GEARBOXES
Disconnect all wires to battery equal-
Inspect the gearbox in order to discover leaks. In izer before welding on machine. Fail-
case of a small loss, fill the gearbox to the correct ure to do so may result in damage to
level. battery equalizer and batteries.
Replace the oil in the gearboxes and in the pump
drive every 500 hours and whenever contamina- Disconnect ground terminal first.
tion occurs. Reconnect ground terminal last.
5.3.9.7 TRACK DRIVE GEARBOXES, Welding must be done with the battery switches
LEVEL CHECK (Fig. 34-3 and 34-4) in OFF position (switched off).
There are two check plugs on each track drive The ground wire must be connected directly to
gearbox. Move the machine to position the level the component where the welding is made. Fail-
plugs. One plug must be at 12:00 o’clock. The other ure to follow the above instructions could damage
plug will be positioned counterclockwise at the electric and hydraulic components, cylinders, gears
10:00 o’clock position. Remove the plug at the and bearings, due to internal arcing.
10:00 position After unscrewing the level plug , a
small quantity of oil will escape. As soon as this 5.3.12 RADIATOR
happens inspect the oil in order to verify that there This category includes the engine radiator and
is no contamination which requires an unsched- hydraulic oil radiator. Check that there are no ob-
uled replacement structions. Clean the obstructions in order to al-
low the correct air flow and cooling. Cooling ca-
5.3.9.8 TRACK DRIVE GEARBOXES, pacity of heat exchangers of the machine is greatly
FILLING PROCEDURE reduced by deposit of foreign material such as dust
Position the level plugs as described in 5.3.9.7, layers, oil layers, leaves, grass and other material
above. Remove both plugs. which can obstruct air flow. Correct any problem
Top up with suitable oil until it comes out the immediately.
level hole at the 10:00 clock position.
For draining the oil remove the plug in the bot- 5.3.13 HYDRAULIC PISTON RODS
tom of the gearbox. Catch the oil in a suitable con- Check that the rods are not damaged, and that
tainer. Dispose of old oil in a lawful manner. they do not have losses of oil.
Clean if necessary. If this is not done, the shaft
5.3.10 TRACK TENSION seals can fail.
Track tension is maintained by adding grease
through a special fitting, one on each track. 5.3.14 CLEANING
Clean all the marking plates as well as all light-
ing 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
tanks. Do not use acid or abrasive solutions. For Do not start the engine without batteries or dis-
the 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 immedi-
5.4.1 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 wa-
Inspect hoses for leaks and for damage to the out- ter is normally enough to clean terminals and bat-
side surface due to abrasion. tery box. After cleaning, rinse thoroughly with
clean water. Coat the terminals with grease in or-
5.4.3 LEAKS der to prevent future corrosion.
Inspect the machine for leaks of gear oil, hydrau-
lic 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
as working lights and radios, which are much less
5.4.4 GAUGES AND INSTRUMENTS expensive than similar items manufactured for 24
Wipe the faces of gauges with a cloth moistened volt systems. When the 12 volt loads require power
with water. Replace cracked or missing glass. the battery equalizer assures that the current is taken
Fluid-filled (shock resistant) gauges should be re- equally from both batteries. This equalization ex-
placed if the glass is cracked. tends battery life.
The battery equalizer system used on the DD-
5.4.5 BATTERIES 100 and DD-140B includes a system monitor
which also operates status/warning lamps.
WARNING Under normal conditions the battery equalizer
Machine batteries contain acid. Use
system does not require periodic service.
proper precautions and follow the in-
structions listed above.
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 indenta-
tions; if necessary, replace the battery cables. Check
that the battery terminals are not corroded, other-
wise clean and replace them. The voltage of the
battery is 12 volts.
5.4.6 UNDERCARRIAGE 5.5.4 TRACK TENSION
Track tension is maintained by adding grease
DANGER through a special fitting on each track.
Remove pipe and pipe basket from the
machine before performing mainte- 5.6 OTHER INSPECTION AND MAINTENANCE
nance. The max. weight of the ma- (EVERY 500 HOURS)
chine on the undercarriage system
can be in excess of 26,300 kg [58,000 5.6.1 ENGINE BELTS
lb]. Before starting any maintenance
on the undercarriage, the machine WARNING
must be properly supported vertically. Wait for the engine to cool.
The vertical support must include a
locking system that cannot be inad-
Check that belts have the right tension. If they
vertently released allowing the ma-
have loosened, put them under tension. Replace
chine to fall down. Failure to use this
procedure could cause serious injury belts if they are worn over the limits.
or death of the operators. REFER TO: Attachment 1, 3126 OR 3306 Cater-
pillar Diesel Engines.
5.5 OTHER INSPECTIONS AND
MAINTENANCE (EVERY 250 HOURS) 5.6.2 COOLING SYSTEM
Check and/or effect the maintenance of the ma-
chine every 250 hours of engine operation as fol- WARNING
lows: (this control must be carried out together with Wait for the engine to cool.
the daily and weekly controls mentioned previ-
ously). Fill the cooling system with antifreeze.
REFER TO: Attachment 1, Caterpillar Diesel En-
5.5.1 MOTOR MOUNTS AND RADIATORS gines
Check the rubber for wear. If the rubber parts are
worn replace them. 5.6.3 ENGINE OIL BREATHER PIPE
5.5.2 UNDERCARRIAGE ROLLERS WARNING

Replace the rollers in case of damage, flat spots, Wait for the engine to as cool.
etc.
Every 600 hours clean the engine breather pipe.
5.5.3 BREATHER PIPES Clean it more often when operating in dusty con-
ditions. REFER TO: Attachment 1, 3126 OR 3306
WARNING Caterpillar Diesel Engines.
Do not use inflammable solvents, near
fire, sparks or other inflammable 5.6.4 ELECTRIC SYSTEM
sources. Before starting the operation
Inspect all the cables and wires for cracks, bro-
wait until all the machine units (en-
ken connections and loosened attachments. Repair
gine, etc.) are cool.
or replace damaged parts. REFER TO: Figs. 50-
52 and 58-61.
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)
5.7 OTHER CHECKS (EVERY 1000 HOURS OR technical assistance service.
EVERY YEAR)
6.1.3 ENGINE COOLANT TEMPERATURE
5.7.1 ENGINE FUEL FILTERS ALARM
REFER TO Attachment 1, 3126 or 3306 Caterpil- In case of high temperature an automatic device
lar Diesel Engines stops the engine. Once suitable operating tempera-
ture has been reached again, the engine can be
5.7.2 ENGINE COOLING SYSTEM started. If necessary, contact American Augers tech-
nical assistance service.
WARNING
Wait for the engine to cool. 6.1.4 ROTARY AND CARRIAGE DO NOT OP-
ERATE
Add rust inhibitor to the engine cooling system Activation of the es!lok® belt unit by the Compe-
every 600 hours or 12 months. REFER TO Attach- tent Person or loss of signal will lock out the ro-
ment 1, 3126 or 3306 Caterpillar Diesel Engines tary and carriage function. REFER TO: Attachment
3 ES!LOK® Operation and Maintenance Instruc-
5.7.3 EMERGENCY STOP tion Manual.
Verify the perfect operation of both emergency
stop controls. 6.1.5 CLOGGED OIL FILTER
Switching on of one or more lights (Fig. 30, LT2)
5.8 INSPECTIONS AND MAINTENANCE indicates the restriction of the filters. Under con-
EVERY 24 MONTHS ditions of extreme cold it is possible that these
lights switch on when the machine is started and
5.8.1 ENGINE COOLING SYSTEM then switch off by increasing of hydraulic oil tem-
perature. This is normal, but do not operate the
WARNING
machine with one of these lights on in order to
Wait for the engine to cool.
avoid serious damage to the hydraulic system.
Replace the coolant at 1200 hours or 24 months.
7. DEMOLITION
Follow carefully the instructions indicated in At-
tachment 1, 3126 OR 3306 Caterpillar Diesel En- 7.1 MACHINE DEACTIVATION
gines. For demolition of the machine, apply to autho-
rized centers only. The elimination of waste mate-
6. 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
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 collect-
ing sites.
NOTICE
Take used liquids to an authorized re-
cycling center.
NOTICE
American Augers declines any re-
sponsibility in case of recycling or re-
using of parts of the machine.
7.2 RESIDUAL RISKS

Corners of sharp steel parts are dangerous.
Keep the machine in a site inaccessible to people
except those in charge with dismantling.
NOTICE
The machine is made with some non-
biodegradable materials. Take the
machine to an authorized place for
elimination of these materials.
This page was left blank intentionally.
Fig. 1 Declaration of EC Conformity
Not required in North America
Fig. 2 Warranty Certificate
WARRANTY
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 manu-
factured 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 REP-
RESENTATIONS, GUARANTEES, OR WARRANTIES, EXPRESS OR IMPLIED, (INCLUDING,
BUT NOT LIMITED TO, A WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PAR-
TICULAR PURPOSE,) ARE MADE BY MANUFACTURER IN CONNECTION WITH THE
MANUFACTURE OR SALE OF ITS PRODUCTS. NO EMPLOYEE, DISTRIBUTOR, OR REP-
RESENTATIVE 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 CON-
TRACT, 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 RE-
MOVAL 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. 3 Exit Pit Warning
Drilling operations may require construction construction, protection, barricades, traffic con-
of a pit to receive the cutter or mud motor on the trol, installation and type of ladders used in the
exit side of the crossing. pit and personal safety equipment. American
It is the responsibility of the owner to make a Augers recommends that the owner become fa-
safe pit that is in accordance with the rules set miliar with the requirements of 29CFR1910. In-
forth in the (OSHA) Code of Federal Regula- formation can be obtained from your Regional
tions 29. There are specific requirements for pit Department of Labor Office.
Use the es!lok® exit side lockout

system to prevent inadvertent
movement or rotation of the drill
pipe and tooling.
Fig. 4 Pipe Wrench Warning
WARNING
A wrench on rotating drill Do not break out tool

pipe can seriously injure joints with pipe wrenches.
or kill.
Use only suitable equipment to break out tool joints.
Fig. 5 Electrical Hazard Warning
8m (25 ft) Ground (earth) Ground (earth)
Electrical Bonding Cable
8m (25 ft)
Directional Drill Mud Mixer/Cleaner

Return Mud Pit
! WARNING
Electrical Hazard
Erect safety barrier 8m (25 ft) beyond machine.
Make sure grounding stake is properly installed.
Keep spectators away.
Electrical Bonding Cable (not supplied) electrically bonds

mud mixer/cleaner to drill (to maintain equal electrical
potential in event of an electric strike.)
Fig. 6 Machine Labels
15GB7112 8NP41204 8NP41285

8NP41102
15GB7116-1 8NP41103 15GB7113

8NP41117
15GB7155 8NP41101 15GB7119 8NP41283
DIESEL FUEL
8NP41105
8NP41297 8NP41296 HYDRAULIC OIL

8NP41104
CALIFORNIA
Proposition 65 Warning
8NP41271
Diesel engine exhaust and some of its
constituents are known to the State of FILLED WITH OIL __/__/__
California to cause cancer, birth
defects and other reproductive harm
8NP41209
8NP41206
15GB7116 8NP41209
CAUTION ! CAUTION
Disconnect all wires to battery
BEFORE OPERATING equalizer before welding on ma- 15GB7118
RIGHT JACK- chine. Failure to do so may result
UNHOOK BLOCK & in damage to battery equalizer
RAISE and batteries.
CRANE FROM REST Disconnect ground terminal first.
& UNHOOK Reconnect ground terminal last.
DRILLERS CONSOLE Refer to operator’s manual.
ARM CHAIN 8NP47274
8NP41199
8NP41199 8NP47274
Fig. 7 Placement of Labels
15GB7116-1
8NP41117
8NP41102
8NP41103
15GB7116-1
8NP41101
8NP41204
8NP41204
8NP41101
8NP41103
15GB7116-1
8NP41102
15GB7116-1
8NP41297
Fig. 8 Placement of Labels
15GB7116
15GB7118
15GB7113 15GB7116 15GB7155
8NP41209
8NP41271 8NP41285
8NP47274
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
15GB7116 15GB7113 8NP41206 15GB7155 15GB7119 15GB7116
Page 51
Fig. 9 Transporting The Drill
Fig. 10 Lifting The Drill
Spreader bar
Platform
Chains
Fig. 11 DD-100 Transport Position Machine Transport Width: 7 ft 11 in (2413 mm)
64 mm)
44 ft 6 in (135
10 ft 1 in (3073 mm)
11 ft 6 in
(3511 mm)
30 ft 3 in (9246 mm)
Fig. 12 DD-100 Max. Drill Angle (18°)
26 ft 3 in (8000 mm)
18°
18°
18 ft 3 in (5563 mm)
Fig. 13 DD-140B Transport Position Machine Transport Width: 8 ft 4-3/4 in (2559 mm)
783mm)
48 ft 6 in (14,
13 ft 1 in (3988 mm)
29 ft 9.6 in (9,085 mm)
Fig. 14 DD-140B Max. Drill Angle (18°)
26 ft 11 in (8204 mm)
18°
16 ft 6 in (5944 mm)
Fig. 15 Tooling
Fig. 15-1 - Cutting head Fig. 15-2 - Sonde housing
Fig. 15-3 - Barrel reamer
Fig. 15-4 - Blade reamer
Fig. 15-5 - Pullback eye Fig. 15-6 - Duct puller
Fig. 14-5 - Drill string Blade reamer Fig. 15-8 - Pullback swivel Fig. 15-9 - Product line
Fig. 16 Down Hole (Mud) Motor
Cutting bit
Power section Transmission section
Fig. 17 Steering
With cutter head positioned as shown, and thrust without rotation,

bore moves in direction of arrow. Clock face will be represented on
locating receiver.
12
Fig. 18 Clock face display on three brands of receivers
Fig. 19 Tramming
Fig. 20 Hose Carrier Hold-Down
Fig. 21 Handrails
Fig. 22 Console Lock Chain
22-1
Fig. 23 Extending Console
Fig. 24 Storage Box (typ.)
24-1
Fig. 25 Positioning Crane
Fig. 26 Carriage Lock
26-1
Fig. 27 Hand Rails
27-1
27-2
Fig. 28 Instruments & Controls (Engine Panel)
28-1 28-2 28-3 28-4
28-5
28-9
LOW HIGH
28-8 28-6
RPM
THROTTLE
28-7
Fig. 29 Control Console (General Arrangement)
29-1
29-2 29-3 29-4 29-5 29-6
Fig. 30 Control Console
LT3 GAGE2B GAGE2C GAGE2D GAGE2E LT3
GAGE2A GAGE2F
SS7 SS14 SS12 PB3 LT2 LT2 LT2 LT2
TACH
PB2
DM1
SS5
SS11
SS8
SS13 POT1
PD2 PD1
SS17 SS15 SS16
VD6 VD7 VD8
Fig. 31 Setup Control Panel
SS21 SS4 SS22
SS18
SS20 PB4
SS9
FU1 SS6
FU2
FU3
PG4 PG3 SS3 PB1
Fig. 32 Crane Controls
32-1
32-2 32-3 32-4 32-5
Fig. 33 Instruments & Controls (Tramming Control)
SS17 PB2
VD1 PB3 VD2
Fig. 34 Battery Switches and Battery Equalizer (DD-140B shown, DD-100 similar)
34-1
34-2
34-3
34-4
Fig. 35 Pipe Support
Fig. 36 Tie Down Stakes
27-2
Fig. 37 Buried Anchor
Entry Pit
Steel Beam Sheet Piling Chain or Cable
Fig. 38 Table To Convert PSI Reading (Fig. 30-GAGE2A & 2B) to Thrust/Pullback Force
(DD-100)
GAUGE LOW HIGH GAUGE LOW HIGH

PRESSURE RANGE RANGE PRESSURE RANGE RANGE
PSI FORCE (LBS) FORCE (LBS) PSI FORCE (LBS) FORCE (LBS)
900 13610 4388 2600 59886 19306
1000 16332 5265 2700 62608 20184
1100 19054 6143 2800 65330 21061
1200 21777 7020 2900 68052 21939
1300 24499 7898 3000 70774 22817
1400 27221 8876 3100 73496 23694
1500 29943 9653 3200 76218 24572
1600 32665 10531 3300 78940 25449
1700 35387 11408 3400 81662 26327
1800 38109 12286 3500 84384 27204
1900 40831 13163 3600 87106 28082
2000 43553 14041 3700 89828 28959
2100 46275 14918 3800 92550 29837
2200 48997 15796 3900 95272 30715
2300 51719 16674 4000 97995 31592
2400 54441 17551 4100 100717 32470
2500 57163 18429
Fig. 39 Table To Convert PSI Reading(Fig. 30-GAGE2F) to Rotary Torque (DD-100)
GAUGE LOW RANGE HIGH RANGE GAUGE LOW RANGE HIGH RANGE
PSI FORCE (FT-LB) FORCE (FT-LB) PSI FORCE (FT-LB) FORCE (FT-LB)
500 533 168 2400 10656 3369
600 1066 337 2500 11189 3538
700 1598 505 2600 11722 3706
800 2131 674 2700 12255 3875
900 2664 842 2800 12788 4043
1000 3197 1011 2900 13321 4212
1100 3730 1179 3000 13853 4380
1200 4263 1348 3100 14386 4549
1300 4795 1516 3200 14919 4717
1400 5328 1685 3300 15452 4886
1500 5861 1853 3400 15985 5054
1600 6394 2022 3500 16518 5222
1700 6927 2190 3600 17050 5391
1800 7460 2359 3700 17583 5559
1900 7992 2527 3800 18116 5728
2000 8525 2695 3900 18649 5896
2100 9058 2864 4000 19182 6065
2200 9591 3032 4100 19714 6233
2300 10124 3201 4200 20247 6402
Fig. 40 Table To Convert PSI Reading (Fig.30-GAGE2A & 2B) to Thrust/Pullback Force
(DD-140B)
GAUGE FORCE FORCE FORCE GAUGE FORCE FORCE FORCE

PRESSURE (LBS) (LBS) (LBS) PRESSURE (LBS) (LBS) (LBS)
PSI 1ST GEAR 2ND GEAR 3RD GEAR PSI 1ST GEAR 2ND GEAR 3RD GEAR
500 4146 2482 819 2000 66332 39715 13097
600 8292 4964 1637 2100 70478 42197 13915
700 12437 7446 2456 2200 74624 44679 14734
800 16583 9929 3274 2300 78770 47161 15552
900 20729 12411 4093 2400 82916 49643 16371
1000 24875 14893 4911 2500 87061 52125 17189
1100 29020 17375 5730 2600 91207 54607 18008
1200 33166 19857 6548 2700 95353 57090 18826
1300 37312 22339 7367 2800 99499 59572 19645
1400 41458 24822 8185 2900 103644 62054 20463
1500 45604 27304 9004 3000 107790 4536 21282
1600 49749 29786 9822 3100 111936 67018 22100
1700 53895 32268 641 3200 116082 69500 22919
1800 58041 34750 11459 3300 120228 71983 23738
1900 62187 37232 12278 3400 124373 74465 24556
Fig. 41 Table To Convert PSI Reading (Fig. 30-gage2f) to Rotary Torque (DD-140B)
IST GEAR 2ND GEAR 3RD GEAR IST GEAR 2ND GEAR 3RD GEAR
GAUGE FORCE FORCE FORCE GAUGE FORCE FORCE FORCE
PSI (FT-LBS) (FT-LBS) (FT-LBS) PSI (FT-LBS) (FT-LBS) (FT-LBS)
500 4146 2482 819 2000 66332 39715 13097
600 8292 4964 1637 2100 70478 42197 13915
700 12437 7446 2456 2200 74624 44679 14734
800 16583 9929 3274 2300 78770 47161 5552
900 20729 12411 4093 2400 82916 49643 16371
1000 24875 14893 4911 2500 87061 52125 17189
1100 29020 17375 5730 2600 91207 54607 18008
1200 33166 19857 6548 2700 95353 57090 18826
1300 37312 22339 7367 2800 99499 59572 19645
1400 41458 24822 8185 2900 103644 62054 20463
1500 45604 27304 9004 3000 107790 64536 21282
1600 49749 29786 9822 3100 111936 67018 22100
1700 53895 32268 10641 3200 116082 69500 22919
1800 58041 34750 11459 3300 120228 71983 23738
1900 62187 37232 12278 3400 124373 74465 24556
Fig. 42 Air Cleaner
42-2
42-1
Fig. 43 Volume Of Soil Formula
Gallons Water Flow Rate, Gal/Minute

Gallons Soil =
Hole Dia. (inches2) , Gal/ft
) x Bore rate, Ft/min
( 24.5
Use this formula to calculate a fluid-to-soil injection rate, to 800 gallons of soil plus an additional 800 gallons of fluid or
make soil fluid enough to flow out of the bore. As much as a total of 1600 gallons per 100 feet of bore. This volume
two gallons of fluid per gallon of soil could be required to would require a returns pit of approx. 6x6x6 feet. If you have
minimize torque. Example: backreaming a 14-inch diameter reached maximum mud pump rate and still need to reduce
hole= 8 gallons of soil per foot of bore. Progressing at 0.8 ft/ torque, reduce the bore rate (in feet/minute).
min=6.4 gallons of soil per minute. Depending on soil type
you might have to pump 6 gallons of fluid per minute. There-
fore, one hundred feet of bore would generate approximtely
Fig. 44 Steering Radius
eter
diam
pipe
.5 cm of
per 2
5m
si s 30.
radiu
um
Minim
Constant arc bore
Steer down-horizontal-steer up bore
Fig. 45 Approved Replacement Fluids
(Ambient temperature = -18°C to 44°C [0°F to 110°F])
Consult factory for specification at low temperature
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
To order fluids from other suppliers, consult the AA Lubrication Specifications
Fig. 46 Maintenance Schedule

Daily Weekly Monthly 6 Months Yearly After
or 10 hrs or 50 hrs or 250 hrs or 500 hrs or 1000 hrs each job
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. 47 DD-100 Hydraulic Schematic (1 of 3)
Page 71
Page 72
Fig. 50 DD-100 ELECTRIC Schematic (1 of 3)
Page 74
Fig. 52 DD-100 ELECTRIC Schematic (3 of 3)
Page 76
Fig. 53 DD-140B Hydraulic Schematic (1 of 4)
Page 78
Page 80
Fig. 58 DD-140B Electric Schematic (1 of 4)
Page 82
Page 84
This page left blank intentionally
Hose Carrier
Fig. 62 Machine Nomenclature
Undercarriage Rear Thrust Stabilizer (Jack)
Thrust Frame Crane Carriage Breakout Wrench Fixed Wrench
Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Battery Equalizer
Front Foot
Page 87
71
Front Stabilizer (Jack)
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

Joystick de Taladro Electrónico

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Joystick de Taladro Electrónico

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DD-100™/DD-140™ Directional Drill

Operation & Safety

A Division Of American Augers, Inc.

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

1.6 LEGAL ASPECT OF THE MANUAL

1.7.3 MACHINE HANDLING PROCEDURES CAUTION

1.9.3 WARRANTY CERTIFICATE REFER TO: Safety Awareness Program, Paragraph

1.9.4 REQUEST FOR SERVICE SUPPORT 2. DESCRIPTION

4.1.2 GROUND LEVELING

4.3 DANGEROUS ZONES—SAFE DISTANCES

4.6 CONTROLS AND INSTRUMENTS

4.10.1 ADDING PIPE (FIRST SECTION) 4.10.2 USING A MUD MOTOR

4.15 SWITCHING OFF THE ENGINE

WARNING 4.22.3 STARTING THE ENGINE (in case the

Check the level of the electrolyte and add liquid

5.5.2 UNDERCARRIAGE ROLLERS WARNING

7.2 RESIDUAL RISKS

Not required in North America

Use the es!lok® exit side lockout

Fig. 4 Pipe Wrench Warning

A wrench on rotating drill Do not break out tool

Use only suitable equipment to break out tool joints.

8m (25 ft) Ground (earth) Ground (earth)

Electrical Bonding Cable

Directional Drill Mud Mixer/Cleaner

Electrical Bonding Cable (not supplied) electrically bonds

15GB7112 8NP41204 8NP41285

15GB7116-1 8NP41103 15GB7113

15GB7155 8NP41101 15GB7119 8NP41283

8NP41297 8NP41296 HYDRAULIC OIL

Fig. 10 Lifting The Drill

Fig. 12 DD-100 Max. Drill Angle (18°)

29 ft 9.6 in (9,085 mm)

Fig. 14 DD-140B Max. Drill Angle (18°)

Fig. 15-1 - Cutting head Fig. 15-2 - Sonde housing

Fig. 15-3 - Barrel reamer

Fig. 15-4 - Blade reamer

Fig. 15-5 - Pullback eye Fig. 15-6 - Duct puller

Fig. 16 Down Hole (Mud) Motor

With cutter head positioned as shown, and thrust without rotation,

Fig. 18 Clock face display on three brands of receivers

Fig. 20 Hose Carrier Hold-Down

Fig. 23 Extending Console

Fig. 24 Storage Box (typ.)

Fig. 26 Carriage Lock

Fig. 27 Hand Rails

28-1 28-2 28-3 28-4

Fig. 29 Control Console (General Arrangement)

29-2 29-3 29-4 29-5 29-6

LT3 GAGE2B GAGE2C GAGE2D GAGE2E LT3

SS7 SS14 SS12 PB3 LT2 LT2 LT2 LT2

SS17 SS15 SS16

VD6 VD7 VD8

PG4 PG3 SS3 PB1

Fig. 32 Crane Controls

32-2 32-3 32-4 32-5

VD1 PB3 VD2