DD-220T Operation & Safety Instruction Manual Operation & Safety Instruction Manual ... mud swivel...

DD-220TOperation & Safety Instruction Manual

WARNINGUnsafe use of this equipment could result in serious injury or death. This manual con-tains important instructions for the safe operation and recommended maintenance of your DD-220T. All operators and ground personnel must carefully read and under-

stand this manual before starting the machine. Keep this manual available both as a reminder for your experienced operator and as a training aid for your new staff.

Replacement manuals are available by calling American Augers.Telephone: 419-869-7107 or 800-324-4930 (USA Toll Free)

DD-220T Operators ManualForeword

Introduction

Foreword

INTRODUCTION

Since 1970, American Augers has been a devoted manufacturer of trenchless technology equip-ment; customers worldwide recognize the DD-220T as a premier piece of directional drilling equip-ment. American Augers provides its equipment with worldwide technical support, parts and service. American Augers encourages customers to contact the factory with any operational or assistance needs.

Specifications are subject to change without notice or obligation. American Augers will continue to update its product manuals with current operational information, but some units may be retrofitted independently by the customer or by the manufacturer per a customer request at the factory, or while in service, and the information herein may not reflect those changes.

Every effort has been made to adequately cover the operation of the DD-220T in this manual. If you have any questions about any of the features of your specific machine, contact the factory (Telephone: 419-869-7107 or 800-324-4930 (USA Toll Free).

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

Original InstructionsManual Part Number 22DD10000

Released September 2012 Revision 01

Wiggle Steer, es!lok and Quiet-Pak are registered trademarks of American Augers, Inc.All other trademarks are the property of their respective owners.

DD-220T Operators Manual Foreword

Limited Warranty

Limited Warranty

This warranty is extended by American Augers, Incorporated in respect of equipment & products sold. American Augers warrants to the initial purchaser that this Equipment will be free of defects in material and/or workmanship for a period of 2 years from date of shipment to the initial purchaser, or 2000 hours of operation (Engines 2 years/3000 hours, Rack and Pinion 5 years/10,000 hours), whichever occurs first. Once the equipment is placed into service as a retail sale, rental or lease, a properly completed Warranty Registration Certificate must be submitted to American Augers to start and validate warranty coverage.

• The Limited Warranty does not include (1) batteries, lamp bulbs, fuses, various types of gaskets and packing, filter elements, oil lubricants, fluids, track chain, track drive sprockets, Drill Pipe, Auger sections, die holders, wrench wear parts, guide bushings, shaft seals, mud swivel assemblies, valves, piston liners, centrifugal pumps, shaker screens, and other normal wearing or aging parts, (2) engines, (3) transmissions not manufactured by American Augers, and (4) down hole tools & accessories. American Augers extends to the initial purchaser the benefits of any warranty (if any) of the manufacturers or suppliers of any of the excluded items.

• Claims for defects in material and workmanship shall be made in writing by the initial purchaser to American Augers within ten days of defect discovery. American Augers reserves the right to send a service representative, contract an authorized representative, or request that the equipment is returned to the factory for product inspections. Failure on the behalf of the purchaser to permit such above action can cause a voiding of warranty coverage.

• Within the warranty period, American Augers will repair or replace, at its option, free of charge any portion of parts of the new Equip-ment, which are found by American Augers to be defective in material or workmanship. Replacement or repaired parts provided under the terms hereof are guaranteed in like fashion for the remainder of the warranty period. Any parts replaced under the terms of this warranty become the property of American Augers and upon written request, must be returned, transportation prepaid, to American Augers.

• In no event shall American Augers’ liability exceed the purchase price of the Equipment. American Augers reserves the right to fully satisfy its warranty obligation by refunding to the Buyer the full purchase price of the Equipment upon the return of the Equipment by the Buyer, transportation prepaid, to American Augers.

• This warranty applies only if the alleged defective Equipment has been properly maintained and operated as specified by American Augers. This warranty will not apply if the alleged defect is attributable to an unauthorized modification or service repair made, a component part installed, improper equipment storage, neglect or abuse of the equipment on the behalf of the purchaser or their representatives, improper product operation or use of the product exceeding the design limitations, or an attachment supplied, by a party other than American Augers or its subsidiaries, or the authorized representative of any of the foregoing.

• If any tests are conducted to ascertain or demonstrate defects in material or workmanship, such test shall be conducted after rea-sonable notice to American Augers and upon conditions mutually agreed upon in advance of the test, and American Augers may be represented at any test that shall be made. American Augers, at its option may charge the Customer for any tests performed by American Augers at the request of the Customer in respect to the merchandise sold hereunder.

• THE REMEDIES IN THIS WARRANTY SHALL BE EXCLUSIVE AND SOLE REMEDIES OF THE BUYER. THERE ARE NO OTHER WARRANTIES, EXPRESSED OR IMPLIED, OF ANY KIND, INCLUDING BUT WITH-OUT LIMITATION, ANY WARRANTY THAT THE EQUIPMENT IS OF MERCHANTABLE QUALITY OR THAT THE EQUIPMENT IS FIT FOR ANY PARTICULAR PURPOSE. AMERICAN AUGERS WILL HAVE NO MONE-TARY LIABILITY WHATSOEVER FOR ANY DAMAGE, LOSS COSTS, OR EXPENSE (WHETHER GENERAL, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL) SUFFERED BY THE BUYER AS A RESULT OF OR CONNEC-TION WITH THE EQUIPMENT, IN NO EVENT SHALL AMERICAN AUGERS BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT LIMITED TO, FREIGHT CHARGES, TRANSPORTATION CHARGES, DOWNTIME OR OTHER PARTS INCIDENTAL TO THE REMOVAL AND REPLACEMENT OF PARTS REPAIRED OR REPLACED UNDER THIS WARRANTY.


• American Augers reserves the right to modify, alter, and improve any product or parts without incurring any obligation to replace any product or parts previously sold with such modified, altered or improved product or parts.

• No person is authorized to alter or extend this warranty unless made in writing and signed by an officer of American Augers.

• Used products and equipment delivered by American Augers or picked up by American Augers are sold without conditions or war-ranties, express or implied, “as is, where is”, unless there is a clear agreement with the Customer in writing to the contrary. The Cus-tomer agrees to inspect all such equipment before purchase is completed and to accept same without any warranty of merchantability or fitness for a particular purpose.

By acceptance hereof, the Customer covenants and agrees that in the event any products purchased hereunder are resold either in their original form or as a component of another system, the LIMITED WARRANTIES provision set forth above will be included in all sales documents by which the Customer resells any such products. In all such cases, the sales documents by which a purchaser from the Cus-tomer purchases and accepts delivery of the products sold hereunder will include from such LIMITED WARRANTIES and prior to any such sale or delivery and authorized representative of the subsequent purchaser will be made aware of the limitations on the warranty of American Augers or other manufacturer of the products and that the disclaimers of American Augers apply to the resale of such products. The Cus-tomer agrees to indemnify and hold harmless American Augers from any such loss, claim or damage. Including attorney’s fees and expenses resulting from a breach of the foregoing covenant.

DD-220T Operators ManualForeword

Machine Serial Number Locations


Location of Machine Serial Number Plate

Machine Serial Number


Safety Awareness Program

Understanding Operation Safety

This manual is part of the safety system of the equipment. Use it when training personnel who will oper-ate the machine or work on the jobsite. Ensure that a copy is always available with the machine and that the operators have read it, understand it and have access to it. Carefully follow the instructions, advice and pro-cedures it contains. Safety is everyone’s responsibility.

Directional drills have a number of unavoidable hazards unique to their operation. Safety alert decals are provided on American Augers’ equipment to alert the operator to hazards of the machines. The “Safety Alerts” section beginning on page 33 shows these hazard alert signs.

Signal Words

Signal words are used to identify safety information within the text of this manual. They are reserved for personal injury hazards.

is used for a hazard with a high level of risk which, if not avoided, will result in death or serious injury.

is used for a hazard with a medium level of risk which, if not avoided, could result in death or serious injury.

is used for a hazard with a low level of risk which, if not avoided, could result in a minor or moderate injury.

NOTICE: Hazard alert signs are placed on the machine to inform your operator and other personnel of potential hazards that exist while these machines are in operation. These decals should be kept clean and legible. Replacement decals are available from American Augers (Telephone: 419-869-7107 or 800-324-4930 (USA Toll Free)).


DD-220T Operators ManualNotes

Notes

NOTES:



Revision Record

Revision to ManualRevision Number Description of Change Date

00 New Release. Serial numbers under top level 22DD10005 from 7/5/2011DD2200010211.

01 Updated and expanded to include serial numbers under top level 9/12/201222DD10008 from DD2200110812 (machines with split thrust frame)


DD-220T Operators Manual

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Revision Record

Revision to Manual, Continuedvision Number Description of Change Date

8 Refer to the Safety Awareness Program in this manual before attempting to operate this machine


To The Owner

To The Owner

Thank you for your purchase of the American Augers DD-220T. This directional drill, with standard equipment and authorized attachments, is intended to be used for underground drilling and pullback opera-tions.

This manual contains important information that will help you and your crew set up and safely operate the DD-220T. DO NOT operate or permit anyone to operate or service this machine until you have read this Manual. Use only trained operators who have demonstrated the ability to operate and service this machine correctly and safely.

DO NOT use this machine for any application or purpose other than those described in this Manual. Consult the American Augers factory for changes, additions, or modifications that may be required for this machine to comply with various safety requirements. Do not make unauthorized modifications. Unau-thorized modifications could cause serious injury or death. Anyone making such unauthorized mod-ifications is responsible for the consequences.

Make sure this Manual is complete and in good condition. Contact the American Augers factory to obtain additional manuals and for further information about or assistance with your machine. Your American Augers factory has approved service parts and technicians with special training that know the best methods of repair and maintenance for your machine.



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NOTICEBefore using this manual, familiarize yourself with

the Description Of Components on page 15.


PERFORMANCEctual machine, accessory, and component performance, capacity, and results can be adversely fected by or vary with such factors, as environmental conditions, weather, failing to exercise proper maintenance, machine functionality not being utilized within suggested operating levels, mechanical or component substitutions that may alter factory standards, operator

experience, or other unforeseen limitations not previously listed.

DD-220T Operators Manual Table of Contents

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Table of Contentsoreword ............................................................................................. 2Introduction.................................................................................................................. 2Limited Warranty ......................................................................................................... 3Machine Serial Number Locations............................................................................... 4Safety Awareness Program......................................................................................... 5Revision Record .......................................................................................................... 7To The Owner.............................................................................................................. 9

verview ........................................................................................... 15DD-220T Components............................................................................................... 15Ownership of Information .......................................................................................... 18Manufacturer Identification Data................................................................................ 18Machine Identification Data ....................................................................................... 18Scope of Document ................................................................................................... 18Qualification of Personnel.......................................................................................... 19Declaration of Conformity .......................................................................................... 19Use of Personal Protective Equipment...................................................................... 19Legal Disclaimer ........................................................................................................ 19Purpose of Machine................................................................................................... 19Ground Leveling and Soil Conditions ........................................................................ 20Ambient Conditions ................................................................................................... 20Transport ................................................................................................................... 20Operation................................................................................................................... 20Warranty: General Conditions ................................................................................... 20


Limitations of Warranty.............................................................................................. 20Request for Service/Support ..................................................................................... 20Warranty and Service for Diesel Engine.................................................................... 21Instruction Manuals ................................................................................................... 21

fety Information ........................................................................... 23Safety Regulations and Practices.............................................................................. 23Emergency Procedures ............................................................................................. 23Basic Safety Guidelines............................................................................................. 24Utility Locations ......................................................................................................... 25Surface Examination ................................................................................................. 26


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verhead Hazards .....................................................................................................26eferences.................................................................................................................27xit Pit Construction...................................................................................................27efore Starting the Machine.......................................................................................27perating Precautions ...............................................................................................27perator’s Responsibilities.........................................................................................27tarting and Stopping Precautions.............................................................................28rilling Precautions ....................................................................................................28eaming and Installation Precautions........................................................................28aintenance Precautions...........................................................................................29ransporting Precautions ...........................................................................................29oise Level Safety .....................................................................................................29rane Safety (For Machines so Equipped) ................................................................29azardous Chemicals ................................................................................................30elding Safety ...........................................................................................................30

adder Safety .............................................................................................................31anger Zones -- Safe Distances................................................................................31rounding ..................................................................................................................31afety Features - ZAPALERT™.................................................................................32afety Features - es!lok® Exit Side Lockout System.................................................32

ety Alerts...................................................................................... 33

chine Controls............................................................................. 37afety Switches..........................................................................................................37ate and Gate Reset Button......................................................................................40ervice Lights.............................................................................................................41


ngine Monitoring Equipment ....................................................................................53

paration ....................................................................................... 57ite Preparation .........................................................................................................57ydraulic Cranes........................................................................................................57ats and Cribbing ......................................................................................................57rotection of Wires, Cables and Hoses......................................................................57aking Power Connections........................................................................................58rew...........................................................................................................................58he Bore Path ............................................................................................................58uidance System.......................................................................................................58

DD-220T Operators Manual Table of Contents

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Mud Recycling System .............................................................................................. 59ZAPALERT™ Electric Shock Alarm .......................................................................... 59es!lok® Exit Side Lockout System............................................................................. 60

t Up ............................................................................................... 61Starting the Machine for Unloading ........................................................................... 61Assembling the Split Thrust Frame ........................................................................... 63Drill Setup .................................................................................................................. 65Anchor the Machine................................................................................................... 67

perating the DD-220T ................................................................... 70Starting the DD-220T................................................................................................. 70Test the Indicators, Emergency Stop Buttons and All Controls................................. 71Attach the Drilling Fluid Supply Connections............................................................. 71Using the Crane (if so equipped)............................................................................... 71Stopping the Engine .................................................................................................. 71Checks During Operation .......................................................................................... 72Power Wrench Operation .......................................................................................... 72Wrench Pressure Controls ........................................................................................ 72Thrust and Pullback Force Controls .......................................................................... 73Wiggle Steer™ .......................................................................................................... 73Fundamentals: Install Drill Pipe ................................................................................. 74Turn on the Drilling Fluid ........................................................................................... 76Make the Pilot Bore ................................................................................................... 77End of Pilot Bore Drilling............................................................................................ 78

ullback Operations......................................................................... 79


Backreaming and Pullback ........................................................................................ 79Continue Backreaming .............................................................................................. 81Equipment Shutdown ................................................................................................ 81Rig Down ................................................................................................................... 82Disassembling the Split Thrust Frame....................................................................... 83

perating in Different Climates ...................................................... 84Operating in Hot Weather.......................................................................................... 84Operating in Cold Weather ........................................................................................ 84Engine Preheating Devices ....................................................................................... 85


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chine Storage and Transport...................................................... 87inimum Storage Space Required ............................................................................87torage Site Conditions .............................................................................................87reparations for Storage ............................................................................................87ransportation ............................................................................................................88ifting the Machine .....................................................................................................89

neral Maintenance....................................................................... 91ualification of the Technician ...................................................................................91leaning .....................................................................................................................92elding ......................................................................................................................93pproved Replacement Fluids ...................................................................................94

eduled Maintenance................................................................... 95

cifications.................................................................................. 111achine Dimensions / Weight..................................................................................111ower Train..............................................................................................................111rilling Unit ...............................................................................................................111otary Drive .............................................................................................................111arriage Drive ..........................................................................................................111rill Pipe...................................................................................................................111rotective Equipment ...............................................................................................111

pendix .........................................................................................113ppendix A: List of Attachments .............................................................................115ppendix B: Tables Converting Pressure to Torque and Force ..............................116ppendix C: Jackbolt Tightening Procedure ...........................................................121


ple Declaration of Conformity................................................ 123

DD-220T Operators Manual Overview

Overview

OverviewDD-220T Components

1. Hose Carrier2. Carriage3. Rotary Gear Box4. Spindle5. Safety Gate

8. Fixed Clamp9. Front Foot10. Tracks11. Main Junction Box12. Battery and Engine Panel Access Door

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6. Hose Carrier Support7. Wrench Clamp

13. Crane (not shown)


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Overview

-220T Components (Continued)

1. Walkway and Handrail2. ZAPALERT™ Beacon

3. Walkway/Travel Setup Box4. Tool Box

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DD-220T with Standard Thrust Frame



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D-220T Components (Continued)

1. Crane2. Lower Thrust Frame3. Upper Thrust Frame

DD-220T with Split Thrust Frame

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eration and Maintenance Manual

TITLE: DD-220T Operation & Safety Instruction ManualEDITION: 2012Part Number: 22DD10000

nership of Information

American Augers, Inc. reserves all rights to the information in this manual.

The use of the manual is restricted to the customer who received it for purposes of installation, use, and tenance of the relevant machine. American Augers declares that the information contained in this man-its the technical and safety specifications of the machine. American Augers disclaims responsibility for t or indirect damages to persons or property caused when the manual or the machine are used in viola-of the information contained herein.

he information contained in the manual refers only to the machine mentioned under “Machine Identifi-n Data” below. American Augers reserves the right to modify or improve the manual and the machines ut notice.

nufacturer Identification Data

AMERICAN AUGERS, INC.135 U.S. Rt. 42, P.O. Box 814West Salem, Ohio 44287 USATel. 419-869-7107 • Fax 419-869-7425Web Site: www.americanaugers.com

chine Identification Data

Type: Directional DrillModel: DD-220TSerial number: Found on identification plateYear of manufacture: Listed on serial number plate

Location of identification plate: See drawing on page 3.

pe of Document


This manual covers operation, safety and maintenance of the DD-220T (Standard Thrust Frame model Split Thrust Frame model). Planning the bore path, selecting drilling fluid, operating a drilling fluid recy- system and selecting and operating a guidance system are outside the scope of this document. “Hori-al Directional Drilling; Good Practice Guidelines” by the HDD Consortium1 provides information on these other topics. Consult equipment suppliers, engineers and the American Augers factory for additional tance.

1. Available from the Association of Equipment Manufacturers, 6737 W. Washington Street, Suite 2400, Mil-waukee, WI 53214-5647, phone: 414-272-0943 or through the association’s website: shop.aem.org.


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ualification of Personnel

Contact American augers if you have any questions about any aspect of machine operation or safety, if u need further information or instruction or if you need additional copies of the manual or replacement cals (Telephone: 419-869-7107 or 800-324-4930 (USA Toll Free)).

eclaration of Conformity

If required, the Declaration of Conformity is issued at consignment of the machine. A sample document reproduced on page 123. The Declaration of Conformity is not required in North America.

se of Personal Protective Equipment

Improper operation can result in serious injury, death and damage to the equipment. Personnel should read and understand the manual and obtain appropriate training based on their duties. Owner must ensure that all personnel receive instructions about safety. Owner must review all warnings on machine with all personnel.

• Only skilled and authorized personnel should be permitted to transport, operate and maintain the machine.

• Training is available by contacting the American Augers factory.

OTICE: American Augers disclaims any responsibility for damages to persons or property caused by e operation of the machine by untrained personnel or use of the machine in an unauthorized manner.

If personal protective equipment is not used, serious injury or death of personnel can occur. The operator and all other personnel on the jobsite should use proper protective equipment according to their duties.


gal Disclaimer

urpose of Machine

The machine was designed solely for boring a circular section under the earth ready for positioning pipe cable, without the need for backfilling and compacting.

OTICE: American Augers disclaims any responsibility for damages to persons or property caused by e operation of this machine in violation of the instructions contained in this manual.


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und Leveling and Soil Conditions

The DD-220T can operate on surfaces with a maximum lateral inclination of 3° and a slope in the running tion up to 10°. The machine is designed to work on solid ground that can support the load without set-

.

bient Conditions

Temperature limits: -40°F and +100°F (-40°C and +38°C) (with oils and coolants recommended). For eratures not included in this range, contact American Augers.

Relative humidity: 100%Maximum altitude: 6500 feet (2000 m) above sea levelAtmospheric conditions should allow adequate visibility within the operating area.The machine should not be operated when lightning is likely.

nsport

The machine should be transported by a truck tractor in accordance with local and national transporta-laws.

eration

It is recommended only one person operates the controls. Other trained personnel may work near the 20T only if they are wearing appropriate personal protective equipment and follow the safety instruc- in this manual. Further, the operator must remain aware of the location of all other personnel while ating the machine.

rranty: General Conditions

Warranty is provided with the understanding that all safety warnings and instructions will be reviewed by rsonnel. Warranty is subject to the conditions and limitations specified in the warranty certificate located

age 3. If you have questions about the warranty or any part of the machine operation, please contact rican Augers (Telephone: 419-869-7107 or 800-324-4930 (USA Toll Free)).

TICE: Modifications to the equipment made by the customer will reduce warranty coverage. See ited Warranty” on page 3.


itations of Warranty

The warranty for all components that are not manufactured by American Augers are subject to the origi-arranties of their manufacturers and not by American Augers.

uest for Service/Support

For service support in or out of the warranty period, contact American Augers. Provide machine model ber, serial number and number of operating hours.


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arranty and Service for Diesel Engine

The warranty on the engine is valid worldwide and is supplied by the engine dealer in the area where the chine is sold. Only diesel engine dealers are authorized to perform repairs under warranty, provide ser-e and supply spare parts.

struction Manuals

Manuals for components not manufactured by American Augers (e.g., the diesel engine) are included as achments to this manual. For translations of any of the attachments to this Manual, contact the respective uipment manufacturers.



Notes

NOTES:


DD-220T Operators Manual Safety

Safety Information

SafetySafety Regulations and Practices

This manual contains important information about the safety practices and safe operation of the DD-220T. All operators must read and understand the Operation and Safety Instruction Manual before start-ing the machine. Careful adherence to the safety and operating instructions in this manual will help ensure a safe and productive jobsite.

The safety information in this Manual does not replace safety codes, insurance needs, national, provin-cial, state and local laws. Ensure that your machine has the correct equipment required by the local laws and regulations. It is the responsibility of each person working with this equipment to learn and follow all applica-ble local, state, provincial and national safety regulations.

Emergency Procedures

Response to Electrical Strike

Your DD-220T is equipped with the ZAPALERT™ alarm system. If the drill makes contact with a power line and becomes electrically charged, the ZAPALERT™ alarm system will sound a loud, audible signal. The alarm will continue until contact with the electrical line is disconnected.

• If you are on the machine, stay on it. • Remain calm.

NOTICE: American Augers disclaims any responsibility for damages to persons or property caused by operation in violation of safety instructions contained in the manual.

EMERGENCY SHUTDOWN: Push the red Emergency Stop button in one of the following locations:• on the Driller’s Console• on the Main Junction Box• on the Tramming Control

All workers should know the locations of the Emergency Stop buttons before starting the machine on the jobsite.


• Reverse the direction of drill string advance in an attempt to break contact with the electrical line. • If you are not on the machine, do not touch any part of the machine as it may be highly charged. • Notify public safety authorities to secure the area. • Notify the electric utility company immediately. • When the proper utility authorities verify that the power has been disconnected and the work area is

safe, you may get off the machine.

Other workers in the immediate area of the machine should not move. The voltage difference between the equipment and the ground, or between a person’s feet may be sufficient to cause injury or death. Do not touch the machine, hoses, drill pipe, water system, mud mixing system or anything connected to the drill as these items may be highly charged.


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Safety InformationThe ZAPALERT™ alarm may be activated if you break a communication line. However until you are , you must consider the alarm to be an electrical strike. Follow the above procedures and wait for verifi-n from the proper utility authorities.

ponse to a Gas Strike

If a gas line strike occurs, evacuate the area immediately. Turn off all engines. Extinguish all flame and rks immediately. Do not attempt to reverse the bore to break contact as further movement may cause a rk. Contact emergency services and the gas utility company immediately.

ponse to a Fiber Optic Strike

If a fiber-optic strike occurs, stop drilling immediately. Do not look into the cut ends of the cable. This can e severe eye damage. Notify the utility owner.

ponse to a Communications Line Strike

If a communications line strike occurs, stop drilling immediately and notify the utility company.

ponse to a Sanitary/Storm Sewer and Water Strike

If a water or sewer line strike occurs, stop drilling immediately. Warn all bystanders that a strike has rred and that they should stay away. Obtain medical attention for personnel who have come into contact sewage. Notify the utility owner immediately.

ic Safety Guidelines

Before using the DD-220T, all operators should receive thorough training in the use of this equipment. his manual should be used as a training tool.

Jobsite hazards could result in serious injury or death. All personnel on the jobsite must use proper protective equipment according to their duties.


A copy of this manual should remain with the machine and be accessible to all personnel at all times.Personnel on the jobsite should receive training on safety practices, procedures, safety signs and haz-ards. Operators, support personnel, repair technicians, and visitors should be aware of their responsibil-ities and any restrictions to their activities.All new or inexperienced employees should receive a complete orientation to the jobsite and thorough training in their job duties. Never allow inexperienced personnel to operate or work near the machine unless they are carefully supervised.The meaning of the hazard alert signs on the equipment is explained in “Safety Alerts” section beginning on page 33.


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afety InformationFollow all national, state, provincial and local regulations regarding, but not limited to:

In the United States, workplace safety is regulated by the Occupational Safety and Health Administration SHA). OSHA regulations are found in the Code of Federal Regulations, Chapter 29. This is known as CFR1910. Information can be obtained from your Regional U.S. Department of Labor Office. In other untries, the operator is responsible for determining which national, provincial, state and local laws govern erations at the jobsite.

Use required or recommended protective equipment which meets applicable standards when operating this machine:• Hard hats• Safety glasses, goggles, or face shields• Work boots• Work gloves• Highly visible reflective clothing• Hearing protection• Boots and gloves having electrical insulation• Any additional safety equipment mandated by other rules or required by the Owner or regulatory

agencyIf a hazardous situation is suspected, stop work until an evaluation is made and appropriate corrective action is taken.Use hand signals required for specific jobs. Know who has the responsibility for signaling.

. Post the location and phone number of the nearest aid station or hospital. Have a fire extinguisher and complete first aid kit on site. Have at least one of your workers trained in first aid.

Rig operationDrilling fluid system operationRotating drill pipeHandling loose drill pipeMaking/breaking tool jointsPilot bore trackingLocation of utilities and utility clearancesElectrical strike protectionVehicle operationTrench shoring and sloping

Mobile equipment operationConfined space entryNoiseHand and power toolsTraffic controlCommunicationsFall protectionSecurity of jobsite and isolation of hazardsMaterial handling and manual lifting


tility Locations

Electric shock and explosion hazard. Have all utility lines marked before you begin to dig. Notify One Call (by calling 811) as well as utility companies that do not subscribe to the One Call system.

• The One-Call system (dial 811 (US only) or 1-888-258-0808 (US and Canada only)) is in place to facilitate identifying appropriate local utility contacts.

• It is the operator's responsibility to follow applicable laws and regulations which govern locating and avoiding existing utilities.


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Safety InformationBefore beginning any drilling project, have local utility companies mark the location of utility lines buried e area. Design the bore profile to maintain acceptable clearances between underground utilities and tures and the final reamed hole. Carefully consider possible migration of the backreamer from the pilot toward the utility due to excessive steering or a tight radius when establishing clearances.

The One-Call system (dial 811 (US only) or 1-888-258-0808 (US and Canada only)) is in place to facili- identifying appropriate local utility contacts. Additionally, the Pipeline Association for Public Awareness site has several references for excavators at http://www.pipelineawareness.org/excavators. Their avation Safety Guide” describes best practices and contains a guide to state contacts and regulations.

It is the operator's responsibility to follow applicable laws and regulations which govern locating and ding existing utilities.

The location of all identified utilities must be verified using non-destructive methods of excavation. Care-dig a hole by hand and/or automatic vacuum equipment to the utility line to verify its location and depth.

If there is any risk to the utility from the drilling activity, an observation hole must be excavated at or near tility to visually monitor the potentially hazardous situation. A vacuum unit is required to remove the drill-

luid during the process, and high pressure drilling fluid hazards must be addressed. If the bore passes ly by a utility, it may be necessary to continuously monitor the separation after the drill head or reamer es the observation hole, as the drill string or product pipe may subsequently contact the utility during the pletion of the installation.

The drill locator and the drill rig operator should walk the planned bore path with the tracking equipment aluate any potential fields of electromagnetic (active) interference and look for signs of reinforced con- or other possible passive interference that may hinder the operation.

During the actual boring process, if abnormal readings are found with the tracking equipment, the con-or should stop, back up, and verify previous readings prior to commencing the bore. This is critical; as ation from the planned bore profile could result in an underground utility strike. Care must also be taken g the pullback to ensure that utilities are not damaged due to the upsizing by the enlarged backreamer possible straightening of the bore during backreaming and product installation.

face Examination

The job site and the surface along and around the path of the planned bore should be evaluated for indi-ns of possible underground hazards. Transformer boxes, manholes, outbuildings and sheds, gas grills, oor lighting, ditch line depressions and signs of recent road or utility repairs may indicate the presence of tional buried utility lines. Confirm the depth of water and gas shutoff valves. Assume all wires attached to


s are live. Be aware that private utilities and utilities that do not subscribe to the one-call system are not ed by One-Call operators.

erhead Hazards

Overhead lines must be avoided. Overhead lines are of particular concern during mobilization/demobili-n, loading and unloading heavy equipment and while handling drill pipe. If the voltage is unknown, ys maintain at least 20 feet (6 m) of separation between equipment and power lines. If the voltage is n, OSHA regulations outline the required minimum separation in the United States. If necessary, place

ly visible markers on either side of the overhead hazard or designate an individual to notify equipment ators as they approach.


S

Safety

R

OpPr

E

thein

B

O

O

afety Information

eferences

Equipment Manufacturers’ Institute, “Directional Drilling Tracking Equipment Safety Manual”, 2000, Safe eration of Directional Boring Tracking Equipment Video”, 1999, and “Horizontal Directional Drilling Good

actices Guidelines - PDF on CD”, 20012.

xit Pit Construction

Drilling operations may require construction of a pit to receive the cutter or mud motor on the exit side of crossing. It is the responsibility of the crew to make a safe pit that is in accordance with the rules set forth

the (OSHA) Code of Federal Regulations 29 or applicable regulations in other countries.

efore Starting the Machine

• Complete all servicing prescribed in this Operator’s Manual and Attachment A: Diesel Engine Manual.• Check that all hydraulic fittings, bolts and nuts are tight.• Remove all loose objects stored in or on the machine. • Remove all objects which do not belong in or on the machine and its equipment. • Ensure all protective guards, doors, etc. are in place.• Ensure all safety devices are in place and in working order.• Know the location of all personnel on the jobsite.• Walk around the drilling path prior to starting. Check for hazardous areas such as ditches and inclines.• Ensure that traffic and terrain will permit safe operation.• Make sure the ZAPALERT™ system is properly grounded. Test the ZAPALERT™ alarm following pro-

cedures in Attachment 3, “ZAPALERT™ Electric Shock Alarm Instruction Sheet.

perating Precautions

• Place all machine controls in the neutral or OFF position before starting the engine.• Do not start the machine until all personnel are away from rotating or moving parts. • Check the operation of all machine controls before using the machine. • Do not sit or stand on the machine while tramming.


perator’s Responsibilities

• It is the responsibility of the operator to read, understand, and follow the Operator’s Manual and other information provided and use the correct operating procedure. Machines should be operated only by qualified operators and trained helpers.

• Ensure that all underground utilities have been located before drilling begins, and avoid them by using proper drilling techniques.

• Assess the situation using common sense and the benefit of experience and proceed if and only if the work can be safety performed.

• Understand and obey all applicable national, provincial, state, and local codes and regulations. • Point out each of the safety signs on the machine and ensure that the crew understand them.

2. All are available from the Association of Equipment Manufacturers, 6737 W. Washington Street, Suite 2400, Milwaukee, WI 53214-5647, phone: 414-272-0943 or through the association’s website: shop.aem.org.


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Safety

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•

•

Rea

•

Safety Information• Make sure all personnel stay in their prescribed areas.• Ensure that all personnel and objects stay away from rotating or moving parts.• Never leave the operator’s station while the engine is running.• Do not operate the machine while under the influence of alcohol or drugs. • Ensure all safety devices are in place and in working order.• Visually verify all personnel and objects are clear of the machine before startup.• Turn off the machine at the first sign of malfunction or hazardous condition.

rting and Stopping Precautions

• Make sure the ZAPALERT system has been tested and is properly grounded. Follow procedures in Attachment 3, “ZAPALERT™ Electric Shock Alarm Instruction Sheet”.

Be sure all machine controls are in the neutral or OFF position before starting the engine. Securely connect all fluid lines before starting the machine. When shutting down the machine:

• Run the engine at low speed for 5 minutes. • Turn the engine off using stop button or key switch. Wait at least 1 minute before disconnecting the

battery. Failure to wait may cause engine program data loss. • Relieve system pressure. • Remove the starter key (if so equipped).

lling Precautions

• Identify and avoid potential pinch points on the drill rig and support equipment. Maintain safe clearances (at least 3 feet (900 mm)) or as specified by regulatory authorities) between

the bore and all utilities. Minimum clearance must take into consideration the final reamed diameter and the bend radius of the pilot bore.

Stay away from the rotating drill string at all times. Do not operate the drill when personnel are working on or near the drill string. Do not operate the drill without positive communication with the drill locator or exit side personnel. Use the es!lok® Exit Side Lockout System to prevent inadvertent movement or rotation of the drill pipe

and tooling. Operate within the drill pipe manufacturer’s specified maximum torque and thrust/pullback capacity of


the drill pipe. Do not use drilling machine torque to make or break tool joints outside the machine’s wrenches.

• Do not breakout tool joints with pipe wrenches.• Use remote breakout wrenches safely.

ming and Installation Precautions

• Maintain two-way radio communication between the entry and exit sides.• Notify and wait for acknowledgement from all workers before starting to rotate or move the drill pipe. When crossing existing underground utilities, expose the utility at the crossing location and monitor it

during crossing. A power line that was safely passed during drilling may be struck on reaming or pull-back.

• Do not step over rotating drill pipe. Maintain a safe distance when working near rotating drill pipe.


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Safety

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Tr

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80

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afety Information

aintenance Precautions

• Eliminate all power sources (turn off machine, remove key) and relieve system pressures before doing maintenance.

• Allow the machine to cool before servicing. Hydraulic components, engine, radiator and exhaust sys-tems can get hot enough to cause serious injury.

• Use proper lock out and tag out procedures when doing maintenance.• Follow manufacturer’s recommended maintenance procedures. • Allow only properly trained personnel to perform maintenance activities.• Do not modify the machine in any way. • Repair or replace damaged or missing protective guards, doors, etc. • Replace all missing, illegible, or damaged safety signs. Keep all safety signs clean. • Use a piece of cardboard or wood to check for pressurized leaks to prevent fluid penetrating the skin.• Seek medical attention immediately if hydraulic fluid escaping under pressure has penetrated the skin.

Even if the injury seems minor, prompt medical treatment by a physician familiar with this injury is essential. This is a serious condition which can cause serious injury and possibly death.

ansporting Precautions

• Do not sit or stand on the machine while tramming.• Retract the drill frame completely before transporting the drill.• Inspect all tractor trailers being used to transport the machine, including but not limited to checking the

brakes, tires, tire pressure and lights.• Remove or properly secure loose items so they cannot fall off during transport.

oise Level Safety

Exposure to high noise levels may cause hearing loss. Wear appropriate hearing protection.


The sound pressure measured according to ISO 11202:1993, ISO 3746:1995, IEC 651:1979 and IEC 4:1985 is 100 dB(A).

rane Safety (For Machines so Equipped)

• Do not move loads that exceed the crane lift rating.• Do not use crane to lift or move personnel.• Make sure equipment is inspected regularly and maintained properly.


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Safety

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We

IMP• D• D

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Safety Information

ardous Chemicals

lding Safety

Explosion hazard. Flammable solvents could ignite if placed near fire, sparks or other ignition sources. Keep flammable solvents in closed containers and away from fire, sparks and ignition sources.

Inhalation hazard. Dust from drilling fluid additives such as bentonite may irritate the respiratory system or lungs. Prolonged exposure may damage the respiratory system. Use respiratory protection and dust resistant safety goggles.

ORTANT:o not use containers that can leak.o not drain fluids on the ground or dump them into sewage systems, streams, rivers, lakes or the ea.lways follow laws and regulations for proper disposal of waste materials.

Workers can encounter hot surfaces, fire, noxious fumes and other hazards when welding.

These practices can help increase safety when welding:• Follow established welding safety practices and regulations• Assign another worker to “fire watch”• Wear appropriate protective equipment (face shield, fire resistant clothing, etc.)


• Ensure adequate ventilation• Have a first aid kit nearby• If welding in a confined space, follow all confined space regulations and proce-

dures


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Safety

La

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opbowh

driori

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daloc

afety Information

dder Safety

anger Zones -- Safe Distances

A danger zone is any zone inside or near the machine where health, safety and security risks exist. All rsonnel on the jobsite should be advised of these zones, the hazards they may encounter and the safety cautions which are required or recommended.

Hazardous Area: All areas from which a person could touch parts of the machine when it is operating or en maintenance is being performed. Wear appropriate protective equipment.

Electrically Charged Safe Distance: 25 feet (8 m) from the drill hole. Personnel in this zone during drilling erations are at risk in the event an electric line is struck. Wear appropriate protective equipment (insulated ots and gloves). All other personnel must stay out of this zone during drilling or backreaming or any time en an electric line could be struck.

Note that personnel on the exit pit side are also at risk for electric shock during an electric strike. As the ll pipe approaches the exit pit, it could strike a buried power line. During backreaming, the diameter of the

Falls from heights can cause serious injury and death. Use required fall protection equipment when working at heights above grade.

• When working at heights above 4-6 feet (1.2 to 1.8 m) other precautions may be necessary.

• Follow established ladder safety practices and regulations. • Do not use ladders during thunderstorm activity or if conditions are such that light-

ning could occur.

Electrocution Hazard. Personnel are at risk of serious injury or death if an electric line is struck during drilling. All personnel must wear appropriate protective equipment (electrical insulating boots and gloves) on the job site.


ginal pilot hole is increased by the reamer which can contact a power line.

rounding

Metal components on a drill rig site can become electrically charged for a number of reasons: faulty or maged wiring, inductive capacitance from generators, motors, motor drives, transformers, contact with al distribution wiring or underground cables etc. Care should be taken to avoid electrocution.

Electrocution hazard. Improperly grounded components may become electrically charged. Serious injury or death could occur. Bond all fixtures together and ground to a single stake before starting the engine.

• . Follow all local and national codes and regulations with regard to bonding and grounding.


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Safety

ing won thequirackand

Typic

Saf

undeOpeinfor

Saf

tion,Attacmati

IMtio

Safety Information

All metal components on a drill rig site should be bonded together as shown in the drawing below. Bond-ill reduce the electric potential difference between components with respect to any other components e site. Current will not flow between two sections that are at the same electric potential. All remote

pment that is in close proximity to the drill rig must also be electrically bonded to the drill rig, i.e. pipe s, mud pumps etc. This will reduce the risk of shock to any personnel who might contact both the drill rig the remote equipment.

al Bonding Scheme

PORTANT: For additional information on electrical hazards, bonding and grounding, consult publica-ns from the U.S. Occupational Safety and Health Administration.a b

a. Controlling Electrical Hazards, U.S. Department of Labor, OSHA 3075.b. Protection from Step and Touch Potentials, 29CFR1910.269 Appendix C.

Bonding Cable

Ground Stake

Bonding Cable Bonding Cable

Dumpster

Mud SystemCrane

Drill Pipe

Drill Rig

CabinPower Unit

Pit

Bore Path


ety Features - ZAPALERT™

ZAPALERT™ is an electric sensing device used on equipment which has a high likelihood of striking an rground energized power line. Refer to “ZAPALERT™ Electric Shock Alarm” on page 59 (section in

rations chapter) and Attachment 3: “ZAPALERT™ Electric Shock Alarm Instruction Sheet” for complete mation.

ety Features - es!lok® Exit Side Lockout System

The es!lok® Exit Side Lockout system provides a way to disable thrust and rotation from a remote loca- such as the exit side of a direction bore. Refer to “es!lok® Exit Side Lockout System” on page 60 and hment 2: “es!lok® Exit Side Lockout System Operation & Safety Instruction Manual” for complete infor-

on.

DD-220T Operators Manual Safety

Safety Alerts

Whole body entanglement in machinery. Stay safe distance from hazard.

Electrocution hazard. If beacon is flashing, stand back 8 meters.

In case of an electric strike, do not move. Pull drill pipe away from power line.

Crane in wires. Electrocution hazard.

Run-over hazard. Read manual before tramming.

Hazardous area. Keep hands/feet a safe distance.



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Safety

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Safety Information

Precautions about diesel aust

Engage lockplate to prevent slid-ing.

Explosion hazard. Call 811 ore you dig.

High pressure fluid. Keep hands away from hazard.

Do not sit or ride on machine ile tramming.

High pressure fluid; keep hands away.



S

Safety

K

afety Information

Read Operator’s Manual. Use proper lockout and tagout procedures when performing maintenance work.

Hot surface. Do not touch. Stay safe distance from machine.

Electrocution/explosion hazard. eep safe distance.



Notes

NOTES:


DD-220T Operators Manual Controls

Machine Controls

ControlsSafety Switches

There are three push buttons which stop the diesel engines on the DD-220T. These push buttons stop the flow of fuel to the engine and shut down the power in a normal manner. Some movement or rotation may occur due to residual hydraulic pressure or stored energy.

DD-220T Main Control Console - Engine Panel - Immediately stops the engine

ENGINE

1

STOP

STOP


DD-220T Main Junction Box - Immediately stops the engine

1


Page

Controls

DD-2

Machine Controls

20T Tramming Control - Immediately stops the engine

1



M

Controls

D

achine Controls

isable Switches

The Rotary/Carriage Disable is a large, red push button located on the carriage. Push this button to:

• Lock the carriage brake• Lock the rotary brake• Disable wrench travel and wrench separate• Disable the carriage and rotary joysticks

ROTARYCARRIAGEDISABLE

Typical Location of Rotary/Carriage Disable

DD

1M97

36 D

isab

leB

utto

n-a

DD

-210

-Rot

Car

rDis

able



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Controls

Ga

posibelo

IMPres

Machine Controls

te and Gate Reset Button

The DD-220T has an access gate at the top of the wireline walkway. The gate has a reset button that is tioned so it can only be accessed by a person who is outside the gated area (shown in the drawing w).

ORTANT: Only the person who works in the hazard zone should operate the gate reset button. The et should never be operated by anyone else on the jobsite.

When the gate opens • The carriage brake locks• The rotary brake locks• Makeup and breakout are disabled• Wrench travel and wrench separate are disabled• The carriage and rotary joysticks are disabled

RESET

22DD9723-GateReset-1

Gat

e R

eset

But

ton

Loca

tion

Gat

e R

eset

But

ton

Loca

tion-

STFDD-220T Standard Thrust Frame

DD-220T Split Thrust Frame


• Clamps will function

When the gate is subsequently closed • The carriage will travel at slow speed• Makeup and breakout will function slowly• The wrench will travel and separate slowly• Clamps will function

When the reset button is pressed Functions return to normal speed


M

Controls

B

in sy

S

nelig

off

IM•••

•

achine Controls

attery Switch

The battery switch is located inside the Battery and Engine Panel Access door indicated in the drawing “DD-220T Components” on page 15. The switch connects and disconnects the batteries from the electrical stem.

• Rotate the switch to the right to connect.• Rotate left to disconnect.• The battery switch must be in the ON position before starting the engine.• When performing maintenance, install a padlock through the tab and follow proper lockout-tagout pro-

cedures.

PORTANT: DO NOT disconnect the batteries while the engine is running. DO NOT try to stop the engine with this switch. You can damage the electrical system. After you turn off the engine, wait at least 1 minute before you turn the battery switch OFF. This allows

the controller to go through its power-down process where it stores information in memory. Failure to wait may cause engine program data loss.

During maintenance, turn the switch OFF and use proper lockout and tagout procedures.

Battery Switch

Service Light Switches

DS

CF6

631-

Bat

tSw

itch

Loca

tion


ervice Lights

The DD-220T provides for under-shroud service lights which can be used when the battery is discon-cted (i.e., the battery switch is OFF). The lighting circuit remains powered at all times. If under-shroud hts are left on, they will drain the battery.

The Service Light Switch is located on the battery switch panel, shown above. Turn under-shroud lights when not in use.

22DD9723C-batt+lights


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Controls

Ma

Machine Controls

in Control Console - Carriage & Rotary Panel

1. Rotating Pipe Clamp 2. Stationary Pipe Clamp 3. Rotating & Stationary Clamp 4. Carriage Brake 5. Rotary Brake

6. Mud Blow Down 7. Auxiliary Switch8. Carriage Display 9. Rotary Display

CARRIAGE ROTARY

98

3 4 5 6 721



M

Controls

1

2

3C

4

5

achine Controls

Control Icon Function

. Rotating Clamp • Close rotating clamp: rock switch away from you• Open rotating clamp: rock switch toward you

. Stationary Pipe Clamp • Close stationary clamp: rock switch away from you• Open stationary clamp: rock switch toward you

. Rotating & Stationary lamp

• Move wrenches closer together: rock switch away from you

• Move wrenches apart: rock switch toward you

. Carriage Brake • Turn Carriage Brake on: rock switch away from you• Turn Carriage Brake off: rock switch toward you

. Rotary Brake • Turn brake on: rock switch away from you• Turn brake off: rock switch toward you



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Controls

6. M

7. A

8. C

9. R

Machine Controls


ud Blow Down • Close mud blow down valve: rock switch away from you; Closing the valve will allow mud supply and pres-sure to build in the piping from the mud system to the drill.

• Open mud blow down valve: rock switch toward you; Opening the valve releases the pressure and “vents” the mud.

uxiliary Switch • Turn on equipment plugged in Aux switch: rock switch away from you

• Turn off equipment plugged in Aux switch: rock switch toward you

arriage Display The Carriage Display screen is part of the microprocessor control system on the DD-220T. Consult Attachment 4: “DD-220T Displays Operator Manual”, for detailed infor-mation on the carriage-related information and the adjust-ments that can be made from the control panel.

otary Display The Rotary Display screen is part of the microprocessor control system on the DD-220T. Consult Attachment 4: “DD-220T Displays Operator Manual”, for detailed infor-mation on the rotary-related information and the adjust-ments that can be made from the control panel.



M

Controls

M

achine Controls

ain Control Console - Wrench and Engine Panel

1. Emergency Stop 2. Engine Start3. Throttle4. Horn

5. Drill Stop6. Drill Start7. Wrench and Engine Display

ENGINE

1

STOP

56

2

34

7



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Controls

1. E

2. E

3. T

4. H

5. D

6. D

7. WDis

Machine Controls


mergency Stop Stop the engine • Stop the drill and the engine: push button• Enable engine start: button must be pulled out

ngine Start • Remotely start the engine: push buttonNote that the key ignition switch on the Engine Control in the engine compartment must be in the “run” position for remote start to work.

hrottle • Increase throttle, engine runs faster: rock switch away from you

• Decrease throttle, engine runs slower: rock switch toward you

orn • Sound audible alarm to alert workers that drilling opera-tions are about to begin: push button

Ensure that all workers on the job site are aware of the audible alarm and the meaning of the signal.

rill Stop • Turn carriage (thrust/pullback) and drill function off: push button

Note this button does not turn off the engine.

rill Start • Restart carriage (thrust/pullback) and drill function: push button

STOP


rench and Engine play

The Engine Display screen is part of the microprocessor control system on the DD-220T. Consult Attachment 4: “DD-220T Displays Operator Manual”, for detailed infor-mation on the engine-related information and the adjust-ments that can be made from the control panel.


M

Controls

Ty

su

1

2

3

4

5

achine Controls

pical Engine Control Panel

Drawing represents a typical engine control panel. The control panel on your machine may differ. Con-lt Appendix A: Diesel Engine Manual for specific information.

Control Function

. Key Ignition Switch • Stop: Turn the key straight up• Run: Rotate key 45° to the right• Start: Rotate key 90° to the right

. Diagnostic Warning Lights If this light turns on, follow instructions in the Diesel Engine man-ual or contact the engine manufacturer.

. Throttle • Increase engine speed: push control up• Decrease engine speed: pull control down

12

35

4


. Display Screen Displays engine operating information

. Toggle to Diagnostic Display


Page

Controls

Tra

Machine Controls

mming Control

1. Emergency Stop2. Left Track Joystick3. Right Track Joystick4. High/Low Speed5. Engine Throttle

FORWARD

REVERSE

RIGHT

TRACK

LEFT

TRACK

FORWARD

REVERSE

FAST

SLOW LOWER

RAISE

4

2 1

5

3

Tramming Control



M

Controls

1

2

3

4

5

achine Controls


. Emergency Stop Stop the drill and the engine: push button

Button must be pulled out to be able to start the engine.

. Left Track Joysticka

a. Either joystick (left or right) can be used to raise and lower the walkway. The Walkway/Travel Control see page 53 must be in the Walkway position.

Enable the left track: push knob down.

Move the left track forward: push the joystick away from you

Move the left track backward: pull the joystick toward you.

. Right Track Joystick Enable the right track: push knob down.

Move the right track forward: push the joystick away from you.

Move the right track backward: pull the joystick toward you

. High/Low Speed Increase travel speed: push the toggle switch away from you.

Decrease travel speed: pull the toggle switch toward you.

. Engine Throttle Increase engine speed: push the toggle switch away from you.

Decrease engine speed: pull the toggle switch toward you.



Page

Controls

Ma

Machine Controls

in Junction Box

1. Emergency Stop2. Engine Start3. Throttle4. Thrust Frame (Boom) Raise/Lower

5. Mode6. Signal Alarm7. Crane8. Plug

12 3

7

6 5

4

8



M

Controls

1

2

3

4R

5

6

7

achine Controls


. Emergency Stop Stop the engine • Stop the drill and the engine: push button• Enable engine start: button must be pulled out

. Engine Start • Remotely start the engine: push buttonNote that the key ignition switch on the Engine Control in the engine compartment must be in the “run” position for remote start to work.

. Throttle Increase throttle, engine runs faster: turn control to the right

Decrease throttle, engine runs slower: turn control to the left

. Thrust Frame (Boom) aise/Lower

Elevate thrust frame into drilling position: turn and hold control to the right; Release the control when the desired elevation is reached.

Lower thrust frame to transport position: turn and hold control to the left; Release the control when the desired elevation is reached.

. Setup/Drill Mode Enable tramming and setup; drilling is disabled: turn con-trol to the left.

Enable drilling; tramming and setup are disabled: turn control to the right

STOP


. Signal Alarm • Sound audible alarm to alert workers that drilling opera-tions are about to begin: push button

Ensure that all workers on the job site are aware of the audible alarm and the meaning of the signal.

. Crane Extend the crane away from the drill frame: turn and hold the control to the right.

Retract the crane toward the drill frame: turn and hold the control to the left.


Page

Controls

8. P

Machine Controls

lug (Signal) Plug a monitoring device such as a laptop computer into the wireline signal jacks if you are using the wireline sys-tem to monitor the drillhead location.



M

Controls

W

E

moeq

pla

W

achine Controls

alkway/Travel Setup Box

ngine Monitoring Equipment


alkway/Travel Control The Mode button on the Main Junction Box must be in the Travel/Setup position for this control to work.

Raise and lower the walkway: turn the control to the left; Use the tramming control to raise the walkway.

Tram the machine: turn the control to the right; Use the tramming control to maneuver the machine.

WALKWAY TRAVEL


Your diesel engine may be equipped with an engine monitoring display which allows the operator to nitor engine information while the engine is operating. The Cummins Engine Panel is an example of this uipment. Consult your diesel engine manual or other special documentation for more detailed information.

On the DD-220T, much of the information presented on the engine monitoring display screen is also dis-yed on the Engine Display screen on the Control Console in the driller’s cabin.


Page

Controls

Op

Machine Controls

erator’s Chair - Joystick Controls

1. Carriage Joystick Enable2. Wrench Makeup/Breakout3. Wrench Travel

4. Rotary Joystick Enable5. Lower Pipe Support6. Upper Pipe Support

CARRIAGE JOYSTICK ROTARY JOYSTICK

1

2 3 56

4



M

Controls

C

1E

2B

3

R

4E

achine Controls


arriage Joystick Move the carriage forward (thrust direction): push joystick away from you

Move the carriage backward (pullback direction): pull joy-stick toward you

. Carriage Joystick nable

Depress and hold trigger to enable carriage joystick func-tions.

. Wrench Makeup/reakout

Breakout: rock switch forward

Makeup: rock switch backward

. Wrench Travel Wrench travel forward (downhole): rock switch forward

Wrench travel reverse (uphole): rock switch backward

otary Joystick Makeup: push joystick away from you.


Breakout: pull joystick toward you.

. Rotary Joystick nable

Depress and hold trigger to enable rotary joystick func-tions.


Page

Controls

5. L

6. U

Machine Controls

ower Pipe Support Raise pipe support: rock switch forward.

Lower pipe support: rock switch backward.

pper Pipe Support Raise pipe support: rock switch forward.

Lower pipe support: rock switch backward.


DD-220T Operators Manual Operations

Preparation

OperationsSite Preparation

The DD-220T can operate on surfaces with a maximum lateral slope of 3° and a slope in the running direction up to 10°.

Dig an exit pit if required by the conditions at the site. For more information, see “Exit Pit Construction” on page 27. Dig the mud return pit where the drill will enter the ground.

Measure and clearly mark the Electrically Charged Safe distance. See “Danger Zones -- Safe Distances” on page 31. Erect a safety barrier around the danger zone to prevent bystanders from approaching the machine. Prevent anyone who is not wearing proper protective equipment from entering this zone.

Clear all vegetation from the area around the operator’s station when working on electrical jobsites. In the event of an electrical strike, contact with trees, bushes and weeds could result in electrocution.

Hydraulic Cranes

Congested job sites may require the use of a large crane for final placement of the drill. A crane or exca-vator may be used to handle drill pipe and downhole tooling.

Mats and Cribbing

When drilling on soft soil, during a long term setup or during periods of freezing and thawing, it may be necessary to set the drill on mats or cribbing. Suitable mats may be available for rent or lease. Consult a civil engineer for guidance. The weight of the DD-220T is provided in the “Specifications” section beginning on page 111.

Drilling operations may require an exit-side pit. Unsafe pits may collapse resulting in serious injury or death. Follow national and local laws which apply to constructing an exit-side pit.


Do not attempt to drive the machine if the tracks are frozen to the ground. The machine could be dam-aged.

Protection of Wires, Cables and Hoses

The controls are connected to the directional drill by hoses and cables. It is important that these be pro-tected from damage. Route electrical cables and hydraulic hoses overhead to prevent a tripping hazard to the crew. Keep cables and hoses out of puddles and away from dripping water. Avoid sharp edges and places where cables and hoses could be damaged.

Support electrical cables so the weight of the cable does not pull on the connector. This could cause damage and could result in a loose connection. Disconnect electrical cables by pulling the connector, not the cable.


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Operations

Ma

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The

limitsgrouneerbefopipe

Gu

curvtion

Tline more

Tof thsyste

BpropTake

IMP• U

i• T

Preparation

king Power Connections

When connecting hydraulic hoses and electrical cables, follow these best practices:• Remove protective caps• Ensure that couplings are clean and free of debris.• See “Cleaning Hydraulic Connections” section beginning on page 92 and “Cleaning Electrical Connec-

tions” on page 92 for information on proper cleaning techniques.

w

The driller operates the DD-220T from Operator’s Control Panel. Additional personnel include a crane ator, pipe handlers, steering specialist, excavator operator, mud plant operator and general labor. Exit personnel might include a certified welder, pipe handlers and a crane operator.

Bore Path

Numerous factors must be considered when planning the bore path: machine location, entry angle, bend of the drill pipe, bend and tension limits of the pullback material, pipe length and location of under-

nd utilities. Planning the bore path is outside the scope of this manual. Consult a knowledgeable engi- for assistance. Ensure that the bore path and the location of all utilities are clearly marked on the jobsite re beginning operations. When drilling, avoid extreme steering corrections. Drill the first and second drill straight. Consult drill pipe manufacturers for recommended bend radius.

idance System

Guidance systems are electronic devices that enable the bore to be directionally steered on a planned ed path. The guidance devices are installed in the down hole tooling string. They provide drill head loca-information that the operator uses to steer and make directional changes in the bore.

here are 3 types of guidance systems. Wireless walkover, wire line, and wire line magnetic. The wire magnetic type is most commonly used for longer deeper bores because they are more capable and

ORTANT: sing hydraulic hoses and electrical cables longer than 100 feet (30.5 meters) might result in control

ssues.urn off all power to the system when making hydraulic and electrical connections.


accurate than the other types.

he guidance system is not provided as standard equipment with the directional drill. The manufacturer e guidance system will provide technical instructions on the operation and maintenance of the guidance m.

efore beginning the bore, ensure that the guidance system has fresh batteries and has been tested and erly calibrated. Check the location of the drill head frequently to ensure that the bore remains on course. care not to exceed the bend radius of the pipe as this will cause damage or breakage.


P

Operations

M

A of inctor

turmaish

ZA

deWpo“R

ret

usZA

reparation

ud Recycling System

Drilling operations might require fluid quantities of 300 to 500 gallons/minute (1135 to1892 liters/minute). recycling system enables the driller to reclaim most of the drilling fluid for re-use and minimize the amount fresh water required for mixing. The recycling system removes solids from the drilling fluid and usually ludes a high pressure pump (mud pump) to send the fluid through the drill pipe into the bore. The contrac- must provide a trash pump to pump spent drilling fluid from the returns pit to the mud recycling system.

Consult a drilling fluid supplier for assistance in selecting the drilling fluid, preparing an appropriate mix-e and establishing the correct mud pump flow rate for drilling and backreaming. Read the mud system nual or consult the equipment dealer for instructions on operating the mud system and recycling/replen-ing the drilling fluid.

PALERT™ Electric Shock Alarm

The DD-220T is equipped with the ZAPALERT detection device. ZAPALERT is an electric sensing vice used on equipment which has a high likelihood of striking an underground energized power line. hen drill pipe comes in direct contact with a power line, it becomes charged to the same voltage as the wer line. An audible and visual alarm is triggered. Crew members should follow procedures described in esponse to Electrical Strike” on page 23 when an alarm is given.

When utility authorities have verified that the drill and associated equipment are no longer energized, est the ZAPALERT system and set it up properly before resuming drilling operations.

Read and understand the “ZAPALERT Electric Shock Alarm Instruction Sheet” in Attachment 3 before ing the system. Test the system before beginning the drilling project. After a successful test, install the PALERT system ground stake into the ground.

Electrocution hazard. Machine may become electrically charged if drill string contacts a power line. Serious injury or death could occur. All crew members should know the ZAPALERT audible and visible alarm signals and the proper procedures to follow if the drill becomes electrically charged.

• Do not operate the machine until ZAPALERT testing is complete and all issues have been satisfactorily resolved.

• The ZAPALERT ground stake must be installed for the unit to work properly,



Page

Operations

es!

tion,on thDD-2

TThisers athe s

ebetw

Cin At

Preparation

lok® Exit Side Lockout System

The es!lok Exit Side Lockout system provides a way to disable thrust and rotation from a remote loca- such as the exit side of a directional bore. Workers in the exit pit can lockout the drill and work directly e pipe string or exit side tooling. The es!lok system consists of a receiver which is mounted on the 20T and a transmitter that is carried by a person who must work on or near the drill string.

he exposed person can push the “Lock Drill” button before working on or near the drill rod or tooling. sends a signal to the receiver and prevents rotation and thrust. When the designated person and all oth-re clear of potential danger, they push the “Unlock Drill” button. This signals the drill operator to “Reset” ystem and restore thrust and rotation functions.

s!lok is not intended as a substitute for safety procedures or a replacement for clear communication een the exit side crew and the machine operator. It is not intended as an emergency shutdown device.

omplete information on set up, testing and operation of the es!lok Exit Side Lockout System is provided tachment 2. Read and understand these instructions before using es!lok.

Entanglement hazard. Unexpected movement or rotation of the drill string can cause death or serious injury. Use the es!lok system to disable the drill while changing tooling.

• Do not attempt to bypass the es!lok system. Operation of the drill with the es!lok disabled can result in injury and death.

• Before starting es!lok Exit Side Lockout, be sure you have fully charged batteries in the devices. If the machine has been in storage, reconnect the es!lok battery charger to either a 12 volt DC or 24 volt DC supply. Recharge the es!lok batteries until they are fully charged.



Set Up

Using the Tramming Control

The Tramming Control is a hand-held tethered control box. It is used for moving and positioning the DD-220T on the job site and for loading and unloading the machine from a transport. The Tramming Control is stored inside the Tool Box located on the left side of the undercarriage. When in use, it is connected to the Walkway/Travel Setup Box on the rear of the drill by a flexible coiled cord.

Starting the Machine for Unloading

1. Refer to Attachment 1: “Diesel Engine Manual”. 2. Unplug the block heater, if connected. 3. Disconnect battery chargers.4. Pull OUT the emergency stop buttons on the Right Console and the Tramming Control. The engine will

not start if any emergency stop button is pushed in.5. Check the engine oil level, hydraulic fluid level and the diesel fuel level. Fill if necessary.6. Switch all controls OFF or put them in neutral. 7. Turn the Battery switch to the ON position. 8. Insert the key in the Engine Control Panel.9. Turn the switch and hold it in the START position for about 5 seconds while the warning alarm sounds.

This alerts everyone on the jobsite that the engine is going to start. When the delay period times out, the alarm will stop and the engine will start.• You must hold the key in the START position for the full delay period each time you attempt to start the

engine. If you release the key before the end of the delay period, the engine will not start.10. Allow the engine to warm for at least 10 minutes before using any hydraulic controls.

A crushed or damaged Tramming Control could result in unexpected movement of the machine. Unexpected movement can cause death or serious injury. Always replace the Tramming Control inside its storage location when not in use.



Page

Operations

Un

1. 2. 3. 4.

5. 6. 7. 8. 9. 10. 11.

12.

Set Up

loading the Machine from the Transporter

Check diesel fuel, hydraulic fluid and crankcase oil level. Replenish if necessary.Remove the chains and binders from the tie-down rings. Remove the Tramming Control from the Tool Box (see drawing below).Plug the Tramming Control into the receptacle on the Walkway/Travel Setup Box.

Unexpected movement of the machine while tramming can cause death or serious injury. Do not sit or stand on the machine while tramming.

• Use the Tramming Control only while standing at ground level with good visibility.• The tractor trailer should be on a flat, level surface when unloading the machine.

Run-over hazard. If machine runs over you, death or serious injury will occur. The operator must understand how to operate the Tramming Control properly.

• Tramming should be done at low speed. Move the controls slowly and carefully.• All personnel must remain a safe distance away while the machine is being

moved.

Walkway/Travel Setup Box22dd

1000

5-To

olB

ox a

nd C

onne

ct


Start the machine as described in “Starting the Machine for Unloading” on page 61.Turn the Mode control on the Main Junction Box to the Setup Position.Turn the control on the Walkway/Travel Setup Box to Travel Mode.Using the Boom Raise/Lower Control on the Main Junction Box, raise the front of the thrust frame. Set a low engine throttle speed.Press the Reset button on the Tramming Control.Slowly maneuver the machine off the trailer by using the Left Track joystick, the Right Track joystick and the Emergency Stop button on the Tramming Control.Adjust the angle of the thrust frame to ensure the front foot and/or front of the thrust frame doesn’t drag on the ground.

Tool Box


S

Operations

A

bepo

12

3

4

et Up

ssembling the Split Thrust Frame

These instructions apply only to machines with a split thrust frame where the upper thrust frame has en transported separately. The thrust frame can be assembled when the lower thrust frame is in the trans-rt position or after the machine has been set up and the lower thrust frame is in drilling position.

Crush hazard from above. Do not work under either section of the thrust frame until the sections are properly assembled and securely bolted together.

• Do not release the lifting equipment holding the upper thrust frame until the sec-tions are properly assembled and securely bolted together.

Fall from height hazard. Do not sit, stand or walk on the upper thrust frame section until all tensioners are in place, jackbolts are tightened to specifications and handrails are installed.

. Clean and grease all mating surfaces.

. Secure the upper thrust frame to appropriate lifting equipment, using the D-rings on both sides of the thrust frame section.

. Raise the upper thrust frame until it is aligned with

D-Rings

Mating Plate

Upper Thrust Frame

Alignment Side Bar


the lower thrust frame.. Guide the forks into the fork pockets.

• The plate on the upper thrust frame should fit flush against the plate on the lower thrust frame.

• The alignment side bars on the upper thrust frame should fit in the notches on the lower thrust frame.

22dd2251- splitasmOverallFork Pockets

Forks

Alignment Side Bar


Page

Operations

5.

6.

7. 8.

9.

10.

* FTig

Set Up

Insert the two 1-inch bolts to secure. Torque to a maximum of 300 ft/lbs.Verify the alignment using the piece of gear rack in the alignment kit. If necessary, loosen the securing bolts, re-align the thrust frame sections and re-tighten.• The entire length of the drill frame should be

aligned side-to-side and top-to-bottom. • The gear rack should also be aligned so the car-

riage can pass smoothly across the joint between the upper and lower thrust frame.

Insert the tensioner studs. Install the six torque nuts. Hand tighten the ten-sioner until it seats against the washer. Using the torque stick in the alignment kit pro-vided, torque every other jackbolt with 30-70% partial torque*. This will seat the flange.

After all tensioners and jackbolts are partially torqued in place, at 100% target torque, tighten all jackbolts. (Note: preload of 262,00 lbs, a torque of 114 ft/lbs each)

or detailed procedures see “Appendix C: Jackbolt htening Procedure” on page 121

22dd2251- splitasm-step2

1 Inch Securing Bolt

22dd2251- splitasm-step3Tensioner

Tensioner Stud



S

Operations

D

1

234

5

67

8

et Up

rill Setup

Lowering the front foot creates a danger of crushing. Keep all personnel a safe distance away when the machine is being stabilized.

Raising and lowering the drill frame creates a danger of crushing. Keep all personnel a safe distance away when raising or lowering the drill frame.

. Ensure that the carriage lock plates are in locked position and secured with the toggle bar (see drawing).

. Check all fluid levels and replenish if necessary.

. Turn on the power.

. With a low engine throttle speed, make final adjustments in the position of the machine so the drill entry is in-line with the intended bore hole location.

. If the front foot was removed for transport, position it on the ground so that it is in line with the planned bore at the proper setback location.

. Set up the cabin.

carriage lock_line

Toggle Bar

Locked

Unlocked


. Make the electrical connections. Refer to “Making Power Connections” on page 58 and “Protection of Wires, Cables and Hoses” on page 57.

. Turn on the machine as described in “Starting the DD-220T” on page 70.


Page

Operations

Thethru

9.

10.

11.

12.

13.14.

15.16.

17.

18.

19.

Set Up

re are two controls to maneuver the thrust frame into drilling position. Use both controls to adjust the st frame to the desired drilling angle.• The Boom Raise/Lower on the Main Junction Box tilts the thrust frame at a steeper/shallower

angle.• The Carriage Joystick extends/retracts the thrust frame. Note that the carriage must be locked in

order for this control to work.Determine the desired drilling angle. The drawing below shows the maximum angle at which the drill can be used.

Tilt the front of the thrust fame down and extend the thrust frame until the front foot is flat against the ground.

Note that if the front foot is not attached, you will need to lower the end of the thrust frame into the cradle on the front foot. Secure the front foot to the thrust frame.

Turn the control on the Walkway/Travel Setup Box to Walkway Position.

Remove the walkway lock plate. Lower the walkways with the control on the Tram-ming Control Box.

Turn OFF the machine.

18°

254.

9 fe

et (7

7.7

m)

Handrail Sockets and Securing Pins


Fold down the ladder at the base of the walkway and pin in place.

Install the handrails in the sockets provided.• If your machine has a split thrust frame, install

the handrails on the upper thrust frame section. Secure with pins that are attached to the thrust-frame.

Remove the hose carrier hold down. Ladder Pins


S

Operations

A

uspro

Sh

stesid

foo

2

22

22

222223

et Up

nchor the Machine

Depending on the soil conditions at the site, one or more of the following anchoring systems should be ed to stabilize the drill so it does not move as it thrusts pipe into the soil or pulls on a backreamer or the duct.

eet Piling and Steel Beam

To anchor the machine for thrusting operations, excavate a trench in front of the machine and bury a el I-beam. Connect chains from the I-beam to the front foot. Sheet piling may be driven against the back e of the I-beam to improve anchoring in soft conditions.

During pullback, sheet piling may be driven into the ground and in contact with the front edge of the front t as shown in the drawing below.

0. Use the Crane control on the Main Junction Box to extend the crane (if so equipped) away from the drill frame until it reaches the stop.

1. Anchor the machine (see “Anchor the Machine” section beginning on page 67).2. Rotate the toggle bar away from the lock plate on the carriage. Swing the lock plate away from the

socket on the carriage. Drilling operations are done with the lock plate away from the carriage.3. Connect all components on the drill site with a bonding cable and install a ground stake.4. Test the ZAPALERT system (Refer to Attachment 3: “ZAPALERT™ Electric Shock Alarm Instruction

Sheet” for complete information).5. After completing a successful test, install the ZAPALERT ground stake.6. Verify that all protective guards are in place.7. Perform a final walk-around. Inspect all connections.8. Check the function of all controls.9. Check all emergency stop and disable buttons.0. Cycle all equipment several times.



Page

Operations

Con

the f

Tie

back

Set Upcrete Anchor

Create a pit which can be filled with concrete. Place beams or fasteners into the wet concrete and attach ront foot of the drill using fasteners or welding (see drawing below).

Down Stakes

Drive tie down stakes through the square holes in the front foot and into the soil with the bucket of a hoe or excavator.



S

Operations

E

pitdo

bopit

fro

et Up

xcavate the Entry Pit and Returns Pit

The directional drill should be securely anchored before excavating the entry and returns pits. The entry is where the drill pipe of the directional drill enters the ground. It is also where the drilling fluid returns from wnhole.

Connect the two pits with a shallow channel as shown in the drawing below. Fluids returning from the re enter the smaller pit and overflow into the larger pit. Many of the solids settle to the bottom of the larger and do not have to be handled by the fluid recycling equipment.

The contractor provided trash pump is installed in the larger pit. Suspend the trash pump so that soil m the pit floor does not enter the recycling system.

Entry Pit Returns Pit

Trash Pump

Directional DrillPipe and Bit


DD-220T Operators ManualOperations

Operating the DD-220T

Starting the DD-220T

A manufacturer's manual for the diesel engine is supplied with the DD-220T. The following instructions cover general engine starting procedures. Consult the manufacturer’s manual for detailed starting and stop-ping procedures, engine maintenance and repair instructions.

1. If you have not already done so, test the ZAPALERT™ system and verify that the ground stake is installed properly (refer to Attachment 3: “ZAPALERT™ Electric Shock Alarm Instruction Sheet”).

2. Unplug the block heater, if connected. 3. Disconnect all battery chargers.4. Pull OUT all emergency stop buttons. The engine will not start if any emergency stop button is pushed in.5. Check the engine oil level, hydraulic fluid level and the diesel fuel level. DO NOT let the diesel engine

fuel tank run dry. If the tank is dry, bleed the fuel system. Refer to Attachment 1: “Diesel Engine Manual” for instructions.

6. Switch all controls OFF or put them in neutral. 7. Turn the Battery switch to the ON position. 8. You may start the engine from the Engine Control Panel

• Turn the ignition key and hold it in the START position for about 5 seconds while the warning alarm sounds. This alerts everyone on the jobsite that the engine is going to start. When the delay period

Signal lights and operator displays warn of potential operating problems. If ignored, damage to the machine could result. In case of unusual noise, abnormal pressure values, or if signal lights appear, stop the engine immediately and carry out necessary repairs.

Do not use starting fluid (ether). Immediate engine damage and personal injury may result.


times out, the alarm will stop and the engine will start.• You must hold the key in the START position for the full delay period each time you attempt to start the

engine. If you release the key before the end of the delay period, the engine will not start.• When the engine starts, release the key. No throttle action is required during starting. The engine sys-

tem provides the correct amount of fuel. • If the engine fails to start in 30 seconds, release the key switch and wait 2 minutes. This will allow the

starter motor to cool. Then repeat the start process. 9. Alternatively, you may start the engine from the Driller’s Console.

• On the Engine Control Panel, turn the ignition key (2) to the right to enable start. • At the Driller’s Console, push in and hold the Engine Start button.• You will hear a 5 second alarm. There will be a delay. Then the engine will start.


O

Operations

hyfrabeda

Te

all

A

homebe

U

cra

tio

S

IMTF

perating the DD-220TLet the engine run for at least 10 minutes so it is thoroughly warm before operating the machine. Use the

draulic tank heater to ensure that the oil is at least 70°F (21°C) before operating the controls. Only a small ction of the rotary and carriage circuits circulates through the hydraulic tank. The oil in those circuits must warmed very slowly and carefully. Failure to warm the hydraulic oil properly can cause hydraulic system mage and/or other problems.

• Operate the systems very slowly by using the joysticks for 30 minutes.• Increase the speed in small increments after the first 10 minutes.• Before drilling, check the hydraulic filter indicator lights while the rotary and carriage are in motion. Ver-

ify that the lights are not illuminated.• If the lights are lit, continue to warm the system as described above.

st the Indicators, Emergency Stop Buttons and All Controls

If you have not already done so, verify that all gauges on the instrument panel are in working order. Test Emergency Stop buttons, disable switches and all controls.

ttach the Drilling Fluid Supply Connections

Connect the mud mixing equipment (sold separately) to the directional drill by means of a flexible supply se. Read the manufacturer’s instructions on how to operate the transfer pump on the mud mixing equip-nt to ensure an adequate supply of drilling fluid to the mud pump. Have the drilling fluid mixed and ready fore starting the bore.

sing the Crane (if so equipped)

The crane is intended only for handling pipe and tooling. When the crane is not being used, store the ne radio remote in a dry location (the control is not weatherproof).

The crane has several power extension sections on the boom. See the Crane Owners Manual for addi-nal information on operating the crane.

topping the Engine

PORTANT: After you turn off the engine, wait at least 1 minute before you turn the battery switch OFF. his allows the controller to go through its power-down process where it stores information in memory.


ailure to wait may cause engine program data loss.


Page

Operations

Ch

Pow

drawthe tCon

Wr

ing Pconv


ecks During Operation

er Wrench Operation

The power wrench is made up of two individual wrenches - the wrench clamp and fixed clamp (see the ing below). The fixed clamp is used to clamp and hold; the wrench clamp is used to clamp and rotate ool. The wrench is used to makeup and breakout the drill string. Use the Wrench control on the Driller’s sole to control the power wrenches to makeup or breakout.

It is the operator’s responsibility to stop the machine when the instruments report a value outside the normal operating range.

Pipe wrenches can injure or kill. Do not use pipe wrenches. Tighten and loosen tool joints with the power wrenches on the machine.

Fixed Clamp

22dd

1000

5-w

renc

hes

Wrench Clamp


ench Pressure Controls

The maximum torque value is provided by the drill pipe supplier. Refer to “Appendix B: Tables Convert-ressure to Torque and Force” section beginning on page 116 for charts that can be used as a guide to ert the force displayed on the Wrench Pressure gauge to torque.

Direction of Bore


O

Operations

Th

soins

W

ing

forbre

perating the DD-220T

rust and Pullback Force Controls

The maximum thrust and pullback force can be set with the Carriage Speed controls on the Driller’s Con-le. This can prevent applying too much force and damaging the down hole tooling or the product being talled. It can also help the drill operator regulate the rate of advance of the cutter head.

iggle Steer™

American Augers Wiggle Steer™ System is a means to rotate and thrust the drill pipe back and forth dur- steering operations to make it easier to make direction changes.

The Wiggle Steer™ System will rotate the drill pipe in the makeup (clockwise) direction while thrusting ward. It will then rotate the drill pipe in the breakout (counterclockwise) direction but will not thrust in the akout direction.Set the Wiggle Steer™ control switch Off.



Page

Operations

Fun

Mak

1. f

2. 3. 4. 5. 6. 7. 8.

IMP• H

r• P• A

p• A

f

NO(12jets


damentals: Install Drill Pipe

Entanglement hazard and crushing hazard. A person can get caught in the rotating drill string or be crushed by the moving carriage causing death or serious injury. Do not stand on the wireline walkway when the rotary and carriage are operating.

Fall from height hazard. Unexpected movement when operating the machine can cause serious injury. Install all handrails before using the walkway.

ORTANT: igh speed threading of drill pipe joints is not recommended. Damage to drill pipe or the drive unit will

esult.osition the spindle at the rear of the drill frame before loading drill pipe into the directional drill.pply thread joint compound to the spindle pin and drill pipe pin each time it is connected to a drill ipe. This will extend the life of the threads on the spindle. lways turn OFF the drilling fluid pump after boring and before adding or removing drill pipes to keep

luid loss to a minimum.

TE: When it is time for a pipe change, it is better to drill past the pipe joint by about 5 inches 7 mm). Then bring the joint back to the center of the wrench. This will reduce the risk of clogging the


e Up a New Pipe Joint

Clamp the lower shoulder of the joint (made up of the pipe already in the ground and the spindle) in the ixed clamp.

Clamp the upper shoulder of the joint (the spindle) in the wrench clamp.Open the mud blow down.Break the joint.Unclamp the wrench clamp.Unscrew and slowly back the carriage up until the spindle pin clears the wrench.Apply joint compound to the spindle pin.Move the carriage to the rear of the drill frame.

and allows fluid passage when drilling is resumed.


O

Operations

9. 10111213141516

1718

perating the DD-220TRaise the pipe supports.

. Using a crane, lift one section of pipe from storage and place it on to the supports.. Move the spindle down and slowly screw into the pipe box.. Move the carriage and pipe down and apply joint compound.. Move the carriage and thread the pin into the existing pipe box.. Check the pressure setting on the display and ensure it is appropriate for the desired torque. . Makeup until the specified torque is reached, making up both joints.. When the new drill pipe is threaded together tight with full clockwise rotation power, open (unclamp) the

fixed clamps.. Lower the pipe supports.. Close the mud blow down.



Page

Operations

Tur

equitransIt is allow

Wengiand

W

1. 2. F3. A

b4. 5. S


n on the Drilling Fluid

Have an adequate supply of drilling fluid (mud) ready. Check that the supply hose from the mud mixing pment is securely connected to the directional drill. Follow the manufacturer’s instructions to operate the fer pump on the mud mixing equipment to ensure an adequate supply of drilling fluid to the mud pump.

normal for drilling fluid to escape from the cutting head even if the mud pump is not operating. Do not the mud pump to run dry as it will damage the pump.

hile the DD-220T engine is warming, start the mud system (sold separately) and allow that system’s ne to warm up. The procedure below is a general guide. Consult the Mud System Operator’s Manual information from the drilling mud supplier for specific operating procedures and desired mud flow rates.

hen you are ready to begin drilling:

Supercharge the mud pump with an external supply to 30 psi (2.1 bar).ill the pipe with mud before drilling.llow the pressure to build up. Approximately 200 to 300 psi (14-21 bar) is required while drilling the pilot ore.

Monitor the mud flow rate by viewing it on the Mud System Console.et the desired flow of drilling fluid.

Inhalation hazard. Dust from drilling fluid additives such as bentonite may irritate the respiratory system or lungs. Prolonged exposure may damage the respiratory system. Use respiratory protection and dust resistant safety goggles.



O

Operations

M

1.

2.

3. 4. 5.

IM•

•

•

••

perating the DD-220T

ake the Pilot Bore

Rotate in the makeup direction momentarily and release the joystick so that the blade is at the 6 o’clock position.Move the drill carriage forward and push the drill head slowly into the ground, keeping the drill pipe as

Electrocution hazard. Machine may become electrically charged if the drill string contacts a power line. If ZAPALERT™ beacon is flashing, stay back at least 25 feet (8m).

• Do not operate the machine until ZAPALERT™ testing is complete and all issues have been satisfactorily resolved.

• The ZAPALERT™ ground stake must be installed for the unit to work properly,

Entanglement hazard. Rotating shaft can crush body parts or kill you. Keep body parts and clothing away.

PORTANT: Only rotate the drill CLOCKWISE; NEVER COUNTERCLOCKWISE while drilling or backreaming. You

may unthread the drill pipe in the bore and you will not be able to retrieve them. Keep the first drill pipe straight. This will eliminate side pressure on the drill pipes. Use thrust to

advance the pipe. DO NOT make a steering correction until the second pipe is connected. Stop work if the machine is vibrating. This is an indication of incorrect operation, for example advanc-

ing the drill pipe too rapidly. Resume work at a slower speed. Extreme steering maneuvers of the drill head may cause pipe damage or breakage. Since the first pipe length is very important to get the bore path started correctly, proceed very care-

fully. Locate the drill head often, even in the middle of a pipe length, if necessary. Make steering cor-rections after first pipe has been inserted into the ground.


straight as possible. When the drill head is completely in the ground, begin rotating the first drill pipe clockwise (makeup). With the first drill pipe rotating clockwise, slowly thrust the first drill pipe partially into the ground.Stop thrusting forward when the upper shoulder of the first drill pipe is in the jaws of the fixed clamp and the shoulder of the drill spindle is in the jaws of the fixed clamp.


Page

Operations

End

that bend

1.

2. 3.

4.

5. 6.


of Pilot Bore Drilling

Steer the drill head UP to exit the ground. Maintain verbal contact with personnel at the exit point. Verify everyone is clear of the exiting pipe. Plan the exit point so that steer angle is within the minimum pipe radius capacity.

When the tooling emerges from the ground, notify the driller and activate the es!lok® Exit Side Lockout System to disable the drilling rig. Turn off the diesel engine and remove the ignition key. Communicate to all personnel that tooling is being removed and attached at the exit side and that the engine must remain off to ensure crew safety.Using an appropriate tool such as an exit side breakout wrench, remove the drill head assembly. Follow the manufacturer’s instructions for proper use of the tool.Remove the guidance system. Thoroughly clean the guidance system and store it in a safe location.

Entanglement hazard. Unexpected movement or rotation of the drill string can cause death or serious injury. Use the es!lok® system to disable the drill while changing tooling or adding pipe.

• Use a swivel when prereaming and backreaming.• Maintain good communications between drill operator and exit pit crew.• Do not rotate drill pipe until personnel have been notified and they acknowledge

the notification.• Do not attempt to bypass the es!lok® system. Operation of the drill with the

es!lok® disabled can result in injury and death.




Pullback Operations

Backreaming and Pullback

After the completion of the pilot bore, a reamer is used to enlarge the hole so product (cable, tubing, etc) can be pulled back through the hole. The product pipe must be isolated from rotation by using a swivel.

1. Turn off the engine, remove the key and activate es!lok®.2. Install the selected reamer using appropriate tools.3. Install a pullback swivel behind the reamer using appropriate tools. The swivel eliminates twisting the

product being pulled back. 4. If you are prereaming, install a pulling eye behind the swivel so that more drill pipe can be pulled in with-

out rotation. This technique prevents the hole from being free of drill pipe throughout the pre-reaming process. Pulling eyes are also used to pull small diameter product (cable, pipe, etc.) into a pilot hole, if product is 2 inches (50 mm) or smaller.

5. Install a product coupler and attach the product to the coupler. The drawing below shows one configura-tion of tools for backreaming.

Entanglement hazard. Unexpected movement or rotation of the drill string can cause death or serious injury. Use the es!lok® system to disable the drill while changing tooling or adding pipe.

• Use a swivel when prereaming and backreaming.• Maintain good communications between drill operator and exit pit crew.• Do not rotate drill pipe until personnel have been notified and they acknowledge

the notification.• Do not attempt to bypass the es!lok® system. Operation of the drill with the

es!lok® disabled can result in injury and death.



6. Ensure that all exit-side personnel are standing a safe distance from the reamer and pipe.7. Turn on the engine.

Drill String Blade Reamer Pullback Swivel Utility Product Pipe

Pullback Eye Product Coupler


Page

Operations

8. 9. R10. 11. 12. 13.

Rem

1.

2.

3. 4. 5. 6. 7. 8.

9. 10. 11. 12. 13. 14.

Eng

1. 2. 3. 4. 5.

IMP• C• B

Ft

• Hr

• Aa

Pullback OperationsActivate the mud system to ensure that the reamer jets are open.

eset the es!lok® Exit Side Lockout System to restore normal functions to the drill. Slowly pull the reamer back to the pilot hole. Rotate the drill pipe and reamer CLOCKWISE. Slowly pull the reamer into the hole. Advance at a slow rate to ensure the drilling fluid and cuttings mix into a slurry that will flow. Remove each section of pipe from the drill string as it is pulled back. Follow the procedures below. Use a pipe wiper to clean the pipe as it is retracted.

oving Drill Pipe During Pullback or Backreaming

Pullback with the joystick and backream until the joint of the pipe to be removed has just cleared the wrench.Stop the pullback and thrust the pipe forward until the joint is between the fixed and wrench clamps. This will reduce the risk of clogging the reamer jets.Clamp the pipe in the fixed clamp.Clamp the pipe in the wrench clamp.Break the joint.Unclamp the wrench clamp.Raise the pipe supports.Slowly unscrew the pipe and pullback with the carriage until the pin just clears the box but the shoulder can still be clamped in the wrench clamp.Clamp the wrench clamp.Break the joint at the spindle.

ORTANT: lamp the fixed clamp first. Then clamp the wrench clamp.efore breaking out the pipe joint, verify that the upper shoulder of the pipe section still in the ground is ULLY CLAMPED in the fixed clamp. The wrench clamp applies COUNTERCLOCKWISE rotary

orque, which could loosen the joint threads of the pipe sections still in the ground.igh speed unthreading of drill pipe joints is not recommended. Damage to drill pipe or drive unit will

esult.pply thread joint compound to the spindle pin and drill pipe pin each time they are connected to nother pipe.


Unscrew and pull the spindle all the way back.Unclamp the wrench clamp.Remove the drill pipeLower the pipe supports.

age the Next Pipe to be Removed

Thrust the carriage. Stop the spindle pin just before it reaches the wrench clamp.Apply thread joint compound to the spindle pin.Slowly thrust the carriage until the spindle pin engages the box of the next pipe section to be removed.Make the joint.Ungrip the pipe from the fixed clamp.


P

Operations

C

ab

En

bo

E

ullback Operations

ontinue Backreaming

Continue backreaming and removing each section of drill pipe as it emerges from the bore. Repeat the ove steps until all the pipe is removed.

d of Pullback Operations

The pullback operation is complete when the pipe or cable has been installed and pulled back to the re entry opening.

quipment Shutdown

After every day of operation:

• Set the throttle at idle for a few minutes to allow the engine to cool down.• Turn off the engine.• Wait at least 1 minute before you turn the battery switch OFF. This allows the controller to go through

its power-down process where it stores information in memory. Failure to wait may cause engine pro-gram data loss.

• Remove the key from the Engine Control Panel. Store key in a safe location.• Wash the machine. Clean off all mud and other debris.

Water can damage sensitive electronic components. Do not spray water against electronic components and control panels.



Page

Operations

Rig

1. 2.

3. 4. 5.

6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

17. 18.

19. 20.

IMP• T• T

Pullback Operations

Down

Remove the mud hoses.Remove the tie down stakes from the front foot. Do not attempt to remove the tie down stakes by raising the machine’s front foot.Start the engine.Using the Carriage Joystick, position the carriage at the Carriage Lock. Swing the Lock Plate into the socket on the carriage. Rotate the toggle bar to hold the lock plate in posi-tion.Set the machine to Setup mode using the Mode control on the Main Junction Box. Using the Crane control on the Main Junction Box, retract the crane into the foot. Using the Carriage Joystick, position the thrust frame in the transport position.Disconnect the electrical cables. Install caps on cables to prevent contamination.

Unexpected movement of the machine while tramming can cause death or serious injury. Do not sit or stand on the machine while tramming.

• Use the Tramming Control only while standing at ground level with good visibility.

Run-over hazard. If machine runs over you, death or serious injury will occur. The operator must understand how to operate the Tramming Control properly.

• Tramming should be done at low speed. Move the controls slowly and carefully.• All personnel must remain a safe distance away while the machine is being

moved.

ORTANT: he Mode control must be in Travel/Setup Mode to activate the tramming controls. he tractor trailer should be on a flat, level surface when unloading the machine.


Remove and stow the ZAPALERT™ ground stake.Wash mud, drilling fluid and soil off the machine.Install the hose carrier hold down.Remove the handrails from the walkway.Lower the thrust frame into the cradle.Connect the tramming control box. Move the Walkway/Travel Setup Control to the Walkway position. Raise the walkway and secure with the lock plate.Move the Walkway/Travel Setup Control to the Travel position. Slowly tram the rig to the transport trailer.Tram the rig onto the trailer. Proceed slowly when tramming over the edge of the trailer as the machine could swing when changing inclination. Turn off the power. Remove the key and keep in a safe place.Turn off the battery switch and the es!lok charger.


P

Operations

2122

D

po

1. 2.

3.

4. 5. 6. 7.

8.

IM•

ullback Operations. Tie the machine to the trailer deck with chains.. Remove all tools and loose objects from the area and put them into storage.

isassembling the Split Thrust Frame

The thrust frame can be disassembled when it is in drilling position or after it has been lowered to trans-rt position.

If you have not already done so, remove the hand rails from the upper thrust frame section. Using proper lifting equipment, secure the upper thrust frame section using the D-rings on both sides of the thrust frame section.Follow the instructions in “Appendix C: Jackbolt Tightening Procedure” on page 121 to properly loosen the jackbolts.

Crush hazard from above. Do not work under either section of the thrust frame while the sections are being disconnected and disassembled.

Fall from height hazard. Do not sit, stand or walk on the upper thrust frame section after handrails are removed, jackbolts are loosened and tensioners are removed.

PORTANT: Jackbolts must be unloaded gradually. If some jackbolts are fully unloaded prematurely, the remaining

jackbolts will carry the entire load and may be hard to turn. In extreme conditions, the jackbolt can deform.


Remove the tensioner and stud.Verify that the upper thrust frame remains secured to the lifting equipment.Loosen the two 1-inch bolts and remove them.Slide the upper thrust frame away from the lower thrust frame until the alignment forks are clear of the fork pockets. Lower the upper thrust frame to the ground or to the transport truck.

DD-220T Operators ManualOperations

Operating in Different Climates

Operating in Hot Weather

To prevent damage to the machine when operating in hot weather, take the following precautions:

• Follow instructions in the diesel engine manual for operating the engine in hot weather.• Use the appropriate mixture of coolant and water for the temperature range in which you are working.

Test the coolant periodically. Keep the coolant at the correct level in the radiator and the reservoir.• Use the recommended engine oil viscosity for the operating conditions as specified in your diesel

engine manual.• Clean dirt and debris from the radiator and engine daily. Check the air cleaner dust valve daily.• Equipment such as the electrical and electronic components of your machine may have special con-

siderations for operating in very warm temperatures. Consult user’s manuals for these items to deter-mine if there are special requirements for your operating conditions.

Operating in Cold Weather

Only machines especially configured at the factory can work when the ambient temperature is between -40°F to +5°F (-40°C and -15°C). Some machines are equipped with an engine preheater to maintain the minimum temperature needed for starting the diesel engine.

All machines are equipped with preheaters and temperature gauges on the hydraulic oil tanks. Use the preheaters to raise the hydraulic oil temperature.

• Diesel engines cannot be started until the oil temperature reaches 15°F (-9.5°C).• Controls cannot be operated until the oil temperature reaches 40°F (4.4°C).• Hydraulic controls should be operated at 800 rpm (or idle) until the oil reaches 70°F (21.1°C).

Other precautions and special procedures for operating in cold weather are:

• Ensure that the battery is fully charged.• Use the recommended engine oil viscosity for the operating conditions as specified in your diesel

engine manual.• Use the proper cold weather fuel. Cold temperatures can cause water to collect in the fuel tank. A

water sensor will alert the operator to water in the fuel. Drain water from the bottom of the fuel filter using the drain valve.

• Use the appropriate mixture of coolant and water for the temperature range in which you are working. Test the coolant periodically. Keep the coolant at the correct level in the radiator and the reservoir.


• Warm the engine thoroughly before beginning operations. Slowly operate each hydraulic control for about ten minutes. Move the machine very slowly.

• Crack mud hose joints to drain the system.• Place the machine on planks when parking. This will prevent the track from freezing to the ground. Do

not attempt to drive the machine if the tracks are frozen to the ground. Damage could result.


O

Operations

E

HeBloke

tw(hibemi

an

E

of su

perating in Different Climates

ngine Block Heater

The DD-220T engine comes with an Engine Block Heater. Plug the power cord of the Engine Block ater into an external power source to warm up the engine coolant before starting the engine. The Engine ck Heater may also remain plugged in for extended periods of time during extremely cold temperatures to

ep the engine coolant warm continually when the engine is not running.

For air temperatures down to but not lower than -30°F (-34°C), use the Engine Block Heater for at least o hours before starting the engine. This time period may vary depending on ambient weather conditions gh wind situations, for example). When overnight air temperatures approach -40°F (-40°C), heating may required continually when the engine is not running. Do not operate the preheater for more than three (3) nutes after the engine starts.

Refer to Attachment 1: “Diesel Engine Manual” for additional information about the Engine Block Heater d for operating requirements during extreme weather conditions.

ngine Preheating Devices

When working in cold temperatures, it is necessary to use a preheating device to keep the temperature the oil in the diesel engine warm when the machine is turned off. Plug the preheating device to an electric pply that is appropriately rated. Consult Attachment A: Diesel Engine Manual for additional information.

Preheating devices operate on high-voltage (208~240 volts AC). Optional 120 volt AC devices are also available. Connect to a circuit equipped with a ground fault interrupter (GFI). Protect the electric cables from contact with water or other liquids.



Notes

NOTES:


DD-220T Operators Manual Storage and Transport

Machine Storage and Transport

Storage and TransportMinimum Storage Space Required

Consult the “Specifications” on page 111 for the dimensions and weight of the DD-220T to establish stor-age space requirements. The surface must be firm enough to support the weight of the machine and prevent sinking.

Storage Site Conditions

If the machine has been lubricated, it can be stored uncovered for up to 30 days. Protect the machine from salty or acid environments, solvents, gas, flammable liquids and explosives.

For periods longer than 30 days, the machine should be stored in a covered, dry area.

The temperature ranges recommended for storage are between 32°F and 120°F (0°C to 50°C). Refer to Attachment 1: “Diesel Engine Manual” for temperatures outside this range.

Preparations for Storage

For short-term storage, i.e. periods less than 30 days:

1. Clean the machine as described in the “Cleaning” on page 92.2. Make sure there is no water or drilling fluid in the drilling fluid course. If freezing temperatures are

expected, precharge the drilling fluid system with antifreeze when the machine is not in use. 3. Eliminate sediment and water from the tanks (diesel fuel and oil). 4. Disconnect the es!lok® battery charger. This charger is not affected by the Battery switch. If left con-

nected, it could discharge the power unit batteries.5. Lubricate the entire machine according to the 10 Hour Inspection and Maintenance schedule. Coat all

exposed hydraulic cylinder rods with oil to protect against corrosion.

For storing longer than 30 days, follow the procedures for short-term storage plus these additional steps:• Store the machine in a covered, dry location.• Follow manufacturer’s instructions for long-term storage of a diesel engine.• Remove and store the batteries where the temperature will remain between 32°F and 105°F (0°C to


45°C). • Completely fill all gear boxes with lubricant.


Page

Storage and Transport

Tra

latioallowThe ulati

Machine Storage and Transport

nsportation

The machine must be transported in accordance with national, state, provincial and local laws and regu-ns. All components must be properly secured on the rig. If the rig exceeds the overall dimensions ed, it must be flagged according to the highway laws of the countries or states involved in the transport.

transporter is responsible for using the proper method of transport and following all other applicable reg-ons.

Improper operation of controls and use of unsafe techniques can result in serious injury, death and damage to the equipment. Personnel should read the manual and learn proper procedures to transport and lift the machine.



M

Storage and Transport

Li

the

achine Storage and Transport

fting the Machine

Use spreader bars to ensure that lifting lines do not come in contact with the drill. Use chains to anchor machine to the flat rack.

Crush hazard from above. If the load shifts or falls it could crush you or kill you. Use appropriate lifting equipment for the size of the load.

• Use chain or cable suitable for the weight of the machine being lifted. • Ensure load is stable and properly secured before lifting.• All personnel must remain a safe distance away while the machine is being lifted.

Spreader Bar

Platform

Chains



Notes

NOTES:


DD-220T Operators Manual Maintenance

General Maintenance

Maintenance

Hydraulic oil, gearbox oil, diesel engine oil, pin and bearing greases, diesel engine cooling liquid, battery liquids and fuel should be handled with care. Consult Material Safety Data Sheets. Dispose of spent fluids according to laws and regulations. Take appropriate precautions to ensure that these fluids do not leak or spill on the ground or into sewage systems, streams, rivers, lakes or the sea.

Engines, muffler, gearboxes and the hydraulic system can reach very high temperatures. Do not attempt maintenance immediately after stopping work. Wait until the parts are cool.

For additional drawings, diagrams and explanations necessary for maintenance and repair, contact the factory.

Failure to turn off the machine and lockout systems before doing maintenance work may result in personal injury or death. Turn off power, relieve system pressures and turn the Battery switch to the OFF Position. Remove the key from the Engine Start switch. Install a lock on the Battery switch if the machine is so equipped (see drawing below). Use proper lockout and tagout procedures before working on the machine.

Battery SwitchLockout Tab

22DD9723C-batt+lights


Qualification of the Technician

Ensure that all field personnel conducting visual inspections of the rig have adequate training to enable them to identify problems and that they have read and understand this manual.

The maintenance technician must be trained in directional drill operations. The maintenance technician is responsible for conducting maintenance with suitable test and repair equipment, personal protective equipment and attention to safety hazards.


Page

Maintenance

Cle

Gen

the aabranega

Cle

gaugthe pbar))

Cle

petrothe cman

Cle

cleaFailuand

General Maintenance

aning

eral Cleaning

Clean all the marking plates as well as all lighting devices. Do not direct water spray inside the muffler or ir filter, against electric components and control panels or on caps and open tanks. do not use acid or sive solutions. Keep caps and covers for hydraulic connections clean. Contamination of hydraulic oil will tively impact performance of your DD-220T.

aning Plastic and Resin Parts

Avoid using gasoline, kerosene, paint thinner and similar materials when cleaning the instrument cluster, es, console, plastic windows, etc. These materials will cause discoloration, cracking or deformation of art being cleaned. Use ONLY water, mild soap and a soft cloth or compressed air (maximum 30 psi (2 when you clean these parts.

aning Hydraulic Connections

Hydraulic couplings and protective caps must be kept clean and free of all debris. Use an evaporative, leum-based aerosol cleaner. When hydraulic couplings are not connected, replace protective caps on onnectors and hose ends. Failure to keep the hydraulic couplings clean could impact equipment perfor-ce, cause serious damage and may void the product warranty.

aning Electrical Connections

Electrical connectors and dust caps must be kept clean and dry. Use a high quality electrical contact ner. When electrical cables are disconnected, replace dust caps on the connections and cable ends. re to keep the electrical connectors clean could impact equipment performance, cause serious damage may void the product warranty.

Water can damage sensitive electronic components. Do not spray water against electronic components and control panels.



G

Maintenance

W

webe

IM•

•

•

eneral Maintenance

elding

Consult the factory for additional information about preheating or post weld heat treating requirements if lding is necessary in cooler temperatures. Welding should not be done when the ambient temperature is low 0°F.

PORTANT: Disconnect all electrical connections before welding. Damage can occur to processor and electrical

system if electrical components are connected during welding. Disconnect the tramming control before welding. Damage can occur to the system if these electrical

components are connected during welding. Failure to follow welding procedure can cause damage to electric and mechanical components. Dam-

age to components due to improper procedures is not covered under warranty.



Page

Maintenance

Die

Mansche

Ap

theySpecin thCon

sult

General Maintenance

sel Engine Maintenance

Engine maintenance items are outside the scope of this manual. Consult Attachment 1: Diesel Engine ual for recommended engine fluids (gasoline, engine oil, antifreeze) and inspection and maintenance dules. Your engine may have specific requirements related to its emission systems.

proved Replacement Fluids

When adding or replacing fluids, use the same fluid that is in the system. Avoid mixing different fluids as may be incompatible. Use the fluid in the table below or select an equivalent from the American Augers ifications (see Attachment 5: “American Augers Lubrication Guide Revision D”). The compatibility table

e Appendix is a guideline. It lists the compatibility of the main thickener systems used in the industry. tact the factory for advice on the compatibility of a new grease with the one in service.

Fluids oils and greases have been selected specifically for their properties in colder temperatures. Con-the factory for specifications at temperatures outside the ambient temperature range.

Approved Replacement Fluids(Ambient temperature 0°F to 110°F [-18°C to 44°C])

Hydraulic Oil Shell Tellus™ T ISO 46 AA Specification 202

Pump Drive OIl Shell Spirax S™ 80W140 AA Specification 102

Rotary Drive Oil Shell Spirax S™ 80W140 AA Specification 102

Rotary Gearbox Oil Shell Spirax S™ 80W140 AA Specification 102

Carriage Drive Oil Shell Spirax S™ 80W140a AA Specification 102

Track Drive Oil Shell Spirax S™ 80W140 AA Specification 102

Grease Shell Retinax™ LC-2 AA Specification 301


a. Rotary/Planetary Gearbox Oil for machine Serial Number DD2200010211 is Shell Spirax ASX R SAE 75W-90.

Mud Swivel Grease Shell Retinax™ LC-2 AA Specification 301

Slip Sub Grease Jet Lube Kopr Kote AA Specification 302

Water Course Antifreeze Pitt-Penn RV Antifreeze AA Specification 603

DD-220T Operators Manual Maintenance

Scheduled Maintenance

DD-220T Maintenance ScheduleBefore After 10 250 500

Function each job each job hours hours hoursCycle Emergency Stop Buttons X

Engine: Check Fuel Level XEngine: Check Coolant Level X

Engine: Check Crankcase Oil Level XEngine: Check Air Filter Service Indicator X

Check Hydraulic Oil Level XCheck Oil in All Gearboxes X

Leak Check Valves, Hoses, Fittings, Cylinders X XLubricate Grease Fittings X

Inspect Power Wrench Jaw Teeth X XCarriage: Inspect Drill Drive Spindle Saver Sub X

Check/Adjust Track Tension XCheck Crane Pins and Retainers (if so equipped) X

Check Battery Water Level XCheck and Clean Breather Devices X

Change Hydraulic and Charge Pressure Filters X*Change Hydraulic Pump Drive Gearbox Oil X*

Change Carriage Planetary Gearbox Oil X*Change Rotary Drive Gearbox Oil X*

Change Oil in All Gearboxes XTest Hydraulic Oil X

Drain and Flush Mud Hoses and Swivel XCheck Torque on Split Thrust Frame Connectors X

NOTES:

Do not exceed the indicated number of hours without performing the required maintenance* Unless filter indicator shows a change is required more frequently



Page

Maintenance

10

Cyc

Mak

Eng

will cpres

Eng

and filler

IMPize


Hour Inspection and Maintenance

Perform the 10 hour inspection and maintenance items in the Maintenance Schedule.

le Emergency Stop (Disable) Buttons

Verify that all emergency stop buttons are working properly. Perform an operating check of all controls. e necessary repairs before starting operations.

ine: Check Fuel Level

Begin each shift with a full tank of fuel. To prevent dirt and water from reaching the injection parts which ause damage and decrease performance, use clean fuel and service the fuel filter at regular intervals as cribed in the Maintenance Schedule.

ine: Check Coolant Level

Diesel fuel and fuel vapors are combustible. They ignite easily, burn rapidly and can cause serious personal injury. Turn off the engine when refueling. Never allow sparks, flames or smoking materials in the refueling area.

Hot coolant can spray out and cause serious injury. Never remove radiator cap while the engine is hot. Wait for the engine to cool.

• Slowly open the radiator cap and allow pressure to escape slowly.• Always wear face protection (face shield or goggles) when cleaning radiator fins

with compressed air or pressure washer.

ORTANT: Water quality is important to the performance of the cooling system. Use distilled, deion-d or demineralized water when mixing with coolant concentrate.


Coolant should be checked while the coolant is cold. Check that the level of the coolant is at maximum there is no contamination. Add coolant if the level is low. After filling is complete, install and tighten the cap.


S

Maintenance

En

low

En

madefilten

Ch

ing

1. 2. 3.

4.

Ch

leatityIf tch

IM••

N

cheduled Maintenancegine: Check Engine Oil Level

Check that the engine oil is at the maximum level and that there is no contamination. Add oil if level is . Select oil based on specifications in Attachment 1: Diesel Engine Manual.

gine: Check Air Filter Service Indicator

The air filter service indicator provides a quick check of the condition of the air filter(s). When the red rker on the air filter service indicator appears, the air filter is clogged with dust. This causes a substantial crease in engine efficiency and can cause serious damage to inner mechanical parts. Clean or replace the er elements and reset the service indicator. In extremely dusty conditions, increase the frequency of gine air filter maintenance.

eck Hydraulic Oil Level

It is best to check the fluid level when the ambient temperature is 50°F (10°C). Oil level will vary accord- to the effect of temperature (hot oil increases in volume) and the position of the hydraulic cylinders.

Position the machine on a flat surface. Retract all cylinders. Check the level in the tank using the transparent gauge mounted on it. • If the level is too low, add oil to the level indicated on the gauge. • DO NOT overfill the reservoir. After refilling, lock the tank cap.

eck Oil in All Gearboxes

Inspect the hydraulic pump gearbox, the rotary drive gearbox and the carriage planetary gearbox for

PORTANT: Before checking or changing engine crankcase lube oil, wait for the engine to cool. Refer to Attachment 1: “Diesel Engine Manual” for correct crankcase lube oil to use if more oil is

required.

OTE: Very small amounts of contamination of hydraulic oil can damage the system.


ks. In case of a small loss, fill the gearbox to the correct level. After unscrewing a level plug, a small quan- of oil will escape. As soon as this happens inspect the oil in order to verify that there is no contamination. he oil looks dirty or smells burnt, drain the oil and replace it with fresh fluid. If no problems are detected, ange the oil as prescribed on the maintenance schedule.


Page

Maintenance

Hyd

shou

Car

the s

FDisp

Gen

IMP

IMP

Scheduled Maintenanceraulic Pump Drive Gearbox

To check the oil level in the pump drive, remove the level plug in the side of the gearbox. The oil level ld be even with the bottom of the hole.

• To fill, remove the breather plug on top of the gearbox.• Fill with suitable oil until the oil comes out the level hole.• To drain the oil, remove the plug in the bottom of the gearbox. Catch the oil in a suitable container. Dis-

pose of old oil according to local regulations.

riage Planetary Gearbox

Inspect the gearbox for leaks. The oil level for the Carriage Rotary Gear Box should be at the midpoint of ight glass.

Fill with suitable oil until the oil reaches the midpoint of the sight glass.

or draining the oil, remove the plug in the bottom of the gearbox. Catch the oil in a suitable container. ose of old oil according to local regulations.

eral Inspections

ORTANT: Check hydraulic pump drive gearbox oil level when gearbox is cold.

ORTANT: Check carriage rotary drive gearbox oil level when gearbox is cold.

Use of equipment with damaged hoses, fittings, loose or missing fasteners may result in damage to the machine, personal injury or death. Inspect the machine regularly. Replace or repair damaged or missing components promptly.

Hydraulic fluid under pressure can cause serious personal injury and death if


it penetrates the skin. Stay away from the jet.

• Use a piece of cardboard or wood to check for pressurized leaks to prevent fluid penetrating the skin.

• Seek immediate medical attention if hydraulic fluid has penetrated the skin even if the injury seems minor. Prompt medical treatment by a physician familiar with this injury is essential.


S

Maintenance

fluRe

rodse

Re

Lu

thelow

Nfi

cheduled Maintenance

Inspect the machine for leaks of gear oil and hydraulic oil. Leaks should be repaired. Allowing oil or other ids to leak into the environment is unlawful in most locations. Visually inspect all hoses, fittings and pipes. place parts that are damaged.

Check that hydraulic cylinder rods and struts are not damaged and that they do not leak. Keep cylinder s clean to prevent damage. Dirt can cause contamination of the hydraulic fluid and cause failure of shaft

als.

Check all major fasteners, such as hose clamps, stakedown, tie downs, etc. Tighten all loose fasteners. place any that are missing or damaged. Check the control cable connections and ensure they are tight.

brication: General

Grease points must be lubricated daily. Two grease pumps are enough unless otherwise specified. Use grease type specified in the “Approved Replacement Fluids” on page 94. When working in very high or temperatures, consult the factory.

Hot surfaces can cause burns. Do not touch until cool.

OTE: Grease fittings should be kept clean so that contamination is not forced inside. Replace damaged ttings.

Guide to Grease Fitting Location Drawings

Carriage


Wrench

Subframe

Under Thrust Frame22dd10005-side2


Page

Maintenance

Grea

Grea


se Points on Carriage

Eight grease points on both sides of carriage

22dd

4155

-1-C

arria

ge

14dd

6000

-1-W

renc

h

14dd

6000

-2-W

renc

h


se Points on Wrench

Eight grease points on both sides of wrench


S

Maintenance

Gr

Gr


ease Points on Subframe

22dd

1000

5-N

earM

ud

Fitting not visible


ease Points Under Thrust Frame

22dd10005-UnderTF

22dd10005-UnderTF-MainPivot


Page

Maintenance

Car

tion sub.

Rem

wren

1. Ac

2. 3. 4.

o5.

s6. 7.

K

Insta

1. Ar

2. G3. M4. 5.

IMP• U

t• H

d

Scheduled Maintenanceriage: Inspect Spindle Saver Sub

Inspect the spindle saver sub threads for wear or damage. If threads are worn or damaged, the connec-between the drill pipe and the spindle adapter will not be properly secured. Replace the spindle saver

ove a Damaged Saver Sub

The saver sub is threaded onto the end of the drill drive spindle. It is removed from the spindle using the ches. Thread locking compound is used to keep the saver sub from loosening or unthreading.

dvance and position the drill drive carriage so the shoulder of the saver sub is in the jaws of the fixed lamp.

Clamp the shoulder of the saver sub in the fixed clamp.Clamp the spindle shoulder (ABOVE the saver sub joint) in the wrench clamp.Carefully apply heat (approximately 600° F (315° C)) to melt the thread locking compound in the threads f the joint between the spindle (external threads) and the damaged saver sub (internal threads).

Breakout until the threads of the drill drive spindle are completely unthreaded from the damaged saver ub.

Ungrip the damaged saver sub from the fixed clamp.Lift the damaged saver sub from the fixed clamp jaws. Set it aside. Lower a new saver sub in its place.

eep the plastic protector on the external threaded portion to protect the new threads from damage.

ll a New Saver Sub

pply thread locking compound to the threads of the drill drive spindle threads. Manually thread the eplacement saver sub onto the threads of the spindle. Stop when the joint is hand tight.rip the shoulder of the new saver sub in the fixed clamp.akeup to fully tighten the new saver sub to the drill drive spindle.

ORTANT:sing a worn or damaged spindle saver sub will wear or damage each drill pipe as it is connected to

he saver sub while drilling.igh speed threading of drill pipe joints, spindle or saver sub threads is not recommended. Damage to rill drive unit, spindle threads or save sub threads will result.


Ungrip the saver sub from the fixed clamp.Ungrip the spindle shoulder from the wrench clamp.


S

Maintenance

Ad

rec

To

1. 2.

To

1.

2. 3.

To

1.

2. 3. 4. 5. 6. 7.

cheduled Maintenancejust Track Tension

Make a track tension adjustment when the track is too loose. Track tension must always be correct. Cor-t tension is a grease gun reading of 1950 psi (134.45 bar).

Adjust Track

Remove retaining bolts and cover.Remove dirt from around the grease fitting valve.

Tension the Track

Using a grease gun, apply grease to the grease fitting valve until desired tension is reached: 1950 psi (134.45 bar).Replace cover and tighten bolts in place.Repeat procedure for other track.

Loosen Track (for example, to perform maintenance on the track)

Turn grease valve counterclockwise no more than one turn. One turn of the grease valve will release grease. Pressure will drop to zero and the track will be loose.If grease does not start to drain, SLOWLY rotate the track.Remove all excess grease from around the valve.Perform necessary maintenance.Tension track.Replace cover and tighten bolts in place.Repeat procedure for other track, if necessary.

The grease in the hydraulic track tension is pressurized. Grease may be released under pressure and cause serious injury. Loosen the grease valve slowly. Do not loosen the grease valve more than one turn. Do not remove the grease fitting.



Page

Maintenance

250

Eng

cell o

Cbattevolta

Cto clbatte

IMP• W

PG

• T



Perform 10 Hour Inspection and Maintenance items, plus:

ine: Check Battery and Battery Fluid Levels

Check the level of the electrolyte in the batteries. Add distilled water until level is at the split ring of each pening if the level is too low.

BATTERY ACID CAN CAUSE SEVERE BURNS. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Wear eye protection and gloves when working with batteries.

ANTIDOTE:• EXTERNAL: flush with water.• INTERNAL: drink large quantities of water or milk. Follow with milk of magnesia,

beaten egg or vegetable oil. Call Poison control and a physician immediately.• EYES: flush with water for 15 minutes and get prompt medical attention.

All exposed metal parts on a storage battery are “live”. Laying a metal object across the terminals may cause a spark, short circuit or explosion. Personal injury or damage to the equipment may result. Never lay a metal object across the battery terminals.

ORTANT: hen disconnecting battery terminals, remove the Negative (-) GROUND cable first; then remove the

ositive (+). When connecting the cables, connect the Positive (+) first, then connect the Negative (-) ROUND cable last.o prevent damage to the battery, DO NOT over tighten the battery hold down.


heck the battery cables and verify that there are no abrasions or indentations; if necessary, replace the ry cables. Check that the battery terminals are not corroded. Clean and replace them if necessary. The ge of the battery is 12 volts.

lean corrosion off battery terminals. A paste made of sodium bicarbonate and water is normally enough ean terminals and battery box. After cleaning, rinse thoroughly with clean water. Coat the terminals with ry terminal grease or dielectric grease in order to prevent future corrosion.


S

Maintenance

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cheduled Maintenanceeather Devices

Check that there are no obstructions or deposits accumulated. Clean the breather pipes in case of structions. We recommend using an oil solvent (diesel fuel is OK). Clean breather pipes more frequently en operating in dusty conditions.Flywheel gearbox (1)Hydraulic tank (1)Fuel tank (1)



Page

Maintenance

500

Cha

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1. P2. 3. 4. H

5. 6. C7. 8.

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Perform 10 and 250 Hour Inspection and Maintenance items, plus:

nge Hydraulic and Charge Pressure Filter Elements

An indicator light on the Control Panel Display screen will show when hydraulic or charge pressure filter ents must be changed. If the light goes on and stays on, change the filter elements as soon as possible. aulic and charge pressure filter elements should routinely be changed every 500 hours.

lace a container under the filter you are changing to catch any spills.Using a filter wrench, remove the filter element and discard. Clean the area with a clean rag.Apply a thin coat of oil to the o-ring of the new filter element. Install the new oil filter element.

AND TIGHTEN filter until making contact with the base. Continue to tighten 3/4 turn. DO NOT use a fil-ter wrench to tighten the filter. Damage to the filter may result.Run the engine at low speed and operate the rotary.

heck the oil level.Run the engine at high speed for 5 minutes.Turn off the engine and inspect for leaks.

nge Hydraulic Pump Drive Gearbox Oil

• To drain the oil. remove the plug in the bottom of the gearbox. Catch the oil in a suitable container. Dis-pose of old oil according to local regulations.

Support the drill frame with a strong support before draining the hydraulic filters. DO NOT start the engine until personnel have moved away from the area.

IMPORTANT: When changing the charge filter, first, unscrew the drain plug on the bottom of the filter. Then, unscrew the plug on top of filter enough to help bleed out. Finally, unscrew the container and remove the filter element.

ORTANT: Change hydraulic pump drive gearbox oil level when the gearbox is cold.


For filling, use the elbows where breather pipe is positioned. Remove the breather pipes. Fill with suitable oil until the oil comes out the level hole.

nge Carriage Planetary Gearbox Oil

To drain the oil, remove the plug in the bottom of the gearbox. Catch the oil in a suitable container. Dis- of old oil according to local regulations.

ill with suitable oil until the oil reaches the midpoint of the sight glass.

ORTANT: Change hydraulic pump drive gearbox oil level when the gearbox is cold.


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Maintenance

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cheduled Maintenanceange Rotary Drive Gearbox Oil

Remove the fill/level plug.Remove the drain plug and drain the oil. Catch the oil in a suitable container. Dispose of old oil according to local regulations.Insert and tighten the drain plug.Fill drill drive to proper level with gear oil.Insert and tighten the fill plug.

st Hydraulic Oil

After 500 operating hours, obtain a sample of hydraulic oil from the hydraulic tank. Use the inspection ttles provided by American Augers. Send the samples to American Augers for analysis. You will be noti-d if it is necessary to change the hydraulic oil. When changing the oil, the filters must also be changed. llow instructions in “Change Hydraulic Reservoir Oil” on page 107.

ange Hydraulic Reservoir Oil

Hydraulic filters MUST be replaced each time the oil is changed. When draining oil from the reservoir d filter, ALWAYS use a container and dispose of properly. Make sure the container has enough capacity to oid any spillage. NEVER allow oil to drain onto the ground.

PORTANT: Change hydraulic pump drive gearbox oil level when the gearbox is cold.

OTICE: Failure to send in samples for inspection will void the warranty.

Support the drill frame with a strong support before draining the hydraulic filters. DO NOT start the engine until personnel have moved away from the area.

IMPORTANT: Keep hydraulic oil clean, properly filtered and do not allow it to over-heat by overloading.


Verify that the power is off.Clean the external covers and walls of the hydraulic tank.Drain the hydraulic oil from the tank in a container suitable for transportation or disposal.Remove all access covers and remove any deposit of old gaskets.Keep all bolts together.Remove the suction strainers inside the tank.Clean the breather cap with a lint free cloth.Inspect the tank for metal particles and foreign matter. Clean these materials out of the tank to minimize oil contamination.Clean and reassemble the suction strainer. Alternatively, you may wish to use a new suction strainer.

. Put the gasket on the inspection cover and reassemble.


Page

Maintenance

11. Rr

12. ai

13. 14. 15. 16.

Scheduled MaintenanceTighten the bolts on the cover. Refill the reservoir with the hydraulic oil recommended on the “Approved

eplacement Fluids” on page 94. Do not mix products from different companies due to the possibility of eactions among the oil.

Fill the tank to the appropriate level using the gauge on the outside. The oil level will vary considerably ccording to the effect of temperature (hot oil increases in volume) and the position of the hydraulic cyl-

nders.Run the engine at low speed and operate the rotary.Confirm proper oil level in tank.Run the engine at high speed for 5 minutes.Turn off the engine and inspect for leaks.



S

Maintenance

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1.

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efore Each Job

eck Torque on Split Thrust Frame Connectors

This maintenance item applies only to the DD-220T with the Split Thrust Frame. If you have transported ur machine with the upper thrust frame attached to the lower thrust frame, check the alignment and torque fore moving the carriage.

Check the alignment of the two sections of the thrust frame to be sure they have not shifted. Use the piece of gear rack in the alignment kit. If necessary, loosen all bolts, re-align the thrust frame sections and re-tighten.• The entire length of the drill frame should be aligned side-to-side and top-to-bottom. • The gear rack should also be aligned so the carriage can pass smoothly across the joint between the

upper and lower thrust frame.Verify that the jackbolts on the tensioners have been tightened at 100% target torque (preload of 262,00 lbs, a torque of 114 ft/lbs each). For additional information, see “Assembling the Split Thrust Frame” on page 63 and “Appendix C: Jack-bolt Tightening Procedure” on page 121.



Notes

NOTES:


DD-220T Operators Manual Specifications

Specifications

SpecificationsMachine Dimensions / Weight

Length (transport): 52.5 feet (16 m)Width (transport): 8 feet 1 inch (2.46 m)Height (transport): 13 feet 1 inch (3.0 m)Height (at 18° drill angle): 21.3 feet (6.5 m)Total Weight (with wrench): 65000 lb (29483 kg)

Power Train

Engine: Cummins QSL 9 DieselRating: 365 HP (272 kW)Fuel Capacity: 270 gallons (1022 liter)Hydraulic capacity: 270 gallons (1022 liter)

Drilling Unit

Travel System: Self-propelled on Track Crawler AssemblyMaximum Flat Surface Speed: 2 mph (3.22 km/h)Drill Angle: 10° - 18°Wrench Clamp: Open top with 10 inch (254 mm) separationHold Down System: H-Beam Type

Rotary Drive

Rotary System: (2) Pinion and gear drive. Infinitely variable torqueMaximum Rotary Torque: 30000 ft-lbs (40674 Nm)Maximum Rotary Speed: 95 RPMFluid Course: 3 inch (76 mm)Maximum Flow: Up to 650 gallons (2460 liters)/minute

Carriage Drive

Carriage System: Rack and pinion (6) pinion drive with adjustable force limiter


Maximum Thrust/Pullback: 220000 pounds (94 tonnes)Maximum Carriage Speed: 90 feet (27 m)/minute

Drill Pipe

Length (each section): Range II - 34 feet (10.4 m)

Protective Equipment

ZAPALERT™ system with ground stakees!lok® Exit Side Lockout System


Notes

NOTES:


DD-220T Operators Manual Appendix

Appendix

Appendix

The appendix contains information that we believe the operator of the DD-220T will find useful to have available for reference during the operation of the DD-220T. The information is placed in the appendix because it is of general interest or it supplements the information in the body of the man-ual.



Notes

NOTES:


DD-220T Operators Manual Appendix A

Appendix A: List of Attachments

Appendix AAttachment 1: Diesel Engine Manual

Attachment 2: es!lok® Exit Side Lockout System Operation & Safety Instruction Manual (American Augers’ Part Number 8ER10040)

Attachment 3: ZAPALERT™ Electric Shock Alarm Instruction Sheet

Attachment 4: DD-220T Displays Operator Manual

Attachment 5: American Augers Lubrication Guide Revision D


DD-220T Operators ManualAppendix B

Appendix B: Tables Converting Pressure to Torque and Force

Appendix BConverting Gauge Pressure to Rotary Torque

Hydraulic Gauge Rotary Torque Rotary Torque Rotary TorquePressure (PSI) Low Range 49 RPMMid Range 65 RPM High Range 95 RPM

(Lbs-Ft) (Lbs-Ft) (Lbs-Ft)

500 727 552 377600 1453 1103 753700 2180 1655 1130800 2907 2206 1506900 3633 2758 1883

1000 4360 3310 22591100 5087 3861 26361200 5813 4413 30121300 6540 4964 33891400 7267 5516 37651500 7993 6068 41421600 8720 6619 45181700 9447 7171 48951800 10173 7723 52721900 10900 8274 56482000 11627 8826 60252100 12354 9377 64012200 13080 9929 67782300 13807 10481 71542400 14534 11032 75312500 15260 11584 79072600 15987 12135 82842700 16714 12687 86602800 17440 13239 90372900 18167 13790 94133000 18894 14342 9790


3100 19620 14893 101673200 20347 15445 105433300 21074 15997 109203400 21800 16548 112963500 22527 17100 116733600 23254 17651 120493700 23980 18203 124263800 24707 18755 128023900 25434 19306 13179


A

Appendix B

ppendix B: Tables Converting Pressure to Torque and Force

Converting Gauge Pressure to Rotary Torque (Continued)

Hydraulic Gauge Rotary Torque Rotary Torque Rotary TorquePressure (PSI) Low Range 49 RPMMid Range 65 RPM High Range 95 RPM

(Lbs-Ft) (Lbs-Ft) (Lbs-Ft)

4000 26160 19858 135554100 26887 20409 139324200 27614 20961 143084300 28340 21513 146854400 29067 22064 150624500 29794 22616 154384600 30520 23168 15815



Page

Appendix B

HP


Converting Gauge Pressure to Thrust/Pullback Force

ydraulic Gauge 1st Gear 2nd Gear 3rd Gear 4th Gearressure (PSI) 18 Ft/Min-Lbs Force 24 Ft/Min-Lbs Force 38 Ft/Min-Lbs Force 90 Ft/Min-Lbs Force

900 24289 17611 10951 43611000 29147 21133 13141 52341100 34005 24655 15331 61061200 38862 28178 17521 69781300 43720 31700 19711 78511400 48578 35222 21902 87231500 53436 38744 24092 95951600 58294 42266 26282 104671700 63151 45789 28472 113401800 68009 49311 30662 122121900 72867 52833 32852 130842000 77725 56355 35042 139572100 82583 59877 37233 148292200 87440 63400 39423 157012300 92298 66922 41613 165732400 97156 70444 43803 174462500 102014 73966 45993 183182600 106871 77488 48183 191902700 111729 81011 50374 200622800 116587 84533 52564 209352900 121445 88055 54754 218073000 126303 91577 56944 226793100 131160 95099 59134 235523200 136018 98622 61324 244243300 140876 102144 63515 252963400 145734 105666 65705 261683500 150592 109188 67895 270413600 155449 112711 70085 27913



A

Appendix B

ppendix B: Tables Converting Pressure to Torque and Force

Converting Gauge Pressure to Thrust/Pullback Force (Continued)

Hydraulic Gauge 1st Gear 2nd Gear 3rd Gear 4th GearPressure (PSI) 18 Ft/Min-Lbs Force 24 Ft/Min-Lbs Force 38 Ft/Min-Lbs Force 90 Ft/Min-Lbs Force

3700 160307 116233 72275 287853800 165165 119755 74465 296583900 170023 123277 76655 305304000 174881 126799 78846 314024100 179738 130322 81036 322744200 184596 133844 83226 331474300 189454 137366 85416 340194400 194312 140888 87606 348914500 199170 144410 89796 357644600 204027 147933 91987 366364700 208885 151455 94177 375084800 213743 154977 96367 383804900 218601 158499 98557 392535000 223459 162021 100747 40125



Page

Appendix B

H


Converting Wrench Pressure Gauge Reading to Breakout/Makeup Torque

ydraulic Gauge Breakout Torque Makeup TorquePressure (PSI) Wrenches Setting Horizontal (Ft-Lbs) Wrenches Setting Horizontal (Ft-Lbs)

100 3038 2279200 6077 4558300 9115 6836400 12153 9115500 15192 11394600 18230 13673700 21269 15951800 24307 18230900 27345 205091000 30384 227881100 33422 250661200 36460 273451300 39499 296241400 42537 319031500 45575 341821600 48614 364601700 51652 387391800 54690 410181900 57729 432972000 60767 455752100 63806 478542200 66844 501332300 69882 524122400 72921 546902500 75959 569692600 78997 592482700 82036 615272800 85074 63806


2900 88112 660843000 91151 68363

DD-220T Operators Manual Appendix C

Appendix C: Jackbolt Tightening Procedure

Appendix C


Extracted from vendor brochure (www.superbolt.com)


Notes

NOTES:


DD-220T Operators Manual Declaration of Conformity

Sample Declaration of Conformity

Horizontal Directional DrillDD-220T


American Augers, Inc.135 US Route 42

P.O. Box 814West Salem, Ohio 44287

www.americanaugers.com

Always include machine serial number when ordering partsDue to our continuing product improvement, machine specifications are subject to change without notice.

Original InstructionsManual Part Number 22DD10000

Released September 2012 Revision 01

DD-220T Operation & Safety Instruction Manual Operation & Safety Instruction Manual ... mud swivel...

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