dd-1100 rst operation & safety instruction manual€¦ · dd-1100 rst operation & safety...

DD-1100 RSTOperation & 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-1100 RST. All operators and ground personnel must carefully read and understand this manual before starting the machine. Keep this manual available both as a reminder for your experienced operator and as a training aid for your new staff.

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

DD-1100 RST Operators ManualForeword

Introduction

Foreword

INTRODUCTION

Since 1970, American Augers has been a devoted manufacturer of trenchless technology equip-ment; customers worldwide recognize the DD-1100 RST as a premier piece of directional drilling equipment. 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.

Every effort has been made to adequately cover the operation of the DD-1100 RST in this man-ual. If you have any questions about any of the features of your specific machine, contact the fac-tory (Telephone 419-869-7107 or 800-324-4930 (USA Toll Free)).

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 maybe 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.

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

Original InstructionsManual Part Number 50DD10100

Released January 2014 Revision 01

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

DD-1100 RST 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-1100 RST Operators ManualForeword

Machine Serial Number Locations


Location of Machine Serial Number Plate

Machine Serial Number

Driller’s Console - side view

DD-1100 RST Operators Manual Foreword

Safety Awareness ProgramUnderstanding 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-1100 RST Operators ManualNotes

Notes

NOTES:


DD-1100 RST Operators Manual Forward

Revision Record

Revision to ManualRevision Number Description of Change Date

00 New Release; Serial numbers under top level 50DD10002 from 8/8/2011RS11000020111

01 Updated Approved Replacement Fluids table and engine maintenance 1/10/2014items; revised Maintenance Schedule; added hydraulic pump drivemaintenance item; updated safety decals section and carriagethrust/pullback chart


DD-1100 RST 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

DD-1100 RST Operators Manual Forward

To The Owner

To The OwnerThank you for your purchase of the American Augers DD-1100 RST with optional carriage position sen-

sor. This directional drill, with standard equipment and authorized attachments, is intended to be used for underground drilling and pullback operations.

This manual contains important information that will help you and your crew set up and safely operate the DD-1100 RST. 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. Unautho-rized modifications could cause serious injury or death. Anyone making such unauthorized modifi-cations 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 withthe “DD-1100 RST Components” section beginning

on page 17.


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-1100 RST Operators Manual Table of Contents

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

verview ........................................................................................... 17DD-1100 RST Components....................................................................................... 17Operation and Maintenance Manual ......................................................................... 19Ownership of Information .......................................................................................... 19Manufacturer Identification Data................................................................................ 19Machine Identification Data ....................................................................................... 19Scope of Document ................................................................................................... 19Qualification of Personnel.......................................................................................... 20Declaration of Conformity .......................................................................................... 20Use of Personal Protective Equipment...................................................................... 20Legal Disclaimer ........................................................................................................ 20Purpose of Machine................................................................................................... 20Ground Leveling and Soil Conditions ........................................................................ 21Ambient Conditions ................................................................................................... 21Transport ................................................................................................................... 21Operation................................................................................................................... 21


Warranty: General Conditions ................................................................................... 21Limitations of Warranty.............................................................................................. 21Request for Service/Support ..................................................................................... 21Warranty and Service for Diesel Engine.................................................................... 22Instruction Manuals ................................................................................................... 22

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


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urface Examination ..................................................................................................26verhead Hazards .....................................................................................................26eferences.................................................................................................................27xit Pit Construction...................................................................................................27efore Starting the Machine.......................................................................................27perating Precautions ...............................................................................................27perator’s Responsibilities.........................................................................................27aterial Handling Precautions; Crane Safety ............................................................28rilling Precautions ....................................................................................................28eaming and Installation Precautions........................................................................28aintenance Precautions...........................................................................................29ransporting Precautions ...........................................................................................29elding Safety ...........................................................................................................29oise Level Safety .....................................................................................................30adder Safety .............................................................................................................30azardous Chemicals ................................................................................................30anger Zones -- Safe Distances................................................................................31rounding ..................................................................................................................31afety Features - ZAPALERT™.................................................................................32afety Features - es!lok® Exit Side Lockout System.................................................32afety Features - Fire Extinguisher............................................................................32

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

chine Controls............................................................................. 37afety Switches..........................................................................................................37isable Switches........................................................................................................40


attery Switch and Light Switch.................................................................................41etup Box...................................................................................................................42adio Remote Transmitter .........................................................................................44ypical Engine Control Panel .....................................................................................46riller’s Console Map .................................................................................................48ressure Gauges .......................................................................................................49arriage/Rotary/Wrench Operations Panel................................................................50ngine/Wiggle Steer® Panel......................................................................................53arious Functions Panel ............................................................................................55arriage Position Meter (Optional).............................................................................56


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riller’s Console .............................................................................. 57reparation....................................................................................... 59Site Preparation......................................................................................................... 59Site Layout................................................................................................................. 59Cranes ....................................................................................................................... 60Mats and Cribbing ..................................................................................................... 60Protection of Wires, Cables and Hoses..................................................................... 60Making Power Connections....................................................................................... 60Crew .......................................................................................................................... 60The Bore Path ........................................................................................................... 61Guidance System ...................................................................................................... 61Mud Recycling System .............................................................................................. 61ZAPALERT™ Electric Shock Alarm .......................................................................... 61es!lok® Exit Side Lockout System............................................................................. 62

t Up ............................................................................................... 63Set Up the Machine ................................................................................................... 63Anchor the Machine................................................................................................... 69Excavate the Entry Pit and Returns Pit ..................................................................... 71

arting the DD-1100 RST ............................................................... 72Starting the DD-1100 RST......................................................................................... 72

perating the DD-1100 RST ........................................................... 74Test the Indicators, Emergency Stop Buttons and all Controls ................................. 74Attach the Drilling Fluid Supply Connections............................................................. 74


Power Wrench Operation .......................................................................................... 74Checks During Operation .......................................................................................... 75Thrust and Pullback Force Controls .......................................................................... 75Converting Gauge Pressure to Torque and Force .................................................... 75Using a Mud Motor .................................................................................................... 75Fundamentals: Install Drill Pipe ................................................................................. 76Turn on the Drilling Fluid ........................................................................................... 77Make the Pilot Bore ................................................................................................... 78End of Pilot Bore Drilling............................................................................................ 79

ullback Operations ......................................................................... 80


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ackreaming and Pullback.........................................................................................80ontinue Backreaming...............................................................................................83quipment Shutdown .................................................................................................83ig Down....................................................................................................................84

erating in Different Climates ...................................................... 85perating in Hot Weather...........................................................................................85perating in Cold Weather.........................................................................................85ngine Block Heater ..................................................................................................86ngine Preheating Devices........................................................................................86

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

neral Maintenance....................................................................... 89ualification of the Technician ...................................................................................89leaning .....................................................................................................................89elding ......................................................................................................................90iesel Engine Maintenance........................................................................................91pproved Replacement Fluids ...................................................................................91

eduled Maintenance ...................................................................920 Hour Inspection and Maintenance.........................................................................93fter First 100 Hours of Operation ...........................................................................101


50 Hour Inspection and Maintenance.....................................................................10200 Hour Inspection and Maintenance.....................................................................103

cifications.................................................................................. 107achine Dimensions / Weight..................................................................................107ower Supply Unit....................................................................................................107ower Train..............................................................................................................107rilling Unit ...............................................................................................................107otary Drive .............................................................................................................107arriage Drive ..........................................................................................................107


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Wrench Assembly.................................................................................................... 107Drill Pipe .................................................................................................................. 108Protective Equipment .............................................................................................. 108Controls ................................................................................................................... 108

ppendix ......................................................................................... 109Appendix A: List of Attachments ............................................................................. 111Appendix B: Wiggle Steer and Wiggle Steer Codes ............................................... 113Appendix C: Dual Power Units and ROOTS .......................................................... 115Appendix D: Tables Converting Pressure to Torque and Force ............................. 117

mple Declaration of Conformity ............................................... 123



Notes

NOTES:


DD-1100 RST Operators Manual Overview

Overview

OverviewDD-1100 RST Components

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1. Auxiliary Power Unit2. Rotary Gear Box3. Carriage4. Spindle5. Top Clamp6. Thrust Frame7. Walkways and Handrails8. Wrench Clamp9. Fixed Clamp10. Guide Bushing

11. Front Foot12. Cables (both sides of rig)13. Sliding Dolly14. Lifting Legs15. Rear Foot16. Cross Bracing17. Support Strut18. Hose Carrier19. Light Bar (not shown)


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Overview

-1100 RST Components (Continued)

1. Diesel Engine2. Hydraulic Tank3. Fuel Filler Pipe4. Battery Box5. Valve Bank6. Filters7. Electrical Box

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TITLE: DD-1100 RST Operation & Safety Instruction ManualEDITION: 2013Part Number: 50DD10100

wnership 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 intenance of the relevant machine. American Augers declares that the information contained in this man-l fits the technical and safety specifications of the machine. American Augers disclaims responsibility for ect or indirect damages to persons or property caused when the manual or the machine are used in viola-n of the information contained herein.

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

anufacturer Identification DataAMERICAN 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

achine Identification DataType: Directional DrillModel: DD-1100 RST (with carriage position sensor (optional))Serial number: Found on identification plateYear of manufacture: Listed on serial number plate

Location of identification plate: See drawing on page 3.


cope of DocumentThis manual covers operation, safety and maintenance of the DD-1100 RST. Planning the bore path,

lecting drilling fluid, operating a drilling fluid recycling system and selecting and operating a guidance sys- are outside the scope of this document. “Horizontal Directional Drilling; Good Practice Guidelines” by the D Consortium1 provides information on these and other topics. Consult equipment suppliers, engineers

d the American Augers factory for additional assistance.

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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alification of Personnel

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

laration of ConformityIf required, the Declaration of Conformity is issued at consignment of the machine. A sample document produced on page 123. The Declaration of Conformity is not required in most countries.

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 the 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.

TICE: American Augers disclaims any responsibility for damages to persons or property caused by 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.


al Disclaimer

pose of MachineThe machine was designed solely for boring a circular section under the earth ready for positioning pipe ble, without the need for backfilling and compacting.

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


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round Leveling and Soil Conditions

The DD-1100 RST can operate on surfaces with a maximum lateral inclination of 3° and a slope in the ning direction up to 5°. The machine is designed to work on solid ground that can support the load without

ttling.

mbient Conditions

Temperature limits: The machine, with factory fill of lubricants, is designed to work in temperatures from °F and +110°F (-15°C and +43°C). For temperatures not included in this range, contact American Augers. fer to “Operating in Hot Weather” on page 85 and “Operating in Cold Weather” on page 85 for additional ormation.

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.

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

n laws.The wrenches may be removed and shipped separately to reduce transport weight.

perationIt is recommended only one person operates the controls. Other trained personnel may work near the

-1100 RST if they are wearing appropriate personal protective equipment and follow the safety instruc-ns in this manual. Further, the operator must remain aware of the location of all other personnel while erating the machine.

arranty: General ConditionsWarranty is provided with the understanding that all safety warnings and instructions will be reviewed by

personnel. Warranty is subject to the conditions and limitations specified in the warranty certificate. The rranty certificate is on page 3. If you have questions about the warranty or any part of the machine opera-n, please contact American Augers (Telephone: 419-869-7107 or 800-324-4830 (USA Toll Free)).

OTICE: Modifications to the equipment made by the customer might reduce warranty coverage. See


mitations of WarrantyThe warranty for all components that are not manufactured by American Augers are subject to the origi-

l warranties of their manufacturers and not by American Augers.

equest for Service/SupportFor service support in or out of the warranty period, contact American Augers. Provide machine model

mber, serial number and number of operating hours.

Limited Warranty” on page 3.


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rranty 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 hine is sold. Only diesel engine dealers are authorized to perform repairs under warranty, provide ser-and supply spare parts.

truction Manuals

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

pment manufacturers.


DD-1100 RST Operators Manual Safety

Safety Information

SafetySafety Regulations and Practices

This manual contains important information about the safety practices and safe operation of the DD-1100 RST. All operators must read and understand the Operation and Safety Instruction Manual before starting 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-1100 RST 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 and the ZAPALERT is reset.

• 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 advice contained in the manual.

EMERGENCY SHUTDOWN: Push the red Emergency Stop button in one of the following locations:• on the right control panel on the Driller’s Console• near the outside hydraulic connections on each Power Supply Unit • on the Engine Control Panel in the Power Supply Unit

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 sure, must consider the alarm to be an electrical strike. Follow the above procedures and wait for verification the proper utility authorities.

ponse to a Gas Strike

If a gas line strike occurs, evacuate the area immediately. Shut down all engines. Extinguish all flame sparks immediately. Do not attempt to reverse the bore to break contact as further movement may se a spark. 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-1100 RST, all operators should receive thorough training in the use of this equip-ment. This manual should be used as a training tool.

Jobsite hazards could result in serious injury or death. All personnel on the jobsite should 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 the “Safety Alerts” section begin-ning 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 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 ExaminationThe 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 HazardsOverhead 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.


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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 ConstructionDrilling 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.• Securely connect all fluid lines before starting the machine. • 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.• Make sure the ZAPALERT system has been tested and is properly grounded. Follow procedures 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.

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 the bore is started, and avoid them by using proper drilling techniques.

• Assess the situation using common sense and the benefit of his/her experience and proceed if and only if the work can be safely 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. • Make sure all operating personnel observe and use safe operating practices.• Visually verify that all personnel and objects are clear of the machine before startup.

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 Information• Make sure all personnel stay in their prescribed areas. • Ensure that all personnel and objects stay away from rotating or moving parts.• 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. 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. • Turn off the machine at the first sign of malfunction or hazardous condition.

terial Handling Precautions; Crane Safety

• Use appropriate lifting equipment for the size of the load.• Do not move loads that exceed the crane lift rating.• Discard and replace damaged or worn lifting equipment (e.g., slings, chains, ropes, etc.) Use a tether line to stabilize the load and minimize twisting and turning.

• Stand away from suspended loads. Do not approach the load until it has been lowered to hand-height.• Use proper hand signals and know who has the responsibility for signaling.• Do not use to lift or move personnel.• Make sure equipment is inspected regularly and maintained properly.

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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aintenance Precautions

• Eliminate all power sources (turn off machine and 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 it is in motion.• 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 secure loose items so they cannot fall off during transport.

elding Safety

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”.• Do not leave a welder alone.


• 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 Information

ise Level Safety

The sound pressure measured according to ISO 11202:1993, ISO 3746:1995, IEC 651:1979 and IEC 1985 is 102 dB(A).

der Safety

ardous Chemicals

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

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

• When working at heights about 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.

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.


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.

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.


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afety Information

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. On electrical jobsites, wear appropriate protective uipment (insulated boots and gloves). All other personnel must stay out of this zone during drilling or back-ming or any time when an electric line could be struck. You may wish to set up a safety barrier around the

nger zone to prevent anyone who is not wearing appropriate safety gear from entering this zone.

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

rounding

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.

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 codes and regulations with regard to bonding and grounding.


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.

All metal components on a drill rig site should be bonded together as shown in the drawing below. Bond- will reduce the electric potential difference between components with respect to any other components the site. Current will not flow between two sections that are at the same electric potential. All remote uipment that is in close proximity to the drill rig must also be electrically bonded to the drill rig, i.e. pipe ks, mud pumps etc. This will reduce the risk of shock to any personnel who might contact both the drill rig

d the remote equipment.


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Safety Information

al Bonding Scheme

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 61 and Attach-t 3, “ZAPALERT™ Electric Shock Alarm Instruction Sheet” for complete information.

ety Features - es!lok® Exit Side Lockout System

PORTANT: For additional information on electrical hazards, bonding and grounding, you may wish to nsult publications 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 Supply Unit

Pit

Bore Path


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. Refer to “es!lok® Exit Side Lockout System” on page 62 and hment 2, “es!lok® Exit Side Lockout System Operation & Safety Instruction Manual” for complete infor-

on.

ety Features - Fire ExtinguisherA dry chemical fire extinguisher approved for Class B & C type fires should be either on your machine or e Driller’s Cabin.

DD-1100 RST 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 (25 feet).

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

Keep hand and feet at a safe dis-tance.

Diesel engine exhaust warning Read manual before lifting.



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Safety

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Safety Alerts

High Pressure Fluid. Read oper-r’s manual for proper service procedures.

Crushing of feet. Keep feet safe distance from hazard.

Explosion hazard. Call 811 ore you dig.

Electrocution/explosion hazard. Keep safe distance.

Read operator’s manual. Use proper lockout and tagout procedures when performing maintenance work.



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afety Alerts

Stay safe distance from achine.

Body crush hazard. Stay safe dis-tance from machine.

Hot surface. Do not touch. Body crush hazard from side. Stay safe distance from machine.



Notes

NOTES:


DD-1100 RST Operators Manual Controls

Machine Controls

ControlsSafety Switches

There are four push buttons which stop the diesel engines on the DD-1100 RST. 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.

Diesel Engine Stop Push Buttons (2) on Driller’s Console

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Diesel Engine Stop Push Button near the outside hydraulic connections on each Power Supply Unit

50dd

1430

C-h

ose

To turn off both diesel engines:

Push emergency stop button located near the hose connections


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Controls

Dies

Saf

Auxi

Machine Controls

el Engine Stop Push Buttons on Typical Engine Control Panels

ety Switches - Auxiliary Power Unit

There are two push buttons which stop the auxiliary power unit engine.

STOPSTOPn/min

SETUP


liary Engine Stop Push Button on the Setup Box

50DD9790-Setup Box.tif


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Controls

Au

achine Controls

xiliary Engine Stop Push Button on Remote Transmitter

MACHINE STOP

BOTH CYL UP

BOTH CYL DOWN

ASSOC

STORE

DOWNLEFT CYL

DOWNRIGHT CYL

TRO

LLEY RIG

HTTR

OLL

EY L

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8EE11201_2010May10-p8cervis-bwFACE.tif

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able 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 makeup and breakout• Disable wrench travel and wrench separate• Disable the carriage and rotary joysticks

ROTARYCARRIAGEDISABLE

DD

1100

008

-Rot

Car

Dis

able

-edi

ted Typical Location of Rotary/Carriage Disable

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achine Controls

attery Switch and Light Switch

The battery switches are located on the Power Supply Unit as shown in the drawing below. The switch nnects and disconnects the batteries from the electrical system. Rotate to the right to connect. Rotate left disconnect. The battery switch must be in the ON position before starting the engine. Turn the battery itch OFF after you stop the engine and remove the key.

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

Battery Box

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Typical Location of Battery Switch

Light Switch



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up Box

STOPSTOPn/min

SETUP

50DD9790-Setup Box.tif

6

9

3

1

78

2

4

5

REMOTEPENDANT

10


1. Hydraulic Oil Level Indicator2. Carriage Position Indicator3. Throttle4. Emergency Stop Button5. Key Ignition Switch

6. Engine Running Light7. Battery Charging Light8. Oil Pressure Warning Light9. Preheat Light10. Remote Pendant Plug


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achine Controls

Control Function

. Hydraulic Oil Level Indicator Light on: Hydraulic oil level on the Auxiliary Power Unit is low

. Carriage Position Indicator Light on: Carriage is not in proper position for thrust frame setup, take down and rig transport

. Throttle • Increase engine speed: turn control to the right• Decrease engine speed: turn control to the left

. Emergency Stop Button • Stop the Auxiliary Power Unit engine: push button• Enable engine start: button must be pulled out

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

. Engine Running Light Light on: Auxiliary Power Unit engine is on

. Battery Charging Light Light on: Battery not charging

. Oil Pressure Warning Light Light on: Low engine oil pressure

. Preheat Light Light on: Auxiliary Power Unit engine is preheating

0. Remote Pendant Plug Plug umbilical cord for radio remote transmitter in this plug to operate the unit in the event radio communication is not function-ing



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io Remote Transmitter

1. Emergency Stop Button2. Cylinder/Trolleya Joystick3. Right Cylinder Control4. Left Cylinder Control

. The “trolley” on the DD-1100 RST is called a “dolly”.

5. Controller Setup Toggle Switch6. Trigger7. Umbilical Cord Connection (Optional)

MACHINE STOP

BOTH CYL UP

BOTH CYL DOWN

ASSOC

STORE

DOWNLEFT CYL

DOWNRIGHT CYL

TRO

LLEY RIG

HTTR

OLL

EY L

EFT

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15

4

2 3

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ins

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4

5

6

7

achine ControlsRefer to Attachment 5, “Cervis - Wireless SmaRT™ Engineered System Manual” for complete

tructions on replacing batteries and using the transmitter.

Control Function

. Emergency Stop Button Stop the Auxiliary Power Supply engine• Stop the engine: push button• Enable engine start: button must be pulled out

. Cylinder/Trolleya Joystick

a. The “trolley” on the DD-1100 RST is called a “dolly”.

• Move dolly left (away from the drill hole): push joystick to the left• Move dolly right (downhole): push joystick to the right• Lift thrust frame with both cylinders: push the joystick away from

you• Lower thrust frame with both cylinders: pull the joystick toward

you

. Rightb Cylinder Control

b. Right and Left when looking downhole.

Use for making small adjustments in thrust frame position• Move thrust frame up: push toggle away from you• Move thrust frame down: pull toggle toward you

. Left Cylinder Control Use for making small adjustments in thrust frame position• Move thrust frame up: push toggle away from you• Move thrust frame down: pull toggle toward you

. Controller Setup Toggle Switch Refer to Attachment 5, “Cervis - Wireless SmaRT™ Engineered System Manual” for instructions when it is necessary to re-associ-ate the transmitter and receiver.

. Trigger Squeeze the trigger for the cylinder control joystick to work.

. Umbilical Cord Connection The umbilical cord can be used if the radio communication between transmitter and receiver is not functioning.



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Controls

Typ

Machine Controls

ical Engine Control Panel

1. Emergency Stop2. Key Ignition Switch3. Yellow Diagnostic Warning Light4. Red Diagnostic Warning Light

5. Throttle6. Engine Hours Meter7. Display Screen

1

25 6

3

4

1

23

5

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4

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6

7

achine ControlsControls, gauges and displays on an engine panel vary depending on the manufacturer and model of

gine on your machine. Two different, typical control panels are pictured. Consult the Diesel Engine Manual your equipment.

Control Function

. Emergency Stop Stop the engine of the corresponding Power Supply Unit• Stop the drill and the engine: push button• Enable engine start: button must be pulled out

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

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

. Red Diagnostic Warning Light 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

. Engine Hours Meter Displays the number of accumulated hours on the engine.

. Display Screen Displays engine information and diagnostic codes.



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ller’s Console Map

For a larger drawing, see “Driller’s Console” on page 57.

Pressure GaugesVarious Functions Engine & Wiggle Steer

Operations

DD1M9716-Control Panel



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achine Controls

ressure Gauges

1. Top Clamp Pressure Gauge2. Carriage Pressure Gauge3. Wrench Clamps Pressure Gauge

4. Wrench Makeup Pressure Gauge5. Rotary Pressure Gauge

Control Function

. Top Clamp Pressure • Increase pressure: rotate control right• Decrease pressure: rotate control left

. Carriage Pressure - Thrust • Increase pressure: rotate control right• Decrease pressure: rotate control left

. Carriage Pressure - Pullback • Increase pressure: rotate control right• Decrease pressure: rotate control left

1 2 3 4 5

6 7 8 9 10 11 12 13


. Wrench Clamps Pressure - rench

• Increase pressure: rotate control right• Decrease pressure: rotate control left

0. Wrench Camps Pressure - ixed

• Increase pressure: rotate control right• Decrease pressure: rotate control left

1. Makeup Pressure • Increase pressure: rotate control right• Decrease pressure: rotate control left

2. Rotary Pressure - Makeup • Increase pressure: rotate control right• Decrease pressure: rotate control left

3. Rotary Pressure - Breakout • Increase pressure: rotate control right• Decrease pressure: rotate control left


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riage/Rotary/Wrench Operations Panel

14. Carriage Speed Select15. Carriage Joystick16. Carriage Brake17. Wrench Speed18. Wrench Joystick19. Power Unit Select20. Signal Alarm21. Upper Pipe Support

22. Lower Pipe Support23. Wrench Clamp24. Fixed Clamp25. Wrench26. Rotary Brake27. Rotary Speed28. Rotary Speed Select29. Rotary Joystick

15

D1M9716 OperationsPanel

14 201617

19 26 2821 22 27

1823 24 25

29



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achine Controls

Control Function

4. Carriage Speed Select • Need maximum pullback force: set control to 1• Need low pullback force: set control to 4

5. Carriage Joystick • Move drill string down (thrust): push joystick away from you• Move drill string up (pullback): pull joystick toward you

6. Carriage Brake Hold the carriage in position during gear changes or transport• Lock brake: rotate control to the right• Unlock brake: rotate control to the left

7. Wrench Speed • Increase speed: rotate control to the right• Decrease speed: rotate control to the left

8. Wrench Joystick • Move wrench down rack: push the joystick away from you• Move wrench up rack: pull the joystick toward you• Move the fixed clamp and the wrench clamp closer together:

move the joystick to the left• Move the fixed clamp and the wrench clamp apart (a maximum

of 12 inches (305mm)): move the joystick to the right

9. Power Unit Select Select which Power Supply Unit controls pressure:• Power Supply Unit A: rotate switch to the left• Power Supply Unit B: rotate switch to the rightRemove key and store in a safe location. See “Appendix C: Dual Power Units and ROOTS” section beginning on page 115.

0. Signal Alarm • Sound an audible alarm to alert workers that the engines are about to be started or drilling is about to commence. Be sure all workers on the job site are aware of the audible alarm and the meaning of the signal.

1. Upper Pipe Support • Raise the pipe support: move the joystick to the left• Lower the pipe support: move the joystick to the right


2. Lower Pipe Support • Raise the pipe support: move the joystick to the left• Lower the pipe support: move the joystick to the right

3. Wrench Clamp Grip/Ungrip • Wrench clamp grip: rotate control to the right• Wrench clamp ungrip: rotate and hold control to the left• Wrench clamp off: move control to center

4. Fixed Clamp Grip/Ungrip • Fixed clamp grip: rotate control to the right• Fixed clamp ungrip: rotate and hold control to the left• Fixed clamp off: move control to center


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Controls

25.

26.

27.

28.

29.

Machine Controls

Wrench Make/Break • Wrench breakout: rotate and hold control to the right to break the pipe joint

• Wrench makeup: rotate and hold control to the left to make the pipe joint

• Wrench off: move control to center

Rotary Brake Prevent the rotary spindle from turning backwards• Lock brake: Rotate control to the right• Unlock brake: Rotate control to the left

Rotary Speed • Select a custom value; Rotary Speed Select control must be set to “vari” for this control to work.

Rotary Speed Select • Maximum motor displacement, maximum torque and speed: select “low” (immediately sets value to zero)

• Select a custom value: select “vari”• Maximum speed, minimum motor displacement, least amount

of torque: select “high” (immediately sets value to 10)

Rotary Joystick • Rotate pipe in makeup (clockwise) direction: push joystick away from you

• Rotate pipe in breakout (counterclockwise) direction: pull the joystick toward you



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ngine/Wiggle Steer® Panel

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32

33

34

35

36

37

31

30

Power Unit A

Power Unit B Power Unit A

Power Unit B


30. Wiggle Steer® Control31. Rotary RPM Meter32. Throttle33. Engine Start

34. Engine Stop35. Drill Controls - Stop36. Drill Controls - Start37. Status Light Panel


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Controls

30.

31.

32.

33.

34.

35.

36.

37.

Machine Controls

Control Function

Wiggle Steer® Control • Use Wiggle Steer in Auto mode: Rotate control right• Use Wiggle Steer in Manual mode: Rotate control left• Turn off Wiggle Steer: Rotate control to center

Rotary RPM Meter To use the meter to set up Wiggle Steer, see “Appendix B: Wiggle Steer and Wiggle Steer Codes” section beginning on page 113.

Throttle • Increase engine speed: push control away from you• Decrease engine speed: pull control toward you

Engine Start Start the engine of the corresponding Power Supply Unit• Remotely start the engine: push button

Engine Stop Stop the engine of the corresponding Power Supply Unit• Stop the drill and the engine: push button• Enable engine start: button must be pulled out

Drill Controls - Stop • Stop electrical power to the Driller’s Console: push button• Enable drilling: button must be pulled out

Drill Controls - Start • Bring power to the control panel and the drill rig: push button

Status Light Panel Status of the item in the corresponding Power Supply Unit• Filter light on: flow through filter reduced; filter may be clogged• Hydraulic oil light on: oil level low; check and fill• Fuel light on: fuel level low; check and fill• Verify all lights are working: toggle switch to testLights are:

• Rotary Filter 1• Rotary Filter 2• Carriage Filter 1• Carriage Filter 2• Charge Filter


• Return Filter• Hydraulic Oil Level• Fuel Level• Spare (unused light)


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arious Functions Panel

38. Drilling Mud Pressure Gauge39. Guide Bushing40. Top Clamp

43. Auxiliary/Trash Pump - Control44. Drilling Mud - Blowdown Signal Lights45. Drilling Mud Blowdown

DD

1M97

16 V

ario

us

38

39

41

40

43

45

42

44


41. Caterpillar Messenger for Engine A and B (if so equipped)

42. Auxiliary/Trash Pump - Speed


Page

Controls

Car

The

38.

39.

40.

41.En

42.

43.

44.Lig

45.

Machine Controls

riage Position Meter (Optional)On machines equipped with this option, transducers are installed at various points along the carriage. position (in feet) of the carriage is reported on a digital readout located on top of the Driller’s Console.

Control Function

Drilling Mud Pressure Gauge • Displays mud pressure

Guide Bushing • Lower the bushing: move the joystick to the left• Raise the bushing: move the joystick to the right

Top Clamp • Move the top clamp down the thrust frame: push the joystick away from you

• Move the top clamp up the thrust frame: pull the joystick toward you

• Ungrip the top clamp: move the joystick to the left• Grip the top clamp: move the joystick to the right

Caterpillar Messenger for gine A and B

Allow the operator to monitor engine information while the engine is operating (if so equipped)

Auxiliary/Trash Pump Speed Set the limit of the maximum current sent to the auxiliary device. For example, when the value is 30%, the auxiliary device will receive 30% of the maximum current possible.

Auxiliary/Trash Pump Control • Turn Auxiliary Connections On: turn control to ON position• Turn Auxiliary Connections Off: turn control to OFF position

Drilling Mud - Blowdown Signal hts

Mud supply is divided into two hoses for maximum capacity and flexibility. When light is lit, it confirms that blowdown in both hoses is closed or open.

Drilling Mud - Blowdown • Relieve mud pressure in the drill string: turn and hold control to Open

• Stop mud pressure relief: turn and hold control to Close



Driller’s Console

DD-1100 RST Operators ManualControls


NO

Notes

TES:

DD-1100 RST Operators Manual Controls

DD-1100 RST Operators Manual Operations

Preparation

OperationsSite Preparation

The DD-1100 RST can operate on surfaces with a maximum lateral slope of 3° and a slope in the run-ning direction up to 5°.

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 dangerous 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.

Site Layout

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.

Dumpster

Mud SystemCrane


Typical Site Layout

Drill Pipe

Drill Rig

Cabin or Console

Power Supply Unit

Pit

Bore Path


Page

Operations

Cra

ply U

Ma

necematsDD-1

Pro

tectethe cplac

Sdamcabl

Ma

Cre

tracksolemark

muda cra

IMP• U

i• T• W

t• I

Preparation

nes

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

ts and Cribbing

When drilling on soft soil, during a long term setup or during periods of freezing and thawing, it may be ssary to set the drill on mats or cribbing to prevent the machine from settling into the ground. Suitable may be available for rent or lease. Consult a civil engineer for guidance. The weight of the 100 RST is provided in the “Specifications” section beginning on page 107.

tection of Wires, Cables and Hoses

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

es where cables and hoses could be damaged.

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

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.

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.hen connecting screw together couplings, the ball valve must be open. Ball valves in the wrong posi-

ion can cause extreme damage to the Power Supply Units.f it is necessary to disconnect the wrench, unplug the wrench umbilical (electrical) cable at the cabin.


• See “Cleaning Hydraulic Connections” on page 90 and “Cleaning Electrical Connections” on page 90 for information on proper cleaning techniques.

wOperation of this machine requires at least two people: the machine operator (or driller) and the drill ing equipment operator (or drill locator). The driller operates the DD-1100 RST from the Driller’s Con-

which may be located inside a Driller’s Cabin. The drill locator uses the electronic drill tracking system to the location of the drill head along the bore path.

Additional personnel include a crane operator, pipe handlers, steering specialist, excavator operator, plant operator and general labor. Exit side personnel might include a certified welder, pipe handlers and ne operator.


P

Operations

Th

limgronebepip

G

cutio

linmo

of sy

proTa

M

A of inctor

turmaish

ZA

reparation

e Bore Path

Numerous factors must be considered when planning the bore path: machine location, entry angle, bend its of the drill pipe, bend and tension limits of the pullback material, pipe length and location of under-und utilities. Planning the bore path is outside the scope of this manual. Consult a knowledgeable engi-

er for assistance. Ensure that the bore path and the location of all utilities are clearly marked on the jobsite fore beginning operations. When drilling, avoid extreme steering corrections. Drill the first and second drill e straight. Consult drill pipe manufacturers for recommended bend radius.

uidance System

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

There are 3 types of guidance systems. Wireless walkover, wire line, and wire line magnetic. The wire e magnetic type is most commonly used for longer deeper bores because they are more capable and re accurate than the other types.

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

Before beginning the bore, ensure that the guidance system has fresh batteries and has been tested and perly calibrated. Check the location of the drill head frequently to ensure that the bore remains on course.

ke care not to exceed the bend radius of the pipe as this will cause damage or breakage.

ud Recycling SystemDrilling 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

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

deviWhepow“Res

retes

usinZAP

es!

tion,on thDD-1

TThisers athe s

efor cgenc

Cin At

PreparationThe DD-1100 RST is equipped with the ZAPALERT detection device. ZAPALERT is an electric sensing ce used on equipment which has a high likelihood of striking an underground energized power line. n drill pipe comes in direct contact with a power line, it becomes charged to the same voltage as the er line. An audible and visual alarm is triggered. Crew members should follow procedures described in ponse to Electrical Strike” on page 23when the an alarm is given.

When utility authorities have verified that the drill and associated equipment are no longer energized, t 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 g the system. Test the system before beginning the drilling project. After a successful test, install the ALERT system ground stake into the ground.

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 100 RST 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 Exit Side Lockout System is not intended as a substitute for safety procedures or a replacement

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.


lear communication between the exit side crew and the machine operator. It is not intended as an emer-y shutdown device.

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


Set Up

Set Up the Machine

1. Position the front foot and rear foot directly in-line with the planned bore at the proper setback location. Follow the site plan (see drawing below, not to scale) for the proper spacing between the front and rear foot. The lifting legs travel on the rear foot plate as the thrust frame is raised. The plate must be posi-tioned so the lifting legs remain on the plate at all times.

Lowering the front foot and rear 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.

• Secure the machine after raising with support struts and locking devices before operating or performing maintenance tasks.

Pinch point. Moving parts. Keep body and clothing away.

Center Line of Planned BoreCenter Line of Dolly Axle

1


2. Attach the cables provided between the front and rear foot.3. Back the rig over the rear foot to the front foot. Keep the rig aligned with the planned bore.4. The center-line of the axle closest to the front foot is exactly 7 feet (2.1m) away from the foot. This will

help guide the thrust frame into the front foot.

38.5 ft (11.73 m)Front Foot

Rear Foot

12 ft 4 inches (3.76 m)

7 ft (2.1 m)

5 ft 3.5 inches (1.61 m)

4.5 feet (4.42 m)

10 feet (3.05 m)


Page

Operations

5.

6.

7.

8.

9.

Re

Set Up

Disconnect the plug and remove the tail light bumper.Remove the radio remote transmitter from the storage box.Start the auxiliary power unit using the Key Igni-tion Switch on the Setup Box.Remove the lifting leg pins on both sides of the

50dd2100D-setupview

Auxiliary Power Unit

Setup Box

Front Foot

Cross Bracing

Dolly

Dolly Anchor Pin

Lift Cylinder

Lifting Legs

Dolly Landing GearSupport Strut

ar Foot

50dd10002-dxf-RIG

Cable


trailer.Using the radio remote transmitter, lower the lifting legs onto the rear foot.

Lifting Leg Pin DSCF6553-liftinglegpin


S

Operations

1

11

1

1

111

11

et Up

0. Remove the anchor pins from the dolly on both sides of the trailer (see drawing).

1. Set the tractor brakes.2. Check the Carriage Position Indicator light on the

Setup Box. The light should not be lit. This indi-cates that the carriage is in position and ready for setup. (If the light is lit, the carriage is not in posi-tion to begin the setup process. Do not continue setting up the machine until you move the carriage to the proper position and the light goes out.)

3. Slowly move the dolly to the setup position using the joystick on the Radio Remote Receiver. Keep hoses and cables clear of the moving dolly.

4. Install the anchor pins to secure the dolly in the setup position (see drawing showing pin location on underside of rig trailer).

5. Lower the dolly landing gear. 6. Dump the air in the dolly air bags.7. Disconnect the tractor and pull away.

50dd10001-dollyposn1

Anchor Pins

50dd10001-dollyposn2

Anchor Pins


8. Lower the walkways.9. Install the handrails. Secure them to the walk-

ways.


Page

Operations

27. 28.

20.

21.

22.23.24.

25.26.

Set Up

Raise the rig using the joystick on the radio remote transmitter.

Make small adjustments using the right and left cylinder controls to guide the thrust frame into the cradle on the front foot.

Swing the securing arms over the tube. Install the pins and secure with clips. Raise the rig to the desired angle for drilling. Maxi-mum drilling angle is 18°.

Pin the struts. Relieve the pressure in the lifting leg cylinders transferring the weight to the struts.


Secure the rig to the rear foot with cross bracing.Remove the hoses from their transport position on top of the thrust frame.


S

Operations

2

3

3

et Up

9. Unfasten the wrench hose carrier from the car-riage. Photo on the right shows the hose carrier fastened to the carriage in transport position.

0. Carefully uncoil the hose carrier. Lay it flat, extending off the end of the rig past the guide bushing.

1. Using appropriate lifting equipment, lift the wrench and lower it into position on the thrust frame.



Page

Operations

37. 38. 39. 40.

32.

33.

34.

35.

36.

possec

Set Up

Move the power units and driller’s cabin into position.Position the mud system and connect it to the rig.Connect the two mud hoses between the rear swivel and the carriage mud supply lines.Lower the hose support on the power unit facing the rig (see drawing below).

When the wrench is in position on the thrust frame, lower the hook pads.

Insert the pins to secure the hookpads.

“Roll” end of the hose carrier back and attach it to the wrench.

Make the hydraulic and electrical connections from the hose carrier to the fittings on the wrench.

Attach the guide bushing if it was removed for transport.

Photo on right shows the hose carrier in operating ition. Hook pads have been folded down and ured with pins. Guide bushing is in place.

hookpads hose carrier attachment point


Hose Support

50dd

1430

C-h

ose

conn

ectio

ns Hose Connections


S

Operations

41

42

43

4445

4647484950515253

A

uspro

Sh

stesid

foo

et Up. Connect the cables and hydraulic lines to the power units, thrust frame and cabin. Refer to “Protection of

Wires, Cables and Hoses” on page 60 and “Making Power Connections” on page 60.. Disconnect the case drain line on the drill rig from the expansion tank and connect it to the power supply

unit.. Set the hydraulic valves in the correct position for the power configuration you plan to use (See “Appen-

dix C: Dual Power Units and ROOTS” section beginning on page 115). Connect all components on the drill site with a bonding cable and install a ground stake.. Test the ZAPALERT system (Refer to Attachment 3, “ZAPALERT™ Electric Shock Alarm Instruction

Sheet” for complete information).. After completing a successful test, install the ZAPALERT ground stake.. Verify that all protective guards are in place.. Check all fluid levels and replenish if necessary.. Perform a final walk-around. Inspect all connections.. Start the power units (See “Starting the DD-1100 RST” on page 72).. Check the function of all controls.. Check all emergency stop and disable buttons.. Cycle all equipment several times.

nchor the MachineDepending 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.

50dd2100D-setupview-piling


Entry PitChain or Cable

Steel I-BeamSheet Piling


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.

50dd2100D-setupview-concrete

50dd2100D-setupview-stakes



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-1100 RST Operators ManualOperations

Starting the DD-1100 RST

Starting the DD-1100 RST

A manufacturer's manual for the diesel engine is supplied with the DD-1100 RST. The following instruc-tions cover general engine starting procedures. Consult the manufacturer’s manual for detailed starting and stopping 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 the emergency stop buttons on the Driller’s Console and in the Power Supply Units. 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. Insert the key in the Engine Control Panel.9. Turn the key and hold it in the START position for about 5 seconds while the warning alarm sounds. This

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.


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. Alternatively, you may start the engine from the Driller’s Console.

• On the engine panel, turn the ignition key (2) to the right to enable start. • At the Driller’s Console, push the Engine Start button on the Engine console.


S

Operations

hyfrabeda

tarting the DD-1100 RSTLet 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.



Operating the DD-1100 RST

Test the Indicators, Emergency Stop Buttons and all ControlsIf you have not already done so, verify that all gauges on the instrument panel are in working order. Test

all Emergency Stop buttons, disable switches and all controls

Attach the Drilling Fluid Supply ConnectionsConnect the mud mixing equipment (sold separately) hoses to the directional drill. Mix the drilling fluid

before starting the bore.

Power Wrench Operation

The power wrench is made up of two individual wrenches - the wrench clamp and fixed clamp (see the photo below). The fixed clamp is used to clamp and hold; the wrench clamp is used to clamp and rotate the tool. The wrench is used to makeup and breakout the drill string.

Adjust the wrench makeup pressure to limit the force applied when making up a tool joint to prevent damage to the pipe threads. The maximum torque is provided by the drill pipe supplier. Refer to “Appendix D: Tables Converting Pressure to Torque and Force” section beginning on page 117 for charts that can be used as a guide to convert the force displayed on the Wrench Clamp Pressure gauge to torque.

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

Wrench Clamp Fixed Clamp


Wre

nche

s-a

Direction of Bore


O

Operations

C

Th

Dibe

C

forfor

U

muthetio

cu

perating the DD-1100 RST

hecks During Operation

rust and Pullback Force ControlsThe maximum thrust and pullback force can be set with the Carriage Pressure controls on the Operator’s

splay. This can prevent applying too much force and damaging the down hole tooling and the product ing installed. It can also help the drill operator regulate the rate of advance of the cutter head.

onverting Gauge Pressure to Torque and Force

Refer to “Appendix D: Tables Converting Pressure to Torque and Force” section beginning on page 117 charts that can be used as a guide to convert hydraulic gauge pressure readings to thrust and pullback ce and rotary torque.

sing a Mud Motor

Follow the manufacturer’s instructions with respect to installation and operation of the mud motor. The d motor normally requires the use of a non-magnetic pipe section which fits between the mud motor and first section of drill pipe. The locating sonde or other instrument is located inside this non-magnetic sec-

n.

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

Cutting BitPower Section Transmission Section


The use of a mud motor normally requires excavation of a pit in front of the drill. The pit should allow the tting bit to enter the far vertical wall of the pit. Mud motors vary in design.


Page

Operations

Fun

Mak

1. Cd

2. 3. 4.

5.

IMP• H

r• P

d• A

p• A

f

NOclaclawh


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 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 drill drive spindle at the rear of the drill frame before loading drill pipe into the directional rill.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, drill until the carriage is within a few inches of the wrench


e Up a New Pipe Joint

lamp the upper shoulder of the joint (made up of the pipe already in the ground and the drill drive spin-le) in the top clamp.

Clamp the pipe body with the fixed clamp.Break the joint with the rotary.Unclamp the top clamp. Unscrew and slowly back the carriage up until the spindle pin clears the pipe box.Apply joint compound to the spindle pin.

mp. Do not hit the wrench clamp. Then bring the pipe back until the pipe collar clears the wrench mp by about 5 inches (127 mm). This will reduce the risk of clogging the jets and allows fluid passage en drilling is resumed.


O

Operations

6. 7. 8. 9. 1011121314

1516

Tu

eqtraIt iall

temuarat

1. 2. 3.

4. 5.

perating the DD-1100 RSTMove the carriage to the rear of the drill frame.Raise the pipe supports.Using a crane and pipe tongs, lift one section of pipe from storage and place it onto 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 clamp.. Lower the pipe supports.. Resume drilling.

rn on the Drilling Fluid

Have an adequate supply of drilling fluid (mud) ready. Check that the supply hose from the mud mixing uipment is securely connected to the directional drill. Follow the manufacturer’s instructions to operate the nsfer pump on the mud mixing equipment to ensure an adequate supply of drilling fluid to the mud pump. s normal for drilling fluid to escape from the cutting head even if the mud pump is not operating. Do not ow the mud pump to run dry as it will damage the pump.

While the DD-1100 RST engine is warming, start the mud system (sold separately) and allow that sys-’s engine to warm up. The procedure below is a general guide. Consult the Mud System Operator’s Man-

l and information from the drilling mud supplier for specific operating procedures and desired mud flow es.

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.


When you are ready to begin drilling:

Supercharge the mud pump with an external supply to 30 psi (2.1 bar).Fill the pipe with mud before drilling.Allow the pressure to build up. Approximately 200 to 300 psi (14-21 bar) is required while drilling the pilot bore.Monitor the mud flow rate by viewing it on the Mud System Console.Set the desired flow of drilling fluid.


Page

Operations

Ma

1.

2. M

3. 4. 5.

IMP• O

m• K

a• S

i• E• S

fr


ke the Pilot Bore

Rotate in the makeup direction momentarily and release the joystick so that the blade is at the 6 o’clock position.

ove the rotary drill carriage forward and push the drill head slowly into the ground, keeping the drill pipe as straight as possible.

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.

ORTANT:nly rotate the drill CLOCKWISE; NEVER COUNTERCLOCKWISE while drilling or backreaming. You ay unthread the drill pipe in the bore and you will not be able to retrieve them.eep the first drill pipe straight. This will eliminate side pressure on the drill pipes. Use thrust to dvance the pipe. DO NOT make a steering correction until the second pipe is connected.top work if the machine is vibrating. This is an indication of incorrect operation, for example advanc-

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

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


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 carriage is within a few inches of the wrench clamp. Do not hit the wrench clamp. Then see “Make Up a New Pipe Joint” on page 76.


O

Operations

E

thabe

1.

2. 3.

4.

5. 6.

perating the DD-1100 RST

nd of Pilot Bore Drilling

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

nd 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.

Drill String Blade Reamer Pullback Swivel Utility Product Pipe

Pullback Eye Product Coupler


P

Operations

7. 8. 9. 10111213

Re

1.

2.

3. 4. 5. 6. 7.

8. 9. 10111213141516171819

IM••

•

•

ullback OperationsTurn on the engine.Activate the mud system to ensure that the reamer jets are open.Reset 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.

moving Drill Pipe During Pullback or Backreaming

Pullback with the joystick and backream until the pipe collar to be removed has cleared the wrench by about 5 inches (127 mm).Stop the pullback and thrust the pipe forward until the joint is between the fixed clamp and wrench clamp. 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. Do not unscrew.Unclamp the wrench clamp. Unclamp the fixed clamp.Pull the drill string back with the carriage until the drill collar of the pipe still in the ground clears the wrench clamp.Clamp the pipe body in the fixed clamp.Raise the pipe supports.

PORTANT: Clamp the fixed clamp first. Then clamp the wrench clamp. Before breaking out the pipe joint, verify that the upper shoulder of the pipe section still in the ground is

FULLY CLAMPED in the fixed clamp. The wrench clamp applies COUNTERCLOCKWISE rotary torque, which could loosen the joint threads of the pipe sections still in the ground.

High speed unthreading of drill pipe joints is not recommended. Damage to drill pipe or drive unit will result.

Apply thread joint compound to the drill drive spindle pin and drill pipe pin each time they are con-nected to another pipe.


. Slowly unscrew the pipe and pullback with the carriage until the pin just clears the box.. Move the top clamp to the pipe collar.. Clamp the top clamp.. Break the joint at the spindle.. Unscrew the carriage spindle all the way.. Unclamp the top clamp.. Pull the carriage all the way back.. Remove the drill pipe.. Lower the pipe supports.. Follow steps in “Engage the Next Pipe to be Removed” on page 82.


Page

Operations

Eng

1. 2. 3. S

r4. 5.

Pullback Operations

age the Next Pipe to be Removed

Thrust the carriage. Stop the carriage spindle pin just before it reaches the pipe box.Apply thread joint compound to the carriage spindle pin.

lowly thrust the carriage until the carriage spindle pin engages the box of the next pipe section to be emoved.

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 and remove key. 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.

brt

3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

c15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

r26. 27. 28. 29. 30.

om

31. 32. 33. 34.

35.

Pullback Operations

Down

Set the engine RPM to 1500.Move the carriage to the transport position. The Carriage Position Indicator light on the Set Up Box will

e illuminated until the carriage reaches the transport position. Then the light will go out. Do not continue ig down steps until the light goes out. The auxiliary power unit will not start if the carriage is not in the ransport position.Turn off the engines and release pressure. Remove the two mud hoses between the rear swivel and the carriage mud supply lines. Disconnect the cables and hoses from the wrench.Remove the locking pins from the clamps that secure the wrench to the thrust frame.Swing the clamps open and secure them in this position by installing the locking pins.Disconnect the hose carrier from the bracket on the front of the wrench assembly.Install caps on hoses, fittings, and cables to prevent contamination. Using nylon lifting slings instead of chains, remove the wrench from the thrust frame.Transport the wrench separately.Attach the wrench hose carrier transport support.Attach the wrench hose carrier to the carriage.Disconnect all hoses and cables between the Driller’s Console, Power Supply Units and the rig. Install aps on hoses, fittings and cables to prevent contamination.

Remove the rear foot cross bracing.Disconnect the front foot from the thrust frame.Remove the handrails and store them.Fold the walkway toward the thrust frame and secure it with nylon straps.Coil the mud hoses on the rig deck. Secure them with nylon straps.Wash mud, drilling fluid and soil off the machine.Remove and stow the ZAPALERT ground stake.Remove all tools and loose objects from the area and put them into storage.Start the auxiliary power unit.Raise the thrust frame slightly and remove the pins from the struts.Lower the thrust frame and hookup to the tractor. Note: If the rig is equipped with a wireline stairway, emove the hitch pins and carefully lower the rig checking that the stairway does not dig in.


Air up the trailer brakes and air bags.Raise the dolly landing gear.Unpin the dolly from the setup position.Set the tractor brakes.Slowly move the dolly to the transport position using the radio remove. Keep the hoses and cables clear f the dolly. The dolly must be in the transport position to properly support the weight of the rig when it is oved. Pin the dolly in the transport position.

Raise the lifting legs and secure with the transport pins.Shutdown the auxiliary power unit and store the radio remove.Move the rig from the site.Remove the tie down stakes from the front foot. Do not attempt to remove the tie down stakes by raising the front foot with the machine. Load the front foot and rear foot for transport.


Operating in Different Climates

Operating in Hot WeatherTo 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. Check

the collection bowl at the bottom of the fuel-water separator near the fuel system on the engine. Drain water from the collection bowl using the drain valve at the bottom of the bowl.

• 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 all mud line joints and drain the mud line system after every bore and when the machine is not in use.


Page

Operations

Eng

HeaBlockeep

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and

Eng

of thsupp

Operating in Different Climates

ine Block Heater

The DD-1100 RST engine comes with an Engine Block Heater. Plug the power cord of the Engine Block ter into an external power source to warm up the engine coolant before starting the engine. The Engine k Heater may also remain plugged in for extended periods of time during extremely cold temperatures to 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 hours before starting the engine. This time period may vary depending on ambient weather conditions wind situations, for example). When overnight air temperatures approach -40°F (-40°C), heating may quired continually when the engine is not running. Do not operate the preheater for more than three (3) tes after the engine starts.

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

ine Preheating Devices

When working in cold temperatures, it is necessary to use a preheating device to keep the temperature e oil in the diesel engine warm when the machine is turned off. Plug the preheating device to an electric ly rated at 1 kW at 110/220V 50/60 Hz single phase.

Pre-heating devices operate on high-voltage (110 volts or 220 volts AC). Connect to a circuit equipped with a ground fault interrupter (GFI). Protect the electric cables from contact with water or other liquids.


DD-1100 RST Operators Manual Storage and Transport

Machine Storage and Transport

Storage and TransportMinimum Storage Space Required

Consult the “Specifications” section beginning on page 107 for the dimensions and weight of the DD-1100 RST to establish storage space requirements. The surface must be firm enough to support the weight of the machine and prevent sinking.

Storage Site ConditionsIf 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” section beginning on page 89.2. 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

be paccosible

Lift

remolinescom

Machine Storage and Transport

nsportation

The machine must be transported in accordance with local laws and regulations. All components must roperly secured on the rig. If the rig exceeds the overall dimensions allowed, they must be flagged rding to the highway laws of the countries or states involved in the transport. The transporter is respon- for using the proper method of transport and following all other applicable regulations.

ing the Machine

Use spreader bars to ensure that lifting lines do not come in contact with the drill. It may be necessary to ve the wrench assembly prior to lifting the machine. When lifting the Power Supply Unit, secure the load to the lifting points at the ends of the frame. Use spreader bars to ensure that the lifting lines do not e in contact with the power unit.

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.

• Refer to “Rig Down” on page 84 for step-by-step procedures to properly prepare the rig for transport.

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.

Use Caution: Load may not be evenly balanced


Secure all 4 corners

Maxi Rig Lifting-1

DD-1100 RST 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.

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 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.

Cleaning

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 key from the Engine Start switch. Install a lock on the Battery switch if the machine is so equipped. Use proper lockout and tagout procedures before working on the machine.

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


General Cleaning

Clean all the marking plates as well as all lighting devices. Do not direct water spray inside the muffler or the air filter, against electric components and control panels or on caps and open tanks. Do not use acid or abrasive solutions. Keep caps and covers for hydraulic connections clean. Contamination of hydraulic oil will negatively impact performance of your DD-1100 RST.


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Maintenance

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General Maintenanceaning 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 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.

lding

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

ORTANT:urn off engine.isconnect all electrical connections before welding. It is particularly important to disconnect the nega-

ive battery cable from the battery.lamp the ground cable for the welder to the component that will be welded as close as possible to the eld.o not use electrical components to ground the welder.o not weld near the tanks and flammable liquids.ailure to follow welding procedure can cause damage to electric and mechanical components. Dam-ge to components due to improper procedures is not covered under warranty.



G

Maintenance

D

Masc

A

theity

eneral Maintenance

iesel Engine Maintenance

Engine maintenance items are outside the scope of this manual. Consult Attachment 1: Diesel Engine nual for recommended engine fluids (gasoline, engine oil, antifreeze) and inspection and maintenance

hedules. Your engine may have specific requirements related to its emission systems.

pproved Replacement Fluids

When adding or replacing fluids, use the same fluid that is in the system. Avoid mixing different fluids as y may be incompatible. Use the fluid in the table below or contact the factory for advice on the compatibil-

of a new fluid with the one in service.

Approved Replacement Fluids(Ambient temperature 5°F to 110°F [-15°C to 43°C])

Consult factory for specifications at temperatures outside this temperature range.

Carriage Drive Shell Spirax S6 AXME 80W-140 AA Specification 102

Grease Points Shell Gadus S3 V460D 2 AA Specification 301

Hydraulic Oil Shell TellusS2 V46 AA Specification 202

Mud Swivel Grease Shell Gadus S3 V460D 2 AA Specification 301

Pump Drive Shell Spirax S6 AXME 80W-140 AA Specification 102

Rotary Gearbox Shell Spirax S6 AXME 80W-140 AA Specification 102

Slip Sub Grease Jet Lube Kopr Kote AA Specification 302


DD-1100 RST Operators ManualMaintenance

Scheduled Maintenance

DD-1100 RST Maintenance ScheduleAfter 10 100 250 500

Function each job hours 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, Fitting, Cylinders X XLubricate Grease Fittings X

Inspect Power Wrench Jaw Teeth X XInspect Rotary Drive Spindle Saver Sub X

Change Hydraulic Pump Drive Oil X* XCheck Battery Water Level X

Check and Clean Breather Devices XChange Hydraulic and Charge Pressure Filters X**

Change Oil in All Gearboxes XTest Hydraulic Oil X

Drain and Flush Mud Hoses and Swivel X

NOTES:Do not exceed the indicated number of hours without performing the required maintenance* After first 100 hours; then after every 500 hours.** Unless filter indicator shows change required at a more frequent interval



S

Maintenance

10

Cy

Ma

En

wipre

En

anfill

En

low

En

madefilt

IMiz

IM••

cheduled Maintenance

Hour Inspection and Maintenance

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

cle Emergency Stop (Disable) Buttons

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

gine: Check Fuel Level

Begin each shift with a full tank of fuel. To prevent dirt and water from reaching the injection parts which ll cause damage and decrease performance, use clean fuel and service the fuel filter at regular intervals as scribed in Attachment 1: Diesel Engine Manual.

gine: Check Coolant Level

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

gine: Check Engine Oil Level

Hot coolant can spray out and cause serious injury. Do not 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.

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

PORTANT:


Check that the engine oil is at the proper level and that there is no contamination. Add oil if the 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. In extremely dusty conditions, increase the frequency of engine air filter maintenance.

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.


Page

Maintenance

Che

ing t

Che

Gen

NO

1. 2. 3.

4.

IMP

Scheduled Maintenanceck 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-o the effect of temperature (hot oil increases in volume) and the position of the hydraulic cylinders.

ck Oil in All Gearboxes

• Inspect the hydraulic pump gearbox, the rotary drive gearbox and the carriage planetary gearbox for leaks. In the case of a small loss, fill the gearbox to the correct level.

• After unscrewing a level plug, a small quantity of oil will escape. As soon as this happens, inspect the oil in order to verify that there is no contamination. If the oil looks dirty or smells burnt, drain the oil and replace it with fresh fluid. If no problems are detected, change the oil as prescribed on the mainte-nance schedule.

• For Carriage Planetary Gearbox, see page 103.• For Hydraulic Pump Drive Gearbox, see page 103.• For Rotary Drive Gearbox, see page 104.

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

The power unit should be on a flat, level surface. Retract all cylinders. Check the level in the tank using the transparent gauge mounted in it.

• If the oil level is too low, add oil to level indi-cated on the gauge.

• DO NOT overfill the reservoir.After refilling, lock the tank cap.

ORTANT: Check oil level when the gearbox is cold.

Hydraulic Tank Gauge


eral Inspections

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.


S

Maintenance

fluRe

rodse

Re

Lu

thepe

Nfi


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.

bricate Grease Fittings

Grease points must be lubricated daily. Two grease pumps are enough unless otherwise specified. Use

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.

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.


grease type specified in the Approved Replacement Fluids table. When working in very high or low tem-ratures, consult the factory. The drawings below show the location of the grease fittings.


Page

Maintenance

Grea


50dd10002-dxf-RIG

Guide to Grease Fitting Location Drawings

Top Clamp

Carriage

Pipe Support

Wrench

Guide Bushing

Lifting Legs

Underside of Carriage


se Points on Carriage


S

Maintenance

Gr

Gr


ease Points on Top Clamp

Both Sides of Top Clamp

On All Three Sides of Top Clamp

50dd

6104

-Top

Wre

nchG

reas

e1

50dd

6104

-Top

Wre

nchG

reas

e2

50dd6105-TopWrenchRails

Apply Grease to Grease Points on Both Pipe Supports

ase


ease Points on Both Pipe Supports

Underside of Cylinder

50dd

2115

-Rod

Sup

portG

re


Page

Maintenance

Grea

Grea


se Points on Wrench

se Points on Guide Bushing

50dd

2115

-Rod

Sup

portG

reas

e

Apply Grease to Grease Points on All Three Sides of Wrench

Grease Point on Both Sides of Guide Bushing

50dd

2115

-Gui

deB

ushi

ng G

reas

e



S

Maintenance

Gr


ease Points on Lifting Legs

50D

D10

001-

Lifti

ngLe

g



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Maintenance

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connsave

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Tthe w

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ot

5. 6. 7. 8. 9.

t

Insta

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2. 3. 4. 5. U

IMP• U

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D

Scheduled Maintenanceriage: Inspect Spindle Saver Sub

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

ove a Damaged Saver Sub

he saver sub is threaded onto the end of the side entry sub. It is removed from the side entry sub using renches. 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 rench.

Clamp the shoulder of the saver sub in the fixed wrench.lamp the drill drive spindle shoulder (ABOVE the saver sub joint) in the rotating wrench.

Carefully apply heat (approximately 600° F (315° C)) to melt the thread locking compound in the threads f the joint between the drill drive spindle (external threads) and the damaged saver sub (internal hreads).

Breakout until the threads of the side entry sub are completely unthreaded from the damaged saver sub.Ungrip the damaged saver sub from the fixed wrench.Lift the damaged saver sub from the fixed wrench jaws. Set it aside. Clean the threads on the side entry sub.Lower a new saver sub in its place. Keep the plastic protector on the external threaded portion to protect he new threads from damage.

ll a New Saver Sub

Apply thread locking compound to the threads of the side entry sub. Manually thread the replacement aver sub onto the threads of the drill drive spindle. Stop when the joint is hand tight.

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, drill drive spindle or saver sub threads is not recommended. amage to drill drive unit, spindle threads or save sub threads will result.


Grip the shoulder of the new saver sub in the fixed wrench.Makeup to fully tighten the new saver sub to the side entry sub.Ungrip the saver sub from the fixed wrench.

ngrip the drill drive spindle shoulder from the rotating wrench.


S

Maintenance

A

Ch


fter First 100 Hours of Operation

ange Hydraulic Pump Drive Oil

• Remove the drain plug in the bottom of the hydraulic pump drive. • Catch the oil in a suitable container. • Dispose of the oil according to local regulations. • Replace the drain plug. • Fill with suitable oil until oil reaches the proper level on the dipstick.



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Maintenance

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• T


Hour Inspection and Maintenance

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.

heck the battery cables and verify that there are no abrasions or indentations; if necessary, replace the

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.


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.

ather Devices

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


S

Maintenance

50

Ch

eleHy

1. 2. 3. 4.

5. 6. 7. 8.

Ch

rec

Ch

po

IM

IM


0 Hour Inspection and Maintenance

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

ange Hydraulic and Charge Pressure Filter Elements

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

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

ange Hydraulic Pump Drive Gearbox Oil

To check the oil level in the pump drive, use the dipstick (rod) accessible from the engine door. The cor-t level is between the two lines marked on the rod.

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.

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


• 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.

• For filling, use the elbows where breather pipe is positioned. • Remove the breather pipes.• Fill with suitable oil until the oil reaches the proper level on the dipstick.

ange 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-se of old oil according to local regulations.

PORTANT: Check carriage planetary gearbox oil level when the gearbox is cold.


Page

Maintenance

Cha

1. R2.

t3. 4. F5. I

Tes

bottlfied Follo

IMP

NO

Scheduled MaintenanceFill with suitable oil until the oil reaches the midpoint of the sight glass.

nge Rotary Drive Gearbox Oil

emove the fill/level plug.Remove the drain plug and drain the oil. Catch the oil in a suitable container. Dispose of old oil according o local regulations.

Insert and tighten the drain plug.ill drill drive to proper level with gear oil.

nsert and tighten the fill plug.

t Hydraulic Oil

After 500 operating hours, obtain a sample of hydraulic oil from the hydraulic tank. Use the inspection es provided by American Augers. Send the samples to American Augers for analysis. You will be noti-if it is necessary to change the hydraulic oil. When changing the oil, the filters must also be changed. w instructions in “Change Hydraulic Reservoir Oil” on page 105.

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

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

Rotary drive gearbox fill plug



S

Maintenance

Ch

anav

1. 2. 3. 4. 5. 6. 7. 8.

9. 1011

12

13141516

cheduled Maintenanceange 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.

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

Replacement Fluids” on page 91. Do not mix products from different companies due to the possibility of reactions among the oil.

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

. 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.

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.


. Turn off the engine and inspect for leaks.


Notes

NOTES:


DD-1100 RST Operators Manual Specifications

Specifications

SpecificationsMachine Dimensions / Weight

Length (transport): 64 feet 10 inches (19.8 m)Width (transport): 8 feet 1 inch (2.5 m)Height (transport): 11 feet 10 inches (3.6 m)Total Weight (with wrench): 112900 lb (51211 kg)Transport Weight (without wrench): 105040 lb (47746 kg)

Power Supply UnitLength (transport): 19 feet 10.5 inches (6.05 m)Width (transport): 8 feet (2.43 m)Height (transport): 9.5 feet (2.9 m)Transport Weight: 34520 lb (15691 kg)

Power TrainEngine: Caterpillar C-18 Diesel (Tier depends on place of purchase)Rating: 765 HP (570 kW)Fuel Capacity: 650 gallons (2460 liter)Hydraulic capacity: 220 gallons (833 liter)

Drilling UnitDrill Angle: 10° - 18°Wrench Clamp: Triple Jaw Wrenches with 12 inch (305 mm) separationHold Down System: H-Beam Type Front

Rotary DriveRotary System: (4) Pinion and gear drive. Infinitely variable torqueMaximum Rotary Torque: 100000 ft-lbs (135600 Nm)Maximum Rotary Speed: 90 RPMFluid Course: 4 inches (102 mm)


Maximum Flow: Up to 1000 gallons (3785 liters)/minute

Carriage DriveCarriage System: Rack and pinion (6) pinion drive with adjustable force limiterMaximum Thrust/Pullback: 1100000 pounds (500 tonnes)Maximum Carriage Speed: 105 feet (32 m)/minute

Wrench AssemblyWeight: 7900 lbs (3583 kg)


Page

Specifications

Dri

Pro

Co

Specifications

ll Pipe

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

tective Equipment

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

ntrols

Radio Remote Transmitter for setup


DD-1100 RST Operators Manual Appendix

Appendix

Appendix

The appendix contains information that we believe the operator of the DD-1100 RST will find useful to have available for reference during the operation of the DD-1100 RST. The information is placed in the appendix because it is of general interest or it supplements the information in the body of the manual.



Notes

NOTES:


DD-1100 RST 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 6ER30000)

Attachment 3: ZAPALERT™ Electric Shock Alarm Instruction Sheet

Attachment 4: Cervis - Wireless SmaRT™ Engineered System Manual



Notes

NOTES:


DD-1100 RST Operators Manual Appendix B

Appendix B: Wiggle Steer and Wiggle Steer Codes

Appendix BWiggle Steer®

American Augers’ Wiggle Steer® system is a means to rotate and thrust the drill pipe in a back & forth motion to better open the bore path during steering operations. It is recommended when using a mud motor or a jetting head.

The Wiggle Steer system will rotate the drill pipe in the makeup (clockwise) direction while thrusting for-ward. It will then rotate the drill pipe in the breakout (counter-clockwise) direction but will not thrust in the breakout direction. This method reduces the breakout torque and should prevent the drill string tool joints from parting down-hole. The speed of the Wiggle Steer™ rotation and thrust are controlled by the carriage/rotary joystick(s).

Operating Instructions:

1. Stop rotary and thrust functions.2. Set Rotary Makeup to a higher pressure than Rotary Breakout. This will prevent loosening the pipe joint

in breakout direction.3. Rotate the drill pipe to midpoint of the desired direction.

• For steering up, rotate the drill pipe to 12:00 (as seen on a clock face).• For steering to the right, set the drill pipe to 3:00.

4. Use the Wiggle Reset button to reset the counts to zero. Then set the Makeup Counts and Breakout Counts as desired. This sets the number of counts in the clockwise and counter-clockwise direction respectively.


5. Tap the Wiggle Steer button to turn Wiggle Steer On and Off.6. Move Rotary Joystick to desired Makeup rotary speed.7. Move Carriage Joystick in the thrust direction.


Page

Appendix B

Appendix B: Wiggle Steer and Wiggle Steer Codes

STEP PRESS FUNCTION OR MODE COMMENTS

DISPLAYS PULSES FROMROTARY GEAR SENSORS

COUNT MODE NOTICE THE “A” ON THELEFT SIDE

NOTICE THE “R” ON THELEFT SIDE

RATE MODEDISPLAYS ROTARY RPM

RESETS THE COUNT TO “0”

COUNT MODE

MAKEUP DIRECTIONPULSES TO COUNT

SET POINT 1ROTATION IN MAKEUP

DIRECTION

SETS DEGREE OF

BREAKOUT DIRECTIONPULSES TO COUNT

SET POINT 2

ROTATION IN MAKEUPDIRECTION

INCREASES DEGREE OFINCREASESSET POINT 1

ROTATION IN MAKEUPDIRECTION

DECREASES DEGREE OFDECREASESSET POINT 1

ROTATION IN BREAKOUTDIRECTION

SETS DEGREE OF


INCREASES DEGREE OFINCREASESSET POINT 2


DECREASES DEGREE OFDECREASESSET POINT 2

THE PIPE WILL WIGGLEEQUALLY CW & CCW

ABOUT THIS “0”ORIENTATION


REPROGRAM THE METERDO NOT ADJUST

ASKS FOR CODE TOCONSULT FACTORY

INDICATES PROGRAMMINGCOMPLETE

READY TO STARTWIGGLE STEER

DD-1100 RST Operators Manual Appendix C

Appendix C: Dual Power Units and ROOTS

Appendix CThe DD-1100 RST comes equipped with two power units. They are positioned with hydraulic connec-

tions facing opposite directions so the power unit trailer can be located on either side of the drill rig. Each power unit is identified with a label located as shown in the drawing below.

The machine can be operated in one of several different power configurations:

• Both power units running with ‘A’ Primary• Both power units running with ‘B’ Primary

IMPORTANT: • If you are using only one power unit, proportional controls like the carriage and rotary will run at half

speed. Instructions in this manual are written assuming that the machine is operating using both power units.

• Turn off all power to the system when making hydraulic and electrical connections.

powerunit -side1-inside-PU LABEL

POWERUNIT B

POWERUNIT A


• One unit running, powering through unused unit (either A or B)• One unit running, one unit shut down and isolated (either A or B)• One unit running, one unit removed (either A or B)

Changes must be made in hydraulic connections, valve settings, electrical and servo line connections. Contact the factory for detailed instructions to run on one power unit.


Page

Appendix C

Bal

IMP• B• S

Appendix C: Dual Power Units and ROOTS

l Valve Rules of Thumb

Open valve: handle is parallel to the hoseClosed valve: handle is perpendicular to the hose

ORTANT: all valves in the wrong position can cause extreme damage to the power units.ecure ball valve handles with a locking device to prevent inadvertent change of position.

1451D-PwrSkid2-OOC

Valve Open

Valve Closed

Valve Open

Valve Closed


DD-1100 RST Operators Manual Appendix C

Appendix D: Tables Converting Pressure to Torque and Force

Appendix CConverting Gauge Pressure to Rotary Torque

Hydraulic Gauge Rotary Torque Rotary Torque Rotary TorquePressure (PSI) Low Range 25 RPMMid Range 40 RPM High Range 95 RPM

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

600 2882 2078 1273700 4804 3463 2121800 6726 4848 2970900 8647 6233 3818

1000 10569 7618 46671100 12490 9003 55151200 14412 10388 63641300 16333 11773 72121400 18255 13158 80611500 20177 14543 89091600 22098 15928 97581700 24020 17313 106061800 25941 18698 114551900 27863 20083 123032000 29784 21468 131522100 31706 22853 140002200 33628 24238 148492300 35549 25623 156972400 37471 27008 165462500 39392 28393 173942600 41314 29778 182432700 43235 31163 190912800 45157 32548 199402900 47079 33933 207883000 49000 35318 216373100 50922 36703 22485


3200 52843 38088 233333300 54765 39473 241823400 56687 40859 25030


Page

Appendix C


Converting Gauge Pressure to Rotary Torque (Continued)

Hydraulic Gauge Rotary Torque Rotary Torque Rotary TorquePressure (PSI) Low Range 25 RPMMid Range 40 RPM High Range 95 RPM

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

3500 58608 42244 258793600 60530 43629 267273700 62451 45014 275763800 64373 46399 284243900 66294 47784 292734000 68216 49169 301214100 70138 50554 309704200 72059 51939 318184300 73981 53324 326674400 75902 54709 335154500 77824 56094 343644600 79745 57479 352124700 81667 58864 360614800 83589 60249 369094900 85510 61634 377585000 87432 63019 386065100 89353 64404 394555200 91275 65789 403035300 93197 67174 411525400 95118 68559 420005500 97040 69944 428495600 98961 71329 436975700 100883 72714 44546



A

Appendix C

ppendix D: Tables Converting Pressure to Torque and Force

Converting Gauge Pressure to Thrust/Pullback Force

Hydraulic Gauge 1st Gear 2nd Gear 3rd Gear 4th GearPressure (PSI) 24 Ft/Min-Lbs Force 33 Ft/Min-Lbs Force 50 Ft/Min-Lbs Force 105 Ft/Min-Lbs Force

900 120263 90197 60131 300661000 142129 106597 71064 355321100 163995 122996 81997 409991200 185861 139396 92930 464651300 207727 155795 103863 519321400 229593 172195 114796 573981500 251459 188594 125729 628651600 273325 204994 136662 683311700 295191 221393 147595 737981800 317057 237793 158528 792641900 338923 254192 169461 847312000 360789 270592 180394 901972100 382655 286991 191327 956642200 404521 303391 202260 1011302300 426387 319790 213193 1065972400 448253 336190 224126 1120632500 470119 352589 235059 1175302600 491985 368989 245992 1229962700 513851 385388 256925 1284632800 535717 401788 267858 1339292900 557583 418187 278791 1393963000 579449 434587 289724 1448623100 601315 450986 300657 1503293200 623181 467386 311590 1557953300 645047 483785 322523 1612623400 666913 500185 333456 1667283500 688779 516584 344389 1721953600 710645 532984 355322 177661



Page

Appendix C

HP


Converting Gauge Pressure to Thrust/Pullback Force (Continued)

ydraulic Gauge 1st Gear 2nd Gear 3rd Gear 4th Gearressure (PSI) 24 Ft/Min-Lbs Force 33 Ft/Min-Lbs Force 50 Ft/Min-Lbs Force 105 Ft/Min-Lbs Force

3700 732511 549383 366255 1831283800 754377 565783 377188 1885943900 776243 582182 388121 1940614000 798109 598582 399054 1995274100 819975 614981 409987 2049944200 841841 631381 420920 2104604300 863707 647780 431853 2159274400 885573 664180 442786 2213934500 907439 680579 453719 2268604600 929305 696979 464652 2323264700 951171 713378 475585 2377934800 973037 729778 486518 2432594900 994903 746177 497451 2487265000 1016769 762577 508384 2541925100 1038635 778976 519317 2596595200 1060501 795376 530250 2651255300 1082367 811775 541183 2705925400 1104233 828175 552116 2760585500 1126099 844574 563049 2815255600 1147965 860974 573982 286991



A

Appendix C

ppendix D: Tables Converting Pressure to Torque and Force

Converting Gauge Pressure to Breakout/Makeup Torque

Hydraulic Gauge Breakout Torque Makeup TorquePressure (PSI) Cylinder Completely Retracted (Ft-Lbs) Cylinder Completely Extended (Ft-Lbs)

100 7723 5118200 15446 10235300 23169 15353400 30892 20471500 38615 25589600 46338 30706700 54061 35824800 61784 40942900 69507 460601000 77230 511771100 84953 562951200 92676 614131300 100399 665311400 108122 716481500 115845 767661600 123568 818841700 131291 870021800 139014 921191900 146737 972372000 154460 1023552100 162183 1074732200 169906 1125902300 177629 1177082400 185352 1228262500 193075 1279442600 200798 1330612700 208521 1381792800 216244 1432972900 223967 148415


3000 231690 153532


Notes

NOTES:


DD-1100 RST Operators Manual Declaration of Conformity

Sample Declaration of Conformity

Horizontal Directional DrillDD-1100 RST


American Augers, Inc.135 US Route 42

P.O. Box 814West Salem, Ohio 44287

www.americanaugers.comTEL: 419-869-7107 • 800-324-4930 (USA)

FAX: 419-869-7425

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 50DD10100

Released January 2014 Revision 01

dd-1100 rst operation & safety instruction manual€¦ · dd-1100 rst operation & safety...

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