american augers mud pump free sample

The only American Augers cleaning system fitted with an onboard mud pump, the M500PDH is an all-in-one cleaning solution compatible with any 100- or 200-tonne directional drill. This expansive machine features two Derrick® shakers and a true 500 GPM cleaning capacity that handles heavy backreamed fluid with ease.

American Augers mud pumps are standardstand-alone, self-powered machines thatare the perfect accessories to use with mudmotors, large reamers or whenever moremud volume is needed down hole.* Optional Quiet Pak for optimum noise reduction controlP-600 and P-750 Mud Pumps• allow the operator to get enoughflow to keep the bore flushed cleanof cuttings• are designed with a compact skidmounting and provide a smallfootprint that are ideal for mostdrilling environments.• are compatible with any drill brandmaking them suitable for contractorsoperating a variety of sizes, makesand models of drilling equipment.www.AmericanAugers.com

P-600Mud PumpTypical Flow Rates for Popular Size Mud MotorsBe sure to allow enough extra mud flow to flood the boreMUD MOTOR SIZEFLOW RATE/MINUTEInches Millimeters U.S. Gallons Liters3 3/8 85.72 30 - 120 113.6 - 454.23 1/2 88.9 75 - 160 283.9 - 605.74 3/4 120.6 100 - 250 378.5 - 946.46 3/4 171.4 300 - 600 1,136 - 2,271

What Type of Contractor Should Use aMud Pump?• Users of drilling equipment withpumping capacities of 25 U.S.Gallons (95 L)/minute or largerregardless of soil type or conditions.• Drillers typically making bores thatare greater than 6 1/2 in. (165 mm)diameter and more than 200 ft.(61 m) long.• Owners of mud motors for rockdrilling applications.• Operators in areas where muddisposal is expensive or restricted.Both the P-600 and the P-750should be considered when workingin rock formations where the operatingdrill"s on-board mud pump has fluidlimitedcapacities and cannot produceenough pressure to drive the mud motor.www.AmericanAugers.com

MUD MOTOR SIZEP-750Mud PumpTypical Flow Rates for Popular Size Mud MotorsBe sure to allow enough extra mud flow to flood the boreFLOW RATE/MINUTEInches Millimeters U.S. Gallons Liters3 3/8 85.72 30 - 120 113.6 - 454.23 1/2 88.9 75 - 160 283.9 - 605.74 3/4 120.6 100 - 250 378.5 - 946.46 3/4 171.4 300 - 600 1,136 - 2,2718 203.2 400 - 900 1,514 - 3,407

P-600PERFORMANCE SPECIFICATIONSPower TrainEngine:Caterpillar ® C-15 Tier III Diesel* Tier III or Tier 4i determined by country of purchaseFuel Capacity: 300 U.S. Gallons (1,136 L)Rating:475 HP (354 kW)Transmission: Eaton-FRO-16210B, 10 speedMaximum Speed: 2100 RPMClutch:15 1 /2 in. (394 mm) twin diskNoise Rating: 1 meter distance 104 dB(A)3 meter distance 95 dB(A)Battery:(2) Deka 908DMF 12V, 1450 CCAPumpPump Design:Maximum Pressure:Rated Capacity:Bore x Stroke:Tri-Plex 600GPM1,505 psi (104 bar)600 U.S. Gallons* (2,067 L)/minute6 x 6 in. (152.4 x 152.4 mm)* Note: Pump capacity will vary depending on the overall mud weight,drilling fluid mixture/content and working elevationControlsRemote Controls:Instruments:Mud pump throttle, Mud pump start/stop,clutch actuator, horn remoteDigital mud flow meter (gallons/liters per minute)DimensionsLength: 20 ft. (6.096 m)Height: 9 ft. (2.7 m)Width: 8 ft. (2.49 m)WeightTotal Weight:29,800 lbs. (13,520 kg) estimated39,600 lbs. (17,962 kg) with sound enclosureAccessoriesPulsation dampener on inlet and discharge(2) 25 ft. (7.6 m) suction hoses with 6 in. (152.4 mm)kamlock fittings(2) 25 ft. (7.6 m) discharge hoses with 3 in. (76.2 mm)NPT hammer unionsLiner wash system with supply tank(2) 24 volt work lights* Note: All product performance specifications,components, weights, dimensions and otherrelated information is subject to change withoutnotice from the manufacturer.

P-750PERFORMANCE SPECIFICATIONSPower TrainEngine:Caterpillar ® C-18 Tier III Diesel* Tier III or Tier 4i determined by country of purchaseFuel Capacity: 300 U.S. Gallons (1,136 L)Rating:600 HP (447 kW)Transmission: Eaton-RTLO-22918B, 10 speedMaximum Speed: 2100 RPMClutch:15 1 /2 in. (394 mm) twin diskNoise Rating: 1 meter distance 104 dB(A)3 meter distance 95 dB(A)Battery:(2) Deka 908DMF 12V, 1450 CCAPumpPump Design:Maximum Pressure:Rated Capacity:Bore x Stroke:Quintiplex, piston and liner1,500 psi (103 bar)750 U.S. Gallons* (2,839 L)/minute5 1 /2 x 7 7 /8 in. (139.7 x 200 mm)* Note: Pump capacity will vary depending on the overall mud weight,drilling fluid mixture/content and working elevationControlsRemote Controls:Instruments:Mud pump throttle, Mud pump start/stop,clutch actuator, horn remoteDigital mud flow meter (gallons/liters per minute)DimensionsLength: 25 ft. 6 in. (7.8 m)Height: 10 ft. 3 in. (3.12 m)Width: 8 ft. (2.49 m)WeightTotal Weight:47,800 lbs. (21,680 kg)AccessoriesPulsation dampener on inlet and discharge(2) 25 ft. (7.6 m) suction hoses with 6 in. (152.4 mm)kamlock fittings4 in. (102 mm) NPT hammer union discharge connectionLiner wash system with supply tank(2) 24 volt work lights* Note: All product performance specifications,components, weights, dimensions and otherrelated information is subject to change withoutnotice from the manufacturer.

AMERICAN AUGERSThe American Augers line of underground construction equipment is second-to-none.• Auger Boring Machines• Maxi-Rig & Mid-Size Directional Drills• Oil & Gas Drilling Rigs• Mud Pump & Cleaning Systems• Product Tooling & AccessoriesAmerican Augers products are manufactured at the company’s 241,000 square-foot facility in West Salem, Ohio,in the heart of Amish country between Columbus and Cleveland.Since the founding of American Augers in 1970, there has never been a change in the company’s core value:having products developed by a can-do work force that focuses on mechanical, technological and customer-baseddesign improvements. Our goal is to always exceed customer expectations by providing products that are not acost of doing business, but an Investment in Success.Did You Know? American Augers was the first HDD manufacturer to eliminate chain and utilize a rack andpinion carriage design which is now the industry standard. Our rack and pinion drive provides smoother carriagemovement, more precise operating control, long system life and no complicated parts.American Augers machines are supported through a dedicated parts and technical service department. We are hereto help whenever you need us 24 hours a day, 7 days a week, emergency or not.www.AmericanAugers.comEnvironmental CommitmentAmerican Augers is committed to manufacturing equipment that helps to preserve the sanctity of the globalenvironment, and has done so by reducing noise and/or emissions outputs, and emphasizing the fact that ourtrenchless technology equipment requires little or no open cutting, which has very minimal impacts on naturalsurfaces, features, or habitats.1212

American Augers was established in 1970 to providea full line of modern equipment for the trenchlessexcavation construction industry. The company is organizedin three product divisions to serve the full rangeof trenchless technology. American Directional Drillis the division producing the leading line of HorizontalDirectional Drills. We are proud of our equipmentand the job it can do. We encourage you to call us forany and all of your drilling needs.Every effort has been made to cover adequately theINTRODUCTIONoperation of the DD-100 and DD-140 directionaldrills. Specifications are subject to change without noticeor obligation to retrofit units already in the field.This manual will be constantly updated to remain currentwith new operations. Please call if there are areasrequiring further explanation or instruction. Materialcontained herein may not be reproduced in whole or inpart without the express written permission of AmericanAugers Inc., the Innovative Leader in the TrenchlessIndustry.Machine Serial NumberEngine Serial NumberLocation of Machine SN PlateLocation of Engine SN PlateDD-100 and DD-140 are trademarks of American Augers, inc.Copyright © 2001 by American AugersPart Number: DD100140BOOK-01 November 2001Page 2Refer to the Safety Awareness Program in this manual before attempting to operate this machine.

TABLE OF CONTENTS1. GENERAL INFORMATION1.1 USE AND MAINTENANCE MANUAL1.1.1 DATA OF MANUAL1.1.2 CONTENTS OF MANUAL1.1.3 WHO SHOULD USE THIS MANUAL1.1.3.1 TRANSPORTER1.1.3.2 USER1.1.3.3 MAINTENANCE TECHNICIAN1.1.4 OWNERSHIP OF INFORMATION1.2 MANUFACTURER IDENTIFICATION DATA1.3 MACHINE IDENTIFICATION DATA1.4 DECLARATION OF EC CONFORMITY1.5 GENERAL INFORMATION ON SAFETY1.5.1 SAFETY STANDARD1.5.1.1. SAFETY AWARENESSPROGRAM1.5.2 QUALIFICATION OF PERSONNEL1.5.3 USE OF PERSONAL PROTECTIVEEQUIPMENT1.5.4 DANGEROUS ZONES—SAFE DIS-TANCES1.6 LEGAL VALUE OF THE MANUAL1.7 USES ALLOWED1.7.1 FEATURES OF THE SOIL TO BEDRILLED1.7.1.1 TYPES OF SOIL1.7.1.2 GROUND LEVELING1.7.1.3 AMBIENT CONDITIONS1.7.2 FEATURES OF TRANSPORT1.7.3 MACHINE HANDLINGPROCEDURES1.7.3.1 TRANSPORT1.7.3.2 USE1.7.3.3 MAINTENANCE1.8 USES NOT ALLOWED1.9 WARRANTY1.9.1 GENERAL CONDITIONS1.9.2 LIMITATIONS OF WARRANTY1.9.3 WARRANTY CERTIFICATE1.9.4 REQUEST FOR SERVICESUPPORT1.9.5 WARRANTY AND SERVICE FORCATERPILLAR ENGINE1.10 SERVICE AGREEMENT1.11 CONVENTIONS1.11.1 CONVENTIONS OF TERMINOLOGY1.11.2 TYPOGRAPHIC CONVENTIONS2. DESCRIPTION2.1 PARTS OF THE MACHINE2.2 DESCRIPTION OF THE MACHINE2.2.1 THRUST FRAME2.2.2 CARRIAGE2.2.3 REAR THRUST STABILIZERS2.2.4 FRONT STABILIZERS2.2.5 FIXED WRENCH2.2.6 BREAKOUT WRENCH2.2.7 MUD2.2.8 MUD PUMP2.2.9 TIE DOWN SYSTEM2.2.10 DRILL PIPE2.2.11 ES!LOK ®2.2.12 ZAP ALERT ®2.2.13 UNDERCARRIAGE2.2.14 CRANE2.3 PURPOSE OF THE MACHINE2.4 STRUCTURE2.5 TECHNICAL SPECIFICATIONS2.5.1 GENERAL FEATURES (DD-100)2.5.2 GENERAL FEATURES(DD-140B)2.5.3 DIESEL ENGINE (DD-100)2.5.4 DIESEL ENGINE (DD-140B)2.5.5 ELECTRICAL SYSTEM2.5.6 HYDRAULIC SYSTEM (DD-100)2.5.7 HYDRAULIC SYSTEM (DD-140B)2.5.8 PERFORMANCE AS SUPPLIED(DD-100)2.5.9 PERFORMANCE AS SUPPLIED(DD-140B)2.5.10 VIBRATION2.5.11 NOISE2.6 RESPONSIBILITY3. STORAGE AND TRANSPORT3.1 STORAGE3.1.1 MINIMUM STORAGE SPACEREQUIRED3.1.1.1 PROTECTION WHILE INSTORAGE3.1.2 STORAGE SITE ENVIRONMENT3.1.3 PROCEDURES OF STORAGE3.1.3.1 DRAIN OR PROTECT FLUIDCOURSERefer to the Safety Awareness Program in this manual before attempting to operate this machine. Page 3

3.2 TRANSPORT3.2.1 PRELIMINARY OPERATIONS FORLOADING THE MACHINE FORTRANSPORTATION3.2.2 PROCEDURES OF POSITIONING3.2.3 TRANSPORTATION3.2.4 LOADING OF THE MACHINE FORTRANSPORTATION3.2.5 TRANSPORT CONDITIONS3.2.6 UNLOADING OPERATIONS3.3 LIFTING THE MACHINE4. USE4.1 WORKING SITE PHYSICAL FEATURES4.1.1 MINIMUM SPACE REQUIRED4.1.2 GROUND LEVELING4.1.3 TYPE OF GROUND4.1.4 LIGHTING4.1.5 OPERATING TEMPERATURES4.1.6 RELATIVE HUMIDITY4.1.7 MAXIMUM ALTITUDE4.1.8 ATMOSPHERIC CONDITIONS4.2 FUNCTION OF THE MACHINE4.2.1 NORMAL OPERATION4.3 DANGEROUS ZONES—SAFE DISTANCES4.3.1 DANGEROUS PARTS ANDDESCRIPTION OF THE RISK4.3.1.1 TIE DOWN4.3.1.2 REAR THRUST STABILIZERS4.3.1.3 FRONT STABILIZERS4.3.1.4 CARRIAGE4.3.1.5 WRENCH ASSEMBLY4.3.1.6 CUTTING HEAD4.3.1.7 DRILL PIPE4.3.1.8 MUD SYSTEM4.3.1.9 REAMING TOOLS4.3.1.10 DIESEL ENGINE AND MUFFLER4.3.1.11 PERSONAL PROTECTIVEEQUIPMENT4.4 QUALIFICATION OF THE OPERATOR4.5 POSITION OF THE OPERATOR4.6 CONTROLS AND INSTRUMENTS4.6.1 CONTROLS4.6.1.1 TRAMMING CONTROL4.6.1.2 EMERGENCY STOP PUSH BUTTONS4.6.2 INSTRUMENTS (LIST)4.6.2.1 ENGINE PANEL4.6.2.2 CONTROL PANELGENERAL ARRANGEMENT4.6.2.3 CONTROL CONSOLE4.6.2.4 SET-UP CONTROL PANEL4.6.2.5 CRANE PENDANT CONTROL4.6.2.6 TRAMMING CONTROL4.6.2.7 BATTERY SWITCHES ANDBATTERY EQUALIZER4.6.3 ES!LOK ® LOCKOUT SYSTEM4.6.4 ZAP ALERT SYSTEM4.7 OPERATION4.7.1 STARTING THE ENGINE4.7.2 MOVEMENT OF THE MACHINE4.8 SET-UP4.8.1 POSITION THE DRILL4.8.2 EXTEND THE DRILLER’S CONSOLE4.8.3 REMOVE HOSE CARRIER HOLD-DOWN4.8.4 INSTALL HANDRAILS4.8.5 POSITION REAR THRUST STABILIZERS4.8.6 POSITION THE CRANE4.8.7 POSITION THE FRONT STABILIZERS4.8.8 THRUST FRAME ANGLE4.8.9 THRUST FRAME EXTENSION4.8.10 ANCHOR THE MACHINE4.8.10.1 PLACING THE TIE DOWN STAKES4.8.10.2 OTHER METHODS OF ANCHORING4.8.10.3 POUR A CONCRETE ANCHOR4.8.10.4 CONSTRUCT A “DEAD MAN”ANCHOR4.8.11 EXCAVATE THE ENTRY PIT4.9 DRILLING PROCESS4.9.1 DEEP CROSSINGS- THE SET UP4.9.2 DEEP CROSSINGS - STEERINGSYSTEM4.9.3 DEEP CROSSINGS - DRILLINGMETHOD4.9.4 SHALLOW CROSSINGS -THEPROCESS4.9.5 APPLICATION OF DRILLING FLUIDTO HORIZONTAL BORING4.9.6 DRILLING FLUID - THE PROCESS4.9.7 CALCULATION OF VOLUME OFFLUID TO VOLUME OF SOIL4.9.8 FLUID DISPOSAL4.9.9 WATER QUALITY4.9.10 MUD MIXINGPage 4Refer to the Safety Awareness Program in this manual before attempting to operate this machine.

4.10 HANDLING PIPE4.10.1 ADDING PIPE (FIRST SECTION)4.10.2 INSTALLING A WIRELINE GUIDANCEINSTRUMENT4.10.3 USING A MUD MOTOR4.10.4 ADDING PIPE (ADDITIONALSECTIONS)4.10.5 REMOVING PIPE4.10.6 CALCULATING ROTARY TORQUEFORCE4.10.6.1 LIMITING ROTARY TORQUE4.10.7 CALCULATING THRUST ANDPULLBACK FORCE4.10.7.1 LIMITING THRUST ANDPULLBACK FORCE4.11 START OF THE DRILLING OPERATION4.12 END OF DRILLING OPERATIONS4.13 START OF PULLBACK OPERATIONS4.14 END OF PULLBACK OPERATIONS4.14.1 REMOVING TIE DOWNSTAKES4.14.2 CLEAN UP4.15 SWITCHING OFF THE ENGINE4.16 EMERGENCY STOP4.17 START AFTER AN EMERGENCY STOP4.18 CHECKS DURING OPERATION4.19 NORMAL OPERATING RANGES OFINSTRUMENTS4.20 ES!LOK ® LOCKOUT SYSTEM4.20.1 START AFTER USE OF ES!LOK ®4.21 USE OF ZAP ALERT ®4.21.1 START AFTER USE OF ZAPALERT4.22 OPERATION WITH AMBIENTTEMPERATURES BETWEEN-40 & -15°C4.22.1 PRE-HEATING DEVICES4.22.2 STARTING THE ENGINE (with themachine kept warm through pre-heaters)4.22.3 STARTING THE ENGINE (without use ofpreheaters)4.22.4 PROTECTING THE FLUID COURSEFROM FREEZING4.22.4.1 DRAIN THE FLUID COURSE5. MAINTENANCE5.1 DANGEROUS ZONES—SAFE DISTANCES5.2 ORDINARY, PERIODICAL ANDPREVENTIVE MAINTENANCE5.2.1 QUALIFICATION OF THE TECHNICIAN5.2.2 FREQUENCY OF INSPECTIONS5.3 SCHEDULED INSPECTION ANDMAINTENANCE5.3.1 MAINTENANCE SCHEDULES OFDIRECTIONAL DRILL MODEL DD-100AND DD-1405.3.1.1 DAILY (OR 10 HOURS)5.3.1.2 WEEKLY (OR 50 HOURS)5.3.1.3 MONTHLY (OR 250 HOURS)5.3.1.4 SIX MONTHS (OR 500 HOURS)5.3.1.5 YEARLY (OR 1000 HOURS)5.3.1.6 AFTER EACH JOB5.3.2 EMERGENCY STOP5.3.3 GREASING5.3.3.1 GREASE POINTS (LIST)5.3.4 ENGINE OIL5.3.5 ENGINE COOLANT5.3.6 AIR FILTERS5.3.7 FUEL5.3.8 HYDRAULIC OIL CIRCUIT5.3.8.1 PROCEDURE FOR REPLACEMENT OFFILTERS5.3.8.2 PROCEDURE FOR REPLACEMENTOF HYD. OIL5.3.9 GEARBOXES AND PUMP DRIVE5.3.9.1 PUMP DRIVE, LEVEL CHECK5.3.9.2 HYD. PUMP DRIVE, FILLINGPROCEDURE5.3.9.3 CARRIAGE ROTARY GEAR BOX5.3.9.4 CARRIAGE ROTARY GEAR BOX,CHECK LEVEL5.3.9.5 CARRIAGE ROTARY GEAR BOX,FILLING PROCEDURE5.3.9.6 TRACK DRIVE GEAR BOXES5.3.9.7 TRACK DRIVE GEAR BOXES,LEVEL CHECK5.3.9.8 TRACK DRIVE GEAR BOXES,FILLING PROCEDURE5.3.10 TRACK TENSION5.3.11 WELDING5.3.12 RADIATOR5.3.13 HYDRAULIC PISTON RODS5.3.14 CLEANING5.4 OTHER INSPECTION ANDMAINTENANCE (50 HOURS)5.4.1 BOLTS AND NUTSRefer to the Safety Awareness Program in this manual before attempting to operate this machine. Page 5

5.4.2 PIPES AND HOSES5.4.3 LEAKS5.4.4 GAUGES AND INSTRUMENTS5.4.5 BATTERIES5.4.5.1 BATTERY EQUALIZER5.4.6 UNDERCARRIAGE5.5 OTHER INSPECTIONS ANDMAINTENANCE (EVERY 250 HOURS)5.5.1 MOTOR MOUNTS AND RADIATORS5.5.2 UNDERCARRIAGE ROLLERS5.5.3 BREATHER PIPES5.5.4 TRACK TENSION5.6 OTHER CHECKS & MAINTENANCE(EVERY 500 HOURS)5.6.1 ENGINE BELTS5.6.2 COOLING SYSTEM5.6.3 ENGINE OIL BREATHER PIPE5.6.4 ELECTRIC SYSTEM5.7 OTHER CHECKS (EVERY 1000 HOURSOR EVERY YEAR)5.7.1 ENGINE FUEL FILTERS5.7.2 ENGINE COOLING SYSTEM5.7.3 EMERGENCY STOP5.7.4 HYDRAULIC OIL AND FILTERS OFHYDRAULIC SYSTEM5.8 INSPECTIONS AND MAINTENANCEEVERY 24 MONTHS5.8.1 ENGINE STOP5.8.2 ENGINE COOLING SYSTEM5.9 OTHER CHECKS (EVERY 2000 HOURS)6. DIAGNOSTIC6.1 OPERATING FAULTS6.1.1 CLOGGED AIR FILTER6.1.2 ENGINE OIL PRESSURE ALARM6.1.3 ENGINE COOLANT TEMPERATUREALARM6.1.4 ROTARY AND CARRIAGE DO NOTOPERATE6.1.5 CLOGGED OIL FILTER(S)7. DEMOLITION7.1 MACHINE DEACTIVATION7.2 RESIDUAL RISKSFig. 1 Declaration of EC ConformityFig. 2 Warranty CertificateFig. 3 Exit Pit WarningFig. 4 Pipe Wrench WarningFig. 5 Electrical Hazard WarningFig. 6 Machine LabelsFig. 7 Placement of Labels, 1 of 2Fig. 8 Placement of Labels, 2 of 2Fig. 9 Transporting The DrillFig. 10 Lifting The DrillFig. 11 Transport Dimensions DD-100Fig. 12 Max. Drill Angle Dimensions DD-100Fig. 13 Transport Dimensions DD-140BFig. 14 Max. Drill Angle Dimensions DD-140BFig. 15 ToolingFig. 16 Down Hole (Mud) MotorFig. 17 SteeringFig. 18 Clock Face DisplayFig. 19 TrammingFig. 20 Hose Carrier Hold DownFig. 21 Hand RailsFig. 22 Console Lock ChainFig. 23 Extending ConsoleFig. 24 Storage BoxFig. 25 Positioning CraneFig. 26 Carriage LockFig. 27 Hand Rail InstallationFig. 28 Engine PanelFig. 29 Control Console General ArrangementFig. 30 Instruments—Control ConsoleFig. 31 Setup ControlsFig. 32 Crane ControlsFig. 33 Tramming ControlFig. 34 Battery Switch & EqualizerFig. 35 Pipe SupportFig. 36 Tiedown StakesFig. 37 Buried AnchorFig. 38 Thrust Conversion Table-DD-100Fig. 39 Torque Conversion Table-DD-100Fig. 40 Thrust Conversion Table-DD-140BFig. 41 Torque Conversion Table-DD-140BFig. 42 Air CleanerFig. 43 Volume of Soil FormulaFig. 44 Steering RadiusFig. 45 Approved Replacement FluidsFig. 46 Maintenance ScheduleFig. 47-49 Hydraulic Schematics—DD-100Fig. 50-52 Electrical Schematics—DD-100Fig. 53-57 Hydraulic Schematics—DD-140BFig. 58-61 Electrical Schematics—DD-140BPage 6Refer to the Safety Awareness Program in this manual before attempting to operate this machine.

Fig. 62 Machine NomenclatureAttachment 1 Cat 3126 or 3306 Diesel Engines.Attachment 2 Es!lok ® Operator’s ManualAttachment 3 Zap-Alert InstructionsAttachment 4 Crane Operator’s ManualAttachment 5 Battery Equalizer Instructions1. GENERAL INFORMATION1.1 USE AND MAINTENANCE MANUAL1.1.1 DATA OF MANUALTITLE: Operation & Safety Instruction Manual,Model DD-100 AND DD-140 Horizontal DirectionalDrillEDITION: 2001Part number: DD100140BOOK-011.1.2 CONTENTS OF MANUALChapter 1 General InformationChapter 2 DescriptionChapter 3 Storage and TransportChapter 4 UseChapter 5 MaintenanceChapter 6 DiagnosticChapter 7 Demolition1.1.3 WHO SHOULD USE THIS MANUAL1.1.3.1 TRANSPORTERThe transporter is not authorized to handle themachine nor start the engine. Only trained personnelhaving a written authorization are allowed toload and unload the machine from the transportvehicle (see: USER). Relevant parts of the manualare in Chapter 3 Storage and Transport.1.1.3.2 USERAt consignment of the machine, a technician eitherfrom the authorized dealer or from AmericanAugers is available for training one or more operators.Only trained personnel are qualified to operateand maintain the machine.We recommend following the procedure of theacceptance and test-run certificate, which must alwayscome with the machine together with themanual for any other subsequent training. The authorizeddealer is always available for any furtherinformation or instruction. The user must read andfollow the manual.1.1.3.3 MAINTENANCE TECHNICIANThe technician in charge of maintenance must getacquainted with operation and handling of themachine, he must be able to check that there areno faults in order to carry out maintenance workwith adequate equipment and protection. In casethe technician is not qualified, he must inform aqualified person so that skilled personnel are calledfor special work (example: adjustment of Caterpillarengine, welding, etc.). The technician mustread and follow the manual.1.1.4 OWNERSHIP OF INFORMATIONAmerican Augers, Inc. reserves all rights to theinformation in this manual.The manual cannot be reproduced or photocopiedin part on in whole without previous writtenauthorization from American Augers, Inc. The useof the manual is restricted to the customer whoreceived it and only for purposes of installation,use and maintenance of the relevant machine.American Augers declares that the informationcontained in this manual fits the technical andsafety specifications of the machine. AmericanAugers disclaims responsibility for direct or indirectdamages to persons or property caused whenthe manual or the machine are used in in violationof the information contained herein.The information contained in the manual refersonly to the machine mentioned in Paragraph 1.3.IDENTIFICATION DATA OF THE MACHINE.American Augers reserves the right to modify orimprove the manual and the machines without notice.1.2 MANUFACTURER IDENTIFICATION DATAAMERICAN AUGERS, INC.135 U.S. Rt. 42, P.O. Box 814West Salem, Ohio 44287 USATel. 419-869-7107 • Fax 419-869-7425Refer to the Safety Awareness Program in this manual before attempting to operate this machine. Page 7

1.3 MACHINE IDENTIFICATION DATAType: Directional DrillModel: DD-100 AND DD-140Serial number: ..........Year of manufacture: ...........Location of identification plate: see diagram onpage 2.1.4 DECLARATION OF EC CONFORMITYIf required, the declaration of EC conformity isissued at consignment of the machine together withthe manual. REFER TO: Attachment 1 Declarationof EC Conformity.1.5 GENERAL INFORMATION ON SAFETY1.5.1 SAFETY STANDARDIn designing and construction of the machine,standards have been adopted in order to satisfy essentialsafety requirements with subsequent modificationsunder applicable directives. In particular,suitable measures to prevent risks for operatorsduring transport, use, maintenance and demolitionof the machine have been completed. Thecomplete documentation of the measures adoptedfor safety purposes is contained in the technicalfile of the machine, registered by the manufacturer.The detailed analysis of risks carried out by themanufacturer are intended to eliminate most of therisks connected with the conditions of use of themachine, both foreseen and reasonably foreseeable.The manufacturer recommends that the user carefullyfollows instructions, procedures and advicecontained in the manual and the laws in force onthe work site, as well as the use of all protectiveequipment, both integrated in the machine andpersonal protective equipment.1.5.1.1. SAFETY AWARENESS PROGRAMUnderstanding Operation SafetyAll references throughout this manual are to currentmodels of the DD-100 AND DD-140 directionaldrill. Please call American Augers if you encounterproblems not addressed in this manual.BE AWARE OF SAFETY INFORMATION.This is the safety alert symbol. This symbol isplaced in the manual to alert you to the potential forbodily injury or death.UNDERSTAND SIGNAL WORDSSignal words are used to identify safety informationwithin the text of this manual, and are used onthe hazard alert signs used on the machine.DANGERindicates an imminently hazardoussituation which, if not avoided, willresult in death or serious personal injury.WARNINGindicates a potential hazard or unsafesituation which, if not avoided, couldresult in death or serious personal injury.CAUTIONindicates a potential hazard or unsafepractice, which if not avoided may resultin minor personal injury or productor property damage.If you are the owner, operator, or the helper usingan American Directional Drill, it is importantthat you recognize that your drill is a powerful pieceof construction equipment. (IT MUST BE OPER-ATED WITH RESPECT AND CAUTION.)All operators or trainees must carefully read andthoroughly understand this Operation Manual beforestarting or using this machine. Thorough trainingof both operators and helpers is essential forthe safe operation of this equipment. Never allowinexperienced personnel to operate or work nearthe machine unless they are carefully supervisedduring training. In the United States, workplacesafety is regulated by the Occupational Health andSafety Administration (OSHA). OSHA regulationsare found in the Code Of Federal Regulations.,Chapter 29. This is known as 29CFR1910. Informationcan be obtained from your Regional U.S.Department of Labor Office.Please note the limited warranty included in thismanual. If you have questions on the warranty orPage 8Refer to the Safety Awareness Program in this manual before attempting to operate this machine.

about any part of the machine operation, pleasecontact American Augers.NOTICELocation of Hazard Alert SignsThe drawings on Fig. 7 and Fig. 8 showthe locations of hazard alert signs asthey are placed on the DD-100 ANDDD-140. These hazard alert signs areplaced on the machine to inform youroperator and other personnel of potentialhazards that exist while thesemachines are in operation. Thesesigns must be kept clean and legible.Replacement signs are available fromAmerican Augers.NOTICEAmerican Augers disclaims any responsibilityfor damages to personsor property caused by operation inviolation of safety advice contained inthe manual..1.5.2 QUALIFICATION OF PERSONNELIf skilled personnel operate the machine accordingto the advice and instructions supplied in themanual, the machine will operate safely. All theoperations of transport, use and maintenance mustbe carried out only by skilled and authorized personnel,after studying and understanding the instructionssupplied by the manual.NOTICEAmerican Augers disclaims any responsibilityfor damages to personsor property caused by the operationof the machine by untrained personnel.1.5.3 USE OF PERSONAL PROTECTIVEEQUIPMENTWARNINGIf personal protective equipment is notused, serious injury or death of personnelcan occur.The operator and all other personnel on theworksite must use proper protective equipmentaccording to their duties.In addition to safety shoes, helmets and safetyglasses, it is necessary to wear hearing protection.The driller, locating device operator and others incontact with the machine should wear electric insulatingboots in case of striking a buried electriccable.1.5.4 DANGEROUS ZONES—SAFE DIS-TANCESAny zone inside or near the machine where thepresence of a person means a risk for his healthand security.All the areas concerned with handling of parts ormachine.During transport, keep a distance of at least 2 m(6.5 feet) away from the drill.While drilling, some drilling fluid can be sprayedfrom the cutting head.In addition, in case of striking a buried electriccable, the earth around the drill can become electricallycharged. Keep spectators at least 8 m (25ft) from the drill and associated equipment.During maintenance, use adequate supports beforereleasing bolts, pins, valves, pipes and pistons.Safety distances during transport: 2 m (6.5 ft)Safety during self-moving: 2 mSafety distances during use: 8 m (25 ft)Safety distances during maintenance: 8 m1.6 LEGAL ASPECT OF THE MANUALNOTICEAmerican Augers disclaims any responsibilityfor damages to personsor property caused by the operationof the machine in violation of the instructionscontained in this manual1.7 USES ALLOWEDWork allowed:Installation of drill pipe into the earth. Rotationof drill pipe. Use of bentonite fluid to create thepilot bore. Removal of drill pipe from the earth.Use of bentonite fluid to back ream the bore. Pullinga reamer through the pilot bore. Pulling productpipe or cable through the bore.Refer to the Safety Awareness Program in this manual before attempting to operate this machine. Page 9

NOTICEAmerican Augers does not bear anyresponsibility for damages caused bythe incorrect use of the machine, norfor wear and damage caused by theparticular quality of the drilled material.1.9 WARRANTY1.9.1 GENERAL CONDITIONSAny warranty is subject to the conditions specifiedin the warranty certificate.Except for the specified exclusions and limitation,the warranty certificate covers all the materialsupplied for a period of 6 months beginningfrom the shipping date.Extensions can be granted only by the Presidentof American Augers and must be signed and enclosedwith the certificate consigned at the time ofsale.No extension can be granted after sale.1.9.2 LIMITATIONS OF WARRANTYThe warranty for all the components bought andnot produced by American Augers directly are subjectto the original warranty of suppliers/manufacturersand therefore defects in materials or workmanshipare considered valid only if they are recognizedby the same suppliers/manufacturers. Inparticular the warranty on the Caterpillar engine issupplied by the Caterpillar dealer in the area wherethe drill is sold.1.9.3 WARRANTY CERTIFICATESee Fig. 2.1.9.4 REQUEST FOR SERVICE SUPPORTFor any request of service support in or out ofthe warranty period, contact your authorized dealer.Have available model number, serial number ofthe machine and working hours indicated on theinstrument (Fig. 30, TACH).1.9.5 WARRANTY AND SERVICE FOR CAT-ERPILLAR ENGINEThe local Caterpillar dealer normally solves problemsrelated to Caterpillar engine. The Caterpillarwarranty is valid worldwide. Only Caterpillar dealersare authorized to perform repairs under warrantyand supply service and spare parts.1.10 SERVICE AGREEMENTContact the local dealer.NOTICEThis manual must be kept for thewhole lifetime of the machine so thatit can be easily found if needed. If themachine is sold, the manual must beprovided to the new owner.1.11 CONVENTIONS1.11.1 CONVENTIONS OF TERMINOLOGYAs the directional drill is not a conventional constructionmachine we list some terms normally usedin the text with their description.FRONT is the end with the wrenchs and foot.LEFT or RIGHT as seen standing behind the machinefacing FRONT. The operator’s console is onthe RIGHT side.1.11.2 TYPOGRAPHIC CONVENTIONSIn the manual different typographic notes havebeen used for identifying dangerous conditions.For example:NOTICENotices, cautions and warnings includingimportant information are setapart from the text.REFER TO: Safety Awareness Program, Paragraph1.5.1.1.2. DESCRIPTION2.1 PARTS OF THE MACHINEThe machine consists of the following assemblies(REFER TO: Fig. 47 & 48).2.2 DESCRIPTION OF THE DIRECTIONAL DRILLwhich contains the operator’s console, engine,hydraulic system and fuel tank.Refer to the Safety Awareness Program in this manual before attempting to operate this machine. Page 11

2.2.1 THRUST FRAME which supports the carriage2.2.14 CRANE used to lift sections of pipe on andoff the machine2.2.2 CARRIAGE which imparts thrust and pullbackforce, and rotary motion to the drill pipe2.2.3 REAR THRUST STABILIZERS (JACKS)which resists the tendency of the drill to move backwardwhen thrusting2.2.4 FRONT STABILIZERS (JACKS) whichwiden the base of the machine and serve to levelthe crane2.2.5 FIXED WRENCH a hydraulic clamp forholding the pipe during tightening or loosening thejoints2.2.6 BREAKOUT WRENCH a moveable wrenchthat applies enough force to loosen pipe joints2.2.7 MUD drilling fluid containing water and usuallybentonite and other additives depending on soilconditions.2.2.8 MUD PUMP a pump separate from the machinethat forces drill fluid through the drill pipe.2.2.9 TIE DOWN SYSTEM H-beam stakes whichare driven through the front foot to anchor the drillto the earth.2.2.10 DRILL PIPE specially designed pipethreaded on both ends that conducts thrust and pullbackforces, and carries drilling fluid to the cuttinghead.2.2.11 ES!LOK ® an exit side lockout system thatis capable of disabling the rotation and linear movementof the drill pipe.2.2.12 ZAP ALERT ® an instrument that sounds analarm should the drill become electrically energized.2.2.13 UNDERCARRIAGE tracks and associatedparts for support and movement of the machine.2.3 PURPOSE OF THE MACHINEThe directional drill is designed for the productionof a bore under the earth with a system moreefficient than conventional excavating. The maintool is the cutting head; it may be equipped with ablade or with hard metal teeth and is able to removesoil. The result is a bore with circular sectionready for positioning pipe or cable, withoutthe need for back filling and compacting. The cuttinghead is advanced by connecting it to sectionsof drill pipe which are added by the operation ofthe directional drill. In addition, soil is removedand the bore is lubricated by use of a mixture ofwater, bentonite and other substances, which isforced into the drill pipe by the mud pump.The actual bore dimension cannot be guaranteedfor each bore. For example: depending on soil conditionsand the size of the pipe or cable to be installed,it may be necessary to enlarge the bore bypulling a reamer through it. Operation in hard rockrequires additional special accessories which arenot supplied and must be ordered separately.NOTICEAmerican Augers disclaims any responsibilityfor differences in dimensionsbetween theoretical and actualbores.2.4 STRUCTUREThe cutting head (connected to drill pipe held bythe machine) is positioned over the desired line ofadvance of the bore. The entry angle of the cuttinghead into the soil is determined by the lengthand depth of the bore, in consideration of the allowablebending of the drill pipe.The drill is anchored in place using the tie downsystem and by positioning the rear thrust stabilizers.Drilling fluid is prepared by a mud mixingsystem (available separately). Operation of the mudpump forces a jet of drilling fluid out orifices inthe cutting head.At the same time, the pipe is advanced by operationof the carriage. It is possible to steer the cuttinghead as it passes through the soil. By know-Page 12Refer to the Safety Awareness Program in this manual before attempting to operate this machine.

2.5.8 PERFORMANCE AS SUPPLIED (DD-100)Max. carriage speed: 30 m/min (100 FPM)Rotary speed: 0—110 rpmDrill angle: 10°-18°2.5.9 PERFORMANCE AS SUPPLIED (DD-140B)Max. carriage speed: 29 m/min (95 FPM)Rotary speed: 0—95 rpmDrill angle: 10°-18°3. STORAGE AND TRANSPORT3.1 STORAGE3.1.1 MINIMUM STORAGE SPACE RE-QUIRED (TRANSPORT POSITION)DD-100: level 3 x 15 m, height 3 m [118 x 590inches, height 118 inches].DD-140B: level 3 x 15 m, height 3.2 m [118 x 590inches, height 126 inches].2.5.10 VIBRATIONVibration is an indication of incorrect operation,such as advancing the drill pipe too rapidly.CAUTIONStop work in case of vibration, whichcould compromise the safety of theoperator or the integrity of the machine.Modify operational procedure2.5.11 NOISEPeople working near and always inside the minimumsafety distance (8 m [25 feet] from the nearestpoint of the machine) must wear adequate hearingprotection suitable to their working position.DANGERThe noise generated by the machinemay cause injury to personnel. Observethe national laws in force aboutthe protection from risks caused bynoise.2.6 RESPONSIBILITYNOTICEAmerican Augers disclaims any responsibilityfor inconvenience, faultsor malfunctioning of the machine incircumstances where proceduresidentified in paragraph 4.18 are not followed.3.1.1.1 PROTECTION WHILE IN STORAGE:If the machine has been lubricated it can be storedin an exposed area up to 30 days. For storage periodsmore than 30 days place it in a covered anddry area. Level the storage site so that the tracksare fully supported.DD-100: The surface must be able to support20,430 kg (45,000 lb)DD-140B: The surface must be able to support26,300 kg (58,000 lb)3.1.2 STORAGE SITE ENVIRONMEN TTemperature allowed: between 0 and +50°C[32°F and 120°F]. For temperatures between 0°and -40°C [32°F and -40°F], consult the Caterpillarmanual and follow the instructions for storageof the engine. Verify that there is no water or drillingfluid in the drilling fluid course and no waterin the diesel fuel and hydraulic oil tanks.3.1.3 PROCEDURES OF STORAGE• Clean all mud and other foreign materials off themachine.• Position the machine on a level surface. Positionthe carriage in the center of the thrust frame. Raisethe front foot by retracting the thrust frame.• Switch off electric system by turning the batteryswitches at the battery box.• Lubricate the entire machine according to thedaily schedule. Coat all exposed hydraulic cylinderrods with oil to protect against corrosion.• For long periods of storage (more than 30 days)place the machine in a covered and dry site, consultand follow the instructions of storage for Caterpillarengine (mentioned in the relevant mainte-Page 14Refer to the Safety Awareness Program in this manual before attempting to operate this machine.

nance manual), disconnect batteries and store themseparately at temperatures above 0°C (32°F).Eliminate sediment and water from the tanks (dieselfuel and oil), top up all the gearboxes and thehydraulic oil tank.• For periods longer than 30 days, disconnect thees!lok ® battery charger located inside the storagebox (Fig. 24-1). This charger is not affected by thebattery switch. If left connected it could dischargethe machine batteries.NOTICEBefore putting the machine back inservice reconnect the es!lok ® batterycharger to either a 12 v DC or 24 v DCsupply and recharge the es!lok ® batteries.Make sure the es!lok ® batteriesare charged before attempting to putthe machine back into service.The machine must be kept away from salty oracid environments, from solvents, gas and inflammableliquids and explosives. REFER TO: Attachment1, Caterpillar 3126 or 3306 Diesel Engines.3.1.3.1DRAIN OR PROTECT FLUID COURSEDrain water or bentonite slurry out of fluid courseincluding main mud pump and associated lines.Alternatively, add antifreeze. REFER TO: Paragraph4.23.4, PROTECTING THE FLUIDCOURSE FROM FREEZING3.2 TRANSPORTWARNINGTransport of the machine must be carriedout by trained and authorized personnelonly, after learning the informationsupplied in the manual.3.2.1 PRELIMINARY OPERATIONS FORLOADING THE MACHINE FOR TRANSPOR-TATIONClean the machine by using a water spray.CAUTIONDon’t direct water spray inside themuffler, or the air filter, against electriccomponents or control panels.WARNINGBefore loading the machine on atrailer, follow the instructions suppliedin this manual carefully.3.2.2 PROCEDURES OF POSITIONINGPosition the thrust frame in order to obtain a minimumoverall dimension.Remove the tie-down stakes from the front footand store them in a safe location. Make sure toretract the thrust frame and raise the rear thruststabilizers.Position the carriage as far forward on the thrustframe as possible.3.2.3 TRANSPORTATIONConsidering dimensions, weight and shape of themachine, the transporter is responsible for usingthe proper method of transport in conformity withlocal regulations. Detailed information on the machinefeatures are in: Chapter 1 GENERAL IN-FORMATION and Chapter 2 DESCRIPTIONparagraph 2.5.1.3.2.4 LOADING THE MACHINE FORTRANSPORTATIONWARNINGMake sure that all personnel keep asafe distance while loading the machinefor transportation. Start up andhandle the machine according to Paragraph4.7. OPERATION. Use the tetheredtramming controls and stay clearof the machine. Always use low speedfor loading and move the controls delicately.WARNINGDo not sit or stand on the machinewhile tramming. Unexpected movementcan cause death or serious injury.Use remote tramming controlonly, while standing at ground levelwith good visibility.Start the engine.Remove the locking bolt from the thrust frameand the thrust frame support.Refer to the Safety Awareness Program in this manual before attempting to operate this machine. Page 15

WARNINGA crushed or damaged tramming controlcould result in unexpected movementof the machine. Unexpectedmovement can cause death or seriousinjury; Always replace the trammingcontrol into its holder.Angle the thrust frame as necessary in order tomake sure that the front foot does not drag on theground.Proceed slowly when passing the edge of thetrailer as the machine could swing, when changingthe inclination.3.3 LIFTING THE MACHINEIf the machine must be lifted (example: to loadon a ship) place the machine on a flat rack withadequate capacity for weight. Position the machineon the flat rack according to paragraph 3.2.4 above.Switch off the engine.Use chains to anchor the machine to the flat rack.Attach the lifting lines to the flat rack, not to themachine. Use spreader bars to ensure that the liftinglines do not come in contact with the machine(Fig.10).4. USE4.1 WORKING SITE PHYSICAL FEATURES4.1.1 MINIMUM SPACE REQUIREDIn working position 2.5 m [8 feet] width and atleast 15 m [50 feet] length. Height required forworking on flat ground: 8 m [26 feet] (to allowadding or removing pipe ). Additional clear distancemust be maintained between the crane andany overhead electric wires. These dimensions donot allow for storage of pipe or tooling nor the setup and operation of a mud plant. In addition, markoff a safety zone 8 m [25 ft] in each direction fromthe machine and prevent spectators from enteringthis zone.150mm [6 inches] high. Otherwise level the siteusing earthmoving equipment.4.1.3 TYPE OF GROUNDThe machine is designed to work on clay, asphalt,cement, rock and normal soil. It is not suitable towork on crumbling, marshy or inconsistent soil,which cannot guarantee traction or support duringwork. REFER TO: Paragraph 1.7 USES AL-LOWED and Paragraph 1.8 USES NOT AL-LOWED.4.1.4 LIGHTINGThere has to be enough light to guarantee goodvisibility of all the movable parts. It may be necessaryto equip the work area with portable lightsfor night operation.4.1.5 OPERATING TEMPERATURE: between -15°C and +40°C [+5°F and 105°F] (with oils andcoolants recommended).For temperature lower than 0°C [32°F] use winterfuel for easier starting and in order to avoid thestoppage of filters from deposits of wax. Make surethat all the liquids have suitable features. REFERTO: Chapter 5 MAINTENANCE.For temperature included between -40°C and -15°C [-40°F and +5°F] REFER TO: Paragraph 4.22OPERATION UNDER AMBIENT TEMPERA-TURES BETWEEN -40°C AND -15°C [-40°FAND +5°F].4.1.6 RELATIVE HUMIDITY ALLOWED duringthe work: 100%4.1.7 MAX. ALTITUDE: 2000 m [6500 ft] abovesea level.4.1.8 ATMOSPHERIC CONDITIONS: they mustallow adequate visibility within the safety area. Itis inadvisable to use the machine during rain wherelightning is present.4.1.2 GROUND LEVELINGThe machine is able to operate on surfaces with amax. lateral inclination of 10°, slope in the runningdirection up to 15° and to cross steps up toRefer to the Safety Awareness Program in this manual before attempting to operate this machine. Page 17

4.2 FUNCTION OF THE MACHINENOTICEFor a detailed description of operationand parts of the machine see Chapter2 (DESCRIPTION.)The directional drill is designed for the productionof a bore under the earth with a system moreefficient than conventional excavating and restorationof the site. The main tool is the cutting head;it may be equipped with a metal shoe or with hardmetal teeth and is able to remove soil. The result isa bore with circular section ready for positioningpipe or cable, without the need for back filling andcompacting.The cutting head is advanced by connecting it tosections of drill pipe which are added by the operationof the directional drill. In addition, soil isremoved and the bore is lubricated by use of amixture of water, bentonite and other substances(drilling fluid, also called mud) , which is forcedinto the drill pipe by the mud pump. The mudcirculates through the annulus of the bore and returnsto the surface at the entry point.The actual bore dimension cannot be guaranteedfor each bore. For example: depending on soil conditionsand the size of the pipe or cable to be installed,it may be necessary to enlarge the bore bypulling a reamer through it. Operation in hard rockrequires additional special accessories which arenot supplied and must be ordered separately.4.2.1 NORMAL OPERATIONThe operator has manual control over the rotationof drill pipe, the advance and return of thecarriage, flow and volume of mud, and operationof the fixed wrench and breakout wrench. The operatoralso has manual control over the movementsof the pipe loader. In addition the operator hasmanual control over the angle of the thrust frame.4.3 DANGEROUS ZONES—SAFE DISTANCESThe machine is designed to be operated by oneoperator, with one additional worker to load andunload pipe baskets as required. This worker mayalso have the duty to mix and transfer mud to thedrill. Other personnel must keep a distance of 8m[25 ft] from the machine. A third worker may beemployed along the intended bore path to operatethe locating instruments and report their readingsto the operator.After moving into position, the machine remainsstationary in operation and has rotating parts, madeup by various movable components, therefore eachpart has to be considered dangerous.4.3.1 DANGEROUS PARTS AND DESCRIP-TION OF THE RISK.4.3.1.1 TIE DOWN SYSTEM consisting of H-beams that are heavy and present a danger of pinchingwhile being installed.4.3.1.2 REAR THRUST STABILIZERS are extendingparts that present a danger of crushing.4.3.1.3 FRONT STABILIZERS are extendingparts that present a danger of crushing.4.3.1.4 CARRIAGE has movement forward andbackward as well as rotating parts, that presentpinch points and a danger of becoming entangled.4.3.1.5 WRENCH ASSEMBLY presents the dangerof pinch points4.3.1.6 CUTTING HEAD tools under fast movementand high power. Can emit fluid under highpressure for cutting the earth, also presents a dangerof becoming entangled.4.3.1.7 DRILL PIPE heavy objects that must beadded or removed from the drill. If handled carelessly,can fall or swing. While being forced intothe earth the drill pipe is exposed and may be inrotation, presenting a danger of becoming entangled.4.3.1.8 MUD SYSTEM presents a danger of highpressure fluid spray4.3.1.9 REAMING TOOLS turn fast under highpower. While on the surface they present a dangerof becoming entangled.Page 18Refer to the Safety Awareness Program in this manual before attempting to operate this machine.

4.3.1.10 DIESEL ENGINE AND MUFFLERproduce high temperatures. Danger of burns.Before approaching always wait until:-the machine is motionless-the engine is off-the movable parts are on the ground or in restposition-the hot parts have cooled.4.3.1.11 PERSONAL PROTECTIVEEQUIPMENTAlways wear suitable personal protective equipment:-protection for hearing-safety shoes-helmet-safety glassesREFER TO: Paragraph 1.5.4 DANGEROUSZONES—SAFE DISTANCESWARNINGWhen using the machine, make surethat all personnel keep a safe distance(8 m [25 ft] in every direction). Useadequate protective equipment for anyoperation to be done near the machine.See Fig. 5.4.4 QUALIFICATION OF THE OPERATORAfter delivery of the machine, a technician fromthe authorized dealer or from American Augers isavailable for training one or more operators. Aftertraining, personnel are qualified for operation andmaintenance of the machine.The operator must know every part of the manual.American Augers is available for any further informationor instruction. It is expected that customerpersonnel will be available and ready fortraining upon the scheduled arrival of the AmericanAugers trainer.4.5 POSITION OF THE OPERATORDuring drilling the only position of the operatorfor operating the machine is at the control console.Additional workers will assist with loadingand unloading the pipe as required. The operatormust not ride on the machine while it is moving.WARNINGDo not sit or stand on machine whiletramming. Unexpected movement cancause death or serious injury. Use remotetramming control box only whilestanding at ground level with good visibility.WARNINGA crushed or damaged tramming controlcould result in unexpected movementof the machine. Unexpectedmovement can cause death or seriousinjury; Always replace the trammingcontrol into its holder.WARNINGBefore leaving the console, make surethat all the controls are in OFF or NEU-TRAL position.4.6 CONTROLS AND INSTRUMENTS4.6.1 CONTROLSThe drilling functions are controlled by levers andswitches mounted on an extendable console. Asan option, the controls can be located inside aweatherproof driller’s cabin.One panel is at the rear of the engine. One panelis on the right side of the machine. The operatingcontrols are on a hinged arm at the right front cornerof the machine.4.6.1.1 TRAMMING CONTROLThe control box can be connected at one of threelocations. The only function of controls on this boxis the positioning of the drill on the job site or forloading and unloading from a transport. This switchbox is connected to the drill by a flexible coiledcord, and a container has been provided to holdthe switch box when it is not in use. The switchbox also contains an emergency stop push button.(Fig. 33, PB2).NOTICEThe switch must be in the SET-UP position(Fig. 31, SS24) to activate thetramming control.Refer to the Safety Awareness Program in this manual before attempting to operate this machine. Page 19

of the drill when making the pilot bore. Do not usethe rear thrust stabilizers to level the drill. Do notuse the rear thrust stabilizers to lift the tracks offthe ground.DANGERKeep personnel at a safe distancewhile lowering stabilizers, theypresent a danger of crushing.4.8.6 POSITION THE CRANERemove the pendant control from the storage boxand connect it at the base of the crane. While thedriller operates the crane controls, the second persondetaches the hook block from its rest. Movementof the right front jack will move the base ofthe crane, so be sure to unhook the crane from itsrest before moving the front jacks.To activate the crane, connect the remote controlcable to the electric socket at the base of the crane.Set the engine throttle (Fig. 30, SS8) to high. Operatethe crane using the controls, (Fig. 27).4.8.7 POSITIONING THE FRONT STABILIZ-ERS (JACKS)Use the controls (Fig. 31, SS18) to select the frontstabilizers. Use the controls (Fig. 31, SS20 andSS21) lower the stabilizers to contact the ground.4.8.8 THRUST FRAME ANGLEThe thrust frame has two independent movements.It can be tilted for changing the drillingangle using the control (Fig. 31, SS22) and can beadvanced or retracted (forward or rearward).4.8.9 THRUST FRAME EXTENSIONTo advance or retract the frame, set the switch(Fig. 31, SS45) to DRILL position.Operate the Thrust/Pullback control (Fig. 30, PD2)to position the carriage at the Carriage Lock (Fig.26). Swing the Lock Plate (Fig. 26-1) into thesocket on the carriage and rotate the toggle bar tohold the Lock Plate in position.In this positon, operation of the Thrust/Pullbackcontrol (Fig. 30, PD2) will extend or retract thethrust frame. Extend the thrust frame until the frontfoot contacts the ground.Install the locking bolt through the holes drilledin the thrust frame and the thrust frame support.This will prevent the thrust frame from sliding onthe frame support.Rotate the toggle bar away from the Lock Plate.Swing the lock plate (Fig. 26-1) away the socketon the carriage. Drilling operations are done withthe lock plate away from the carriage.4.8.10 ANCHOR THE MACHINEDANGERMOVING PARTS. Danger of entanglement.Keep body and clothing away.4.8.10.1PLACING THE TIE DOWN STAKESThe tie down stakes are intended to prevent themovement of the drill as it thrusts pipe into thesoil, or pulls on a backreamer or the product.Placing the tie down augers requires another personin addition to the drill operator. While the secondperson holds the stake in position, the drillerdrives the stake into the ground using a hydraulicstake driver.As an alternative, the stakes can by pushed intothe soil by carefully using the bucket of a backhoeor excavator to exert downward force on the topof the stake.DANGERKeep personnel at a safe distancewhile driving tie down stakes, theypresent a danger of crushing.4.8.10.2 OTHER METHODS OF ANCHORINGTHE DRILLIn especially soft soils or sand, it may be necessaryto use an earth anchor in addition to the tiedown stakes.In hard or rocky soil it may be necessary to cutopenings in the earth to accept the H-beams. Somesoils require the use of a pneumatic drill or otherequipment.4.8.10.3 POUR A CONCRETE ANCHORIn some soils, it will not be possible to install H-beams. After selecting the launch point, the drillermay use conventional excavating techniques toRefer to the Safety Awareness Program in this manual before attempting to operate this machine. Page 23

create a pit which can be filled with concrete. Youmay consider placing beams or fasteners into thewet concrete and attach the front foot of the drillby fasteners or welding.4.8.10.4 CONSTRUCT A “DEAD MAN”ANCHORConstruct a “dead man” anchor by excavating andback filling. One effective method is to use sheetpiling and a steel beam. The sheet piling is placedvertically in the excavation in front in front of thedrill. A steel beam is placed horizontally in frontof the sheet piling. A heavy chain or cable is attachedbetween the steel beam and the front footof the drill. The excavated soil is replaced and compactedover the sheet piling and steel beam. Thisarrangement prevents the drill from moving backwardwhen thrusting the drill string into the earth.See Fig. 37.4.8.11 EXCAVATE THE ENTRY PITThe drill should be anchored to the earth beforeexcavating the entry pit. Use earthmoving equipmentto excavate the entry pit in front of the drill.The pit is used to catch and retain drilling fluidthat returns from the bore. Many drillers excavatea smaller pit to one side of the entry pit and connectthe two pits together with a shallow channel.Fluid returns enter the larger pit and overflow intothe smaller pit. During this process many of thesolids returning from the bore settle to the bottomof the larger pit and do not have to be handled bythe fluid recycling equipment.4.9 DRILLING PROCESSDirectional drilling is the process of directing astring of small pipe, known as a drill string, underan obstacle, attach a cable or larger pipe line, andpull it back to the starting point. Various factorsshould be taken into account such as: 1) Hole size,2) Required curvature, 3) Hole length, 4) Geology,5) Minimum ground coverage, 6) Survey technique,7) Magnetic bearing, 8) Drilling fluids, 9)Entrance angle, 10) Exit angle, 11) Drill pipe, 12)Drilling machine, 13) Preplotting chart, and 14)General working area.There are two categories. The first will be deepcrossings, (4.5 m[15 ft] or more). The second categorywill be shallow crossings (4.5 m [15 ft] orless). In both categories, the basic drilling methodsare the same. The differences are in the mannerof guidance and locating the drill string head.Consult the manufacturer of the locating systemfor exact operating instructions.The directional drill provides the means for rotating,advancing and retracting the drill string. Dependingon the specific project, a certain drill stringdiameter is selected. Selection of drill string diameteror capacity is largely dependent on thelength of the crossing and the anticipated thrustand pullback required for the finished product line.At the leading end of the drill string, a cutting headis attached (see Fig. 15-1). The cutting head is usuallyequipped with nozzles which direct drillingfluid to the soil formation. While the cutting headis being rotated into the ground, drilling fluid ispumped through the drill string and passes throughthe nozzles in the head to carry cuttings back tothe surface. The drilling fluid is also used as a lubricantto reduce friction and heat between the rotatingparts and the ground.4.9.1 DEEP CROSSINGS - THE SETUPA drilled crossing can be set up in several differentways. One method is to drill in a constant arcor semi circle (see Fig. 44). The other methodwould be to enter a hole at a downward angle. Thedrill string is then directed into a horizontal positionand advanced for the distance required to clearthe obstruction. The drill string would then be directedat an upward angle to the exit point A crossingis determined by its depth, starting point andfinishing point.Once these criteria are determined, a set back distanceis calculated for an entering and exiting pointto and from the intended line. A general rule ofthumb is that a drill string can bend at the rate of30.5 m of radius per 2.5 cm of drilling pipe diameter.(Example: the minimum bend radius of a pipe9.85 cm in diameter is approximately 120 m). [Inthe English system a drill string can bend at therate of 100 ft of radius per 1 inch of drilling pipediameter. (Example: the minimum bend radius ofa pipe 3-7/8 inches in diameter is approximatelyPage 24Refer to the Safety Awareness Program in this manual before attempting to operate this machine.

380 ft).]Once the project is established and the enteringand exit points are known, the process can begin.The drill rig is set up and the drill thrust frame isset to the required angle. This is from 10 to 18degrees, depending on the characteristics of thecrossing. The initial pipe section and cutting headare set into the wrench. (Note: While the setup anddrilling is proceeding, a second operation shouldbe started to prepare the product line for installation).The first piece of drill pipe is made out of annonmagnetic material to eliminate any interferenceto the survey probe. This first section is setup tomount the cutting head and the survey probe forguidance. Before the drilling process begins, amagnetic bearing is selected for the desired directionof travel. The survey probe is calibrated tothis bearing and installed in the first section.4.9.2 DEEP CROSSINGS - STEERING SYSTEMWhile the hole is being drilled, the drill string isrotated along with the cutting head as a single section.When steering adjustments are required, thedrill string is not rotated, however, the cutting headoffset is rotated toward the desired direction oftravel and the drill string is advanced forward withoutrotation. The eccentric location of the cuttinghead relative to the center line of the drill stringcreates a wedge type effect when pushed withoutrotation. This causes the drill string to deflect inthe desired direction.The locating probe transmits the orientation ofthe cutter head relative to the face of a clock (Fig.18). Once the orientation is determined, the drillerrotates the drill pipe to the desired location. This isconfirmed by the locating instrument. The drillstring is then rotated to resume cutting. This processis repeated as many times as necessary to assureproper location of the cutting head as itprogresses along the desired path.4.9.3 DEEP CROSSINGS - DRILLINGMETHODWhen drilling begins, the drilling fluid (mud)pump is turned on and the cutting head is rotatedinto the ground. As the first section is being buried,the operator monitors the head location andcompares the information to a plotted chart. If thereis any deviation from the intended line, the operatormakes the steering corrections. Once the firstsection is buried, the drill section is uncoupled fromthe drill spindle and another section of drill pipe isadded. For each section of drill pipe installed, anadditional length of connector wire is also installed,crimped and insulated to complete the circuit forthe survey probe.The sequence continues until the pilot hole iscompleted. By the time the pilot hole is completed,the product line should have been prepared to bepulled back. For pulling back a product line or lines,first the cutting head is removed and a backreameris installed in its place.DANGERROTATING PIPE. Danger of entanglement.Keep body and clothing away.DANGERMOVING PARTS. Pinch point. Keepbody and clothing away.WARNINGA wrench on rotating drill pipe can seriouslyinjure or kill. Do not break outtool joints with pipe wrenchesA backreamer is a cutting head with its cuttersfacing the drill string. Its purpose is to clear a pathfor the product line being installed (Fig. 15-3 &15-4). Directly behind the backreamer (away fromthe drill pipe) a bearing swivel is installed. Thebearing swivel is to attach to a cap that has beeninstalled on the product line. The purpose of thebearing swivel is to prevnt the product line fromrotating as the reamer and drill pipe rotate. As theproduct line is pulled into the hole, the drill stringis rotated and drilling fluid is pumped in to maintainthe integrity of the hole.A rule of thumb states that the back ream diametershould be at least 1.5x the diameter of the productline.In cases where the product line or bundle of linesare larger than the pilot hole, an oversizedbackreamer will be required. When backreamingfor product line installation, a slightly larger holeRefer to the Safety Awareness Program in this manual before attempting to operate this machine. Page 25

than the product line is required so that the drillingfluid can remove the cuttings. The amount ofovercut is largely dependent upon soil conditionsand the type of crossing or obstacle. In cases wherethe ground conditions are soft and basicallyunsupporting, use a barrel reamer. This is a toolwith radial or coned-shaped ends, which whenpulled and rotated through the ground, compactsthe soil in the hole to maintain its integrity. Thebearing swivel is installed behind the barrel reamer.Drilling in hard soil or rock requires a downholemotor (see Fig. 16). Downhole motors are designedand built in various diameters and torque ratingsto accommodate most drilling applications.Downhole motors are used where high cutter bitspeed is desired. In most applications the motorsare used in combination with the bent sub for steeringpurposes. Several manufacturers have combinationsystems for sale or lease.In cases where the hole must be maintained orblowouts must be prevented, use of a wash pipe isrecommended. A wash pipe can be installed whenbackreaming or directly over the drill string. Theuse of a wash pipe provides a maintained annulararea so the drilling fluid can remove the cuttingsand spoil material without increasing downholemud pressures and the probability of a frac-out (inadvertentreturn of fluid).4.9.4 SHALLOW CROSSINGS - THE PROCESSThe DD-100 and DD-140B are not normally usedin shallow drilling (4.5 m [15 ft] or less).DANGERROTATING PIPE. Danger of entanglement.Keep body and clothing away.DANGERMOVING PARTS. Pinch point. Keepbody and clothing away.WARNINGA wrench on rotating drill pipe can seriouslyinjure or kill. Do not break outtool joints with pipe wrenches4.9.5 APPLICATION OF DRILLING FLUID TOHORIZONTAL BORINGWhen using high productivity drills as large asthe DD-100 or DD-140B, a fluid recycling systemis strongly recommended. Drilling operationsmight require fluid quantities of 1135 to 2270 L/minute (300 to 600 GPM). Simply mixing fluid inthese quantities presents a challenge. A recyclingsystem enables the driller to reclaim most of thedrilling fluid for re-use, and minimizes the amountof fresh water required for mixing. The recyclingsystem removes solids from the drilling fluid andusually includes a high pressure pump (mud pump)to send the fluid through the drill pipe into the bore.Controls for an American Directional Drill recyclingsystem fit in the control console next to thedrill controls (see Fig. 29-3).The primary functions of a drilling fluid (mud)in horizontal boring are: 1) to reduce torque associatedwith sticky soil conditions, 2) to aid removalof solids from the freshly cut hole by a flushingaction, and 3) to help stabilize the soil. Water isthe major component of drilling fluids used in horizontalboring. Materials added to water to producea drilling fluid are bentonite and polymer. Factorswhich are very important to drilling fluid qualityare: 1) water quality, 2) formulation of the productsand mixing order, and 3) adequate mixing ofthe products.4.9.6 DRILLING FLUID - THE PROCESSDrilling fluid (mud) consists of water or waterwith additives. Products such as bentonite and polymercan be very helpful for horizontal boring, Optimumdelivery of drilling fluid to soil is criticalfor minimizing operating pressures and torque.There are several key factors which must be consideredto maximize your production: 1) hole size,2) boring rate, and 3) fluid injection rate. Thesethree factors can be used to calculate a fluid-tosoilinjection rate in volume of fluid to volume ofsoil removed. The amount of fluid required to makethe soil flow out the hole is dependent on the typeand amount of clays in the soil.Page 26Refer to the Safety Awareness Program in this manual before attempting to operate this machine.

4.9.7 CALCULATION OF VOLUME OFFLUID TO VOLUME OF SOILThe three pieces of information needed to calculategallons of fluid to gallons of soil at a givenboring rate are: 1) hole volume, per unit of length.,2) boring rate, in length/minute, and 3) pump ratein volume/minute. From this information, the volumecan be calculated (see Fig. 43).Some soils may require more fluid, others less.If you are at the maximum mud pump output andencounter excess torque, then you can reduce therate of advance and vary your pump rate to produceminimum torque to optimize progress. Somesoils will be easier to drill if polymer is added tothe drilling fluid. Bentonite suppliers can offerguidance concerning the use of bentonite and polymerproducts.4.9.8 FLUID DISPOSALDisposal of drilling fluid wastes should be coveredin construction permits. Although drilling fluidadditives such as bentonite and polymer are notconsidered hazardous wastes, local regulationsconcerning fluid disposal vary. While it is importantto a