American Augers DD-440 Use and care manual

DD-440™Trailer Mounted Directional Drill
Operation & Safety
Instruction Manual
WARNING
Unsafe use of this equipment could result in serious injury or death. This manual contains
important instructions for the safe operation and recommended maintenance of your directional
drill.All who operate the directional drill must carefully read and understand this manual
before starting the machine. Keep this manual available both as a reminder for your experienced
operator and as a training aid for your new staff. Replacement manuals are available by
calling AmericanAugers.

Page 2 Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
INTRODUCTION
American Augers was established in 1970 to
provide a full line of modern equipment for the
trenchless excavation construction industry. The
company is organized in three product divisions to
serve the full range of trenchless technology.
American Directional Drill is the division producing
the leading line of Horizontal Directional Drills. We
are proud of our equipment and the job it can do.
We encourage you to call us for any and all of
your drilling needs. Every effort has been made to
cover adequately the operation of the DD-440™
trailer mounted directional drill. Specifications are
subject to change without notice or obligation to
retrofit units already in the field.
This manual will be constantly updated to
remain current with new operations. Please call if
there are areas requiring further explanation or
instruction. Material contained herein may not be
reproduced in whole or in part without the express
written permission ofAmericanAugers Inc., the
Innovative Leader in the Trenchless Industry.
Machine Serial Number ___________________
Engine Serial Number __________________
Copyright © 2001 byAmerican Augers
Part Number: 44DD10000TR
ReleasedAugust 2007 at Revision 00
Location of Engine SN Plate
Location of Machine SN Plates

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Table of Contents
1. GENERAL INFORMATION ...................................................................... 10
1.1 USE AND MAINTENANCE MANUAL ......................................................................... 10
1.1.1 DATA OF MANUAL ...................................................................................................................................... 10
1.1.2 CONTENTS OF MANUAL ............................................................................................................................ 10
1.1.3 WHO SHOULD USE THIS MANUAL ........................................................................................................... 10
1.1.4 OWNERSHIP OF INFORMATION ................................................................................................................. 10
1.2 MANUFACTURER IDENTIFICATION DATA ............................................................... 10
1.3 MACHINE IDENTIFICATION DATA ............................................................................ 11
1.4 DECLARATION OF EC CONFORMITY ....................................................................... 11
1.5 GENERAL INFORMATION ON SAFETY ..................................................................... 11
1.5.1 SAFETY STANDARD .................................................................................................................................... 11
1.5.2 QUALIFICATION OF PERSONNEL ............................................................................................................... 12
1.5.3 USE OF PERSONAL PROTECTIVE EQUIPMENT ......................................................................................... 12
1.5.4 DANGEROUS ZONES—SAFE DISTANCES ................................................................................................. 12
1.6 JOBSITE SAFETY ........................................................................................................... 13
1.6.1 SAFETY PLAN AND CHECKLIST ................................................................................................................. 13
1.6.2 RESPONSIBLE PERSONNEL .......................................................................................................................... 14
1.6.3 HAZARDS ..................................................................................................................................................... 14
1.6.4 VERIFYUTILITYLOCATES .......................................................................................................................... 15
1.6.5 TRAFFIC CONTROL (PEDESTRIAN AND VEHICLE) ................................................................................... 16
1.6.6 SAFE PRACTICES, SAFETY EQUIPMENT ................................................................................................... 16
1.6.7 RESPONSE TO EVENTS ................................................................................................................................17
1.6.8 CONCLUSION ................................................................................................................................................ 17
1.6.9 REFERENCES ................................................................................................................................................. 18
1.7 USES ALLOWED ............................................................................................................ 18
1.7.1 FEATURES OF THE SOILTO BE DRILLED .................................................................................................. 18
1.7.2 FEATURES OF TRANSPORT ........................................................................................................................ 18
1.7.3 MACHINE HANDLING PROCEDURES ......................................................................................................... 18
1.8 USES NOTALLOWED ................................................................................................... 19
1.9 WARRANTY ................................................................................................................... 19
1.9.1 GENERAL CONDITIONS ............................................................................................................................... 19
1.9.2 LIMITATIONS OF WARRANTY ................................................................................................................... 19
1.9.3 LIMITED WARRANTY CERTIFICATE ......................................................................................................... 19
1.9.4 REQUEST FOR SERVICE SUPPORT .............................................................................................................. 20
1.9.5 WARRANTYAND SERVICE FOR CATERPILLAR ENGINE ......................................................................... 20
1.10 SERVICEAGREEMENT ................................................................................................. 20
1.11 CONVENTIONS ............................................................................................................. 20
1.11.1 CONVENTIONS OF TERMINOLOGY ............................................................................................................ 20
1.11.2 TYPOGRAPHIC CONVENTIONS ................................................................................................................... 20
2. DESCRIPTION .......................................................................................... 20
2.1 PARTS OF THE MACHINE ............................................................................................ 20
2.2 DESCRIPTION OF THE DIRECTIONAL DRILL .......................................................... 20
2.2.1 TRUCK TRAILER .......................................................................................................................................... 20

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2.2.2 THRUST FRAME ........................................................................................................................................... 20
2.2.3 CARRIAGE ..................................................................................................................................................... 20
2.2.4 FIXED WRENCH ............................................................................................................................................ 20
2.2.5 BREAKOUT WRENCH .................................................................................................................................. 20
2.2.6 MUD .............................................................................................................................................................. 21
2.2.7 MUD PLANT ................................................................................................................................................. 21
2.2.8 TIE DOWN SYSTEM ..................................................................................................................................... 21
2.2.9 DRILL PIPE ..................................................................................................................................................... 21
2.2.10 ES!LOK® ........................................................................................................................................................ 21
2.2.11 ZAPALERT® ................................................................................................................................................. 21
2.2.12 DRILLER’S CONSOLE ................................................................................................................................... 21
2.3 PURPOSE OF THE MACHINE ...................................................................................... 21
2.4 STRUCTURE ................................................................................................................... 21
2.5 TECHNICAL SPECIFICATIONS ................................................................................... 22
2.5.1 GENERAL FEATURES (DD-440) .................................................................................................................... 22
2.5.2 DIESEL ENGINE ............................................................................................................................................. 22
2.5.3 ELECTRIC SYSTEM ....................................................................................................................................... 22
2.5.4 PERFORMANCEAS SUPPLIED .................................................................................................................... 22
2.5.5 VIBRATION ................................................................................................................................................... 22
2.5.6 NOISE ............................................................................................................................................................. 22
2.6 RESPONSIBILITY .......................................................................................................... 22
3. STORAGE AND TRANSPORT .................................................................. 22
3.1 STORAGE ....................................................................................................................... 22
3.1.1 PROTECTION WHILE IN STORAGE ............................................................................................................. 22
3.1.2 STORAGE SITE ENVIRONMENT .................................................................................................................. 23
3.1.3 PROCEDURES OF STORAGE ........................................................................................................................ 23
3.2 TRANSPORT ................................................................................................................... 23
3.2.1 PRELIMINARY OPERATIONS FOR TRANSPORTATION OF THE MACHINE ............................................ 23
3.2.2 PROCEDURES OF POSITIONING .................................................................................................................. 23
3.2.3 TRANSPORTATION ...................................................................................................................................... 24
3.2.4 PREPARING THE MACHINE FOR TRANSPORTATION .............................................................................. 24
3.3 LIFTING THE MACHINE ............................................................................................... 24
3.3.1 LIFTING ......................................................................................................................................................... 24
4. USE ............................................................................................................. 25
4.1 WORKING SITE PHYSICAL FEATURES ..................................................................... 25
4.1.1 SITE PREPARATION ..................................................................................................................................... 25
4.1.2 MINIMUM SPACE REQUIRED ..................................................................................................................... 25
4.1.3 GROUND LEVELING ...................................................................................................................................... 25
4.1.4 TYPE OF GROUND ........................................................................................................................................ 25
4.1.5 LIGHTING ...................................................................................................................................................... 26
4.1.6 OPERATING TEMPERATURE ....................................................................................................................... 26
4.1.7 RELATIVE HUMIDITYALLOWED ............................................................................................................... 26
4.1.8 MAXIMUM ALTITUDE ................................................................................................................................26
4.1.9 ATMOSPHERIC CONDITIONS ..................................................................................................................... 26
4.2 SPECIAL REQUIREMENTS FOR USING THIS MACHINE ........................................ 26
4.2.1 INCREASED NEED FOR SUPPORT EQUIPMENT ......................................................................................... 26
4.2.2 INCREASED CREW SIZE - DRILL SIDE ........................................................................................................ 27
4.2.3 INCREASED CREW SIZE - EXIT SIDE .......................................................................................................... 27

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4.3 FUNCTION OF THE MACHINE ................................................................................... 27
4.3.1 NORMAL OPERATION ................................................................................................................................. 28
4.4 DANGEROUS ZONES—SAFE DISTANCES ................................................................ 28
4.5 QUALIFICATION OF THE OPERATOR ........................................................................ 29
4.6 POSITION OF THE OPERATOR ................................................................................... 29
4.7 CONTROLS AND INSTRUMENTS ............................................................................... 29
4.7.1 CONTROLS .................................................................................................................................................... 29
4.7.2 INSTRUMENTSAND CONTROLS (LIST) ..................................................................................................... 30
4.7.3 ES!LOK® LOCKOUT SYSTEM ..................................................................................................................... 31
4.7.4 ZAPALERT™ ................................................................................................................................................ 31
4.8 OPERATION ................................................................................................................... 31
4.8.1 STARTING THE ENGINE ............................................................................................................................... 31
4.8.2 OPERATING WITH ONE ENGINE ................................................................................................................. 32
4.8.3 MOVEMENT OF THE MACHINE ................................................................................................................. 32
4.9 SET-UP ............................................................................................................................ 32
4.9.1 POSITION THE DRILL ................................................................................................................................... 32
4.9.2 LOWER TRAILER LANDING GEAR ............................................................................................................. 32
4.9.3 POSITION THE DRILLER’S CONSOLE ......................................................................................................... 32
4.9.4 INSTALL HANDRAILS ON THE WALKWAY .............................................................................................. 32
4.9.5 LOWER SUPPORT JACKS ............................................................................................................................. 32
4.9.6 INSTALL WRENCHES ON DRILLFRAME ................................................................................................... 32
4.9.7 INSTALL FRONT FOOT ................................................................................................................................32
4.9.8 THRUST FRAMEANGLE .............................................................................................................................. 32
4.9.9 THRUST FRAME EXTENSION ..................................................................................................................... 32
4.9.10 FINISH SETUP ............................................................................................................................................... 32
4.9.11 ANCHOR THE MACHINE ............................................................................................................................. 33
4.9.12 EXCAVATE THE ENTRYPIT .......................................................................................................................... 33
4.9.13 CONNECT THE CONTROL CONSOLE .......................................................................................................... 33
4.10 DRILLING PROCESS .................................................................................................... 33
4.10.1 DEEP CROSSINGS - THE SETUP ................................................................................................................... 34
4.10.2 DEEP CROSSINGS - STEERING SYSTEM ..................................................................................................... 34
4.10.3 DEEP CROSSINGS - DRILLING METHOD ..................................................................................................... 34
4.10.4 SHALLOW CROSSINGS - THE PROCESS ..................................................................................................... 35
4.10.5 APPLICATION OF DRILLING FLUID TO HORIZONTALBORING .............................................................. 35
4.10.6 DRILLING FLUID - THE PROCESS ................................................................................................................ 36
4.10.7 CALCULATION OF VOLUME OF FLUID TO VOLUME OF SOIL ................................................................ 36
4.10.8 FLUID DISPOSAL .......................................................................................................................................... 36
4.10.9 WATER QUALITY ......................................................................................................................................... 37
4.10.10 MUD MIXING ............................................................................................................................................... 37
4.11 ADDING AND REMOVING PIPE .................................................................................. 37
4.11.1 ADDING PIPE (FIRST SECTION WITH WALKOVER LOCATION) .............................................................. 37
4.11.2 ADDING PIPE (FIRST SECTION WITH WIRELINE LOCATION) ................................................................. 38
4.11.3 USING A MUD MOTOR ................................................................................................................................38
4.11.4 THE ROTARY BRAKE ................................................................................................................................... 39
4.11.5 THE CARRIAGE BRAKE ............................................................................................................................... 39
4.11.6 OTHER CONTROLS ....................................................................................................................................... 39
4.11.7 INSTALLINGAWIRELINE GUIDANCE INSTRUMENT ............................................................................... 40
4.11.8 ADDING PIPE (ADDITIONAL SECTIONS) ................................................................................................... 41
4.11.9 SETTING CARRIAGE ROTARYSPEED ......................................................................................................... 42
4.11.10 REMOVING PIPE ............................................................................................................................................ 42
4.11.11 CALCULATING ROTARY TORQUE FORCE ................................................................................................. 43
4.11.12 CALCULATING THRUSTAND PULL BACK FORCE ................................................................................... 43

Page 6 Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
4.12 START OF THE DRILLING OPERATION ..................................................................... 44
4.13 END OF DRILLING OPERATIONS ............................................................................... 44
4.14 START OF THE PULLBACK OPERATIONS ................................................................. 44
4.15 END OF PULLBACK OPERATIONS ............................................................................ 45
4.15.1 REMOVING THE TIE DOWN STAKES ......................................................................................................... 45
4.15.2 REMOVAL OF ANCHORS ............................................................................................................................. 45
4.15.3 CLEAN UP ..................................................................................................................................................... 45
4.16 SWITCHING OFF THE ENGINE ................................................................................... 45
4.17 EMERGENCY STOP ....................................................................................................... 46
4.17.1 ROTARY CARRIAGE DISABLE .................................................................................................................... 46
4.18 STARTAFTER AN EMERGENCY STOP ....................................................................... 46
4.19 CHECKS DURING OPERATION ................................................................................... 46
4.20 NORMAL OPERATING RANGES OF INSTRUMENTS ............................................... 46
4.21 ES!LOK® LOCKOUT .................................................................................................... 46
4.21.1 START AFTER USE OF ES!LOK® ................................................................................................................. 47
4.22 USE OF ZAPALERT® .................................................................................................... 47
4.22.1 START AFTER USE OF ZAPALERT® .......................................................................................................... 47
4.23 OPERATION UNDER AMBIENT TEMPERATURES BETWEEN -40°C & -15°C
[-40°F TO +5°F] .............................................................................................................. 47
4.23.1 PRE-HEATING DEVICES ................................................................................................................................47
4.23.2 STARTING THE ENGINE (with the machine kept warm through pre-heaters) ............................................... 48
4.23.3 STARTING THE ENGINE (in case the pre-heaters are not connected while stopped) ................................... 48
4.23.4 PROTECTING THE FLUID COURSE FROM FREEZING ................................................................................ 48
4.24 INSPECTION OF TRAILER BEFORE MOVING .......................................................... 48
5. MAINTENANCE ......................................................................................... 49
5.1 DANGEROUS ZONES—SAFE DISTANCES ................................................................ 49
5.2 ORDINARY, PERIODICAL, AND PREVENTIVE MAINTENANCE ............................ 49
5.2.1 QUALIFICATION OF THE TECHNICIAN ..................................................................................................... 49
5.2.2 FREQUENCY OF INSPECTIONS .................................................................................................................... 49
5.3 SCHEDULED INSPECTION AND MAINTENANCE ................................................... 50
5.3.1 MAINTENANCE SCHEDULES OF DD-440 DIRECTIONAL DRILLS ............................................................ 50
5.3.2 EMERGENCY STOP ....................................................................................................................................... 51
5.3.3 GREASING ..................................................................................................................................................... 51
5.3.4 ENGINE OIL ................................................................................................................................................... 51
5.3.5 ENGINE COOLANT ....................................................................................................................................... 51
5.3.6 AIR FILTERS .................................................................................................................................................. 51
5.3.7 FUEL .............................................................................................................................................................. 51
5.3.8 HYDRAULIC OIL CIRCUIT ........................................................................................................................... 51
5.3.9 GEARBOXESAND PUMP DRIVE ................................................................................................................. 52
5.3.10 WELDING ...................................................................................................................................................... 53
5.3.11 RADIATOR .................................................................................................................................................... 53
5.3.12 HYDRAULIC PISTON RODS ......................................................................................................................... 53
5.3.13 CLEANING ..................................................................................................................................................... 53
5.4 OTHER CHECKS AND MAINTENANCE (50 HOURS) ............................................... 53
5.4.1 BOLTS AND NUTS ........................................................................................................................................ 53
5.4.2 PIPESAND HOSES ........................................................................................................................................ 53
5.4.3 LEAKS ........................................................................................................................................................... 54

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5.4.4 GAUGESAND INSTRUMENTS .................................................................................................................... 54
5.4.5 BATTERIES .................................................................................................................................................... 54
5.5 OTHER INSPECTIONS AND MAINTENANCE (EVERY 250 HOURS) ...................... 54
5.5.1 MOTOR MOUNTS AND RADIATORS ......................................................................................................... 54
5.5.2 BREATHER PIPES .......................................................................................................................................... 54
5.6 OTHER INSPECTION AND MAINTENANCE (EVERY 500 HOURS) ........................ 54
5.6.1 ENGINE BELTS ............................................................................................................................................... 54
5.6.2 COOLING SYSTEM ........................................................................................................................................ 55
5.6.3 ENGINE OILBREATHER PIPE ....................................................................................................................... 55
5.6.4 ELECTRIC SYSTEM ....................................................................................................................................... 55
5.7 OTHER CHECKS (EVERY 1000 HOURS OR EVERY YEAR) ...................................... 55
5.7.1 ENGINE FUELFILTERS ................................................................................................................................. 55
5.7.2 ENGINE COOLING SYSTEM .......................................................................................................................... 55
5.7.3 EMERGENCY STOP ....................................................................................................................................... 55
5.8 INSPECTIONS AND MAINTENANCE EVERY 24 MONTHS ..................................... 55
5.8.1 ENGINE COOLING SYSTEM .......................................................................................................................... 55
6. DIAGNOSTIC ............................................................................................. 55
6.1 OPERATING FAULTS ..................................................................................................... 55
6.1.1 CLOGGEDAIR FILTER ................................................................................................................................... 55
6.1.2 ENGINE OIL PRESSURE ALARM .................................................................................................................. 55
6.1.3 ENGINE COOLANT TEMPERATURE ALARM ............................................................................................. 55
6.1.4 ROTARYAND CARRIAGE DO NOT OPERATE ............................................................................................ 55
6.1.5 CLOGGED OILFILTER ................................................................................................................................... 56
7. DEMOLITION ............................................................................................ 56
7.1 MACHINE DEACTIVATION .......................................................................................... 56
7.2 RESIDUAL RISKS .......................................................................................................... 56

Page 8 Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Table of Figures
Figure 1 Declaration of EC Conformity ............................................................................................................................ 58
Figure 2 Limited Warranty Certification ........................................................................................................................... 59
Figure 3 Exit Pit Warning .................................................................................................................................................. 60
Figure 4 Pipe Wrench Warning .......................................................................................................................................... 60
Figure 5 Electrical Hazard Warning ................................................................................................................................. 61
Figure 6 Machine Labels ................................................................................................................................................... 62
Figure 7 Placement of Labels ............................................................................................................................................ 64
Figure 8 Placement of Labels ............................................................................................................................................ 66
Figure 9 Placement of Labels ............................................................................................................................................ 68
Figure 10 Lifting the Drill ................................................................................................................................................. 72
Figure 11 Drill Unit Dimensions ........................................................................................................................................ 72
Figure 12 Site Layout ........................................................................................................................................................ 73
Figure 13 Entry Pit ............................................................................................................................................................ 73
Figure 14 Main Junction Box ............................................................................................................................................ 74
Figure 15 Hose Caps .......................................................................................................................................................... 75
Figure 16 Setup Valves ...................................................................................................................................................... 75
Figure 17 Installing the Wrench ........................................................................................................................................ 76
Figure 18 Handrails .......................................................................................................................................................... 76
Figure 19 Wireline Conductor ........................................................................................................................................... 77
Figure 20 Cord Grip and Side Entry Sub .......................................................................................................................... 77
Figure 21 Wireline Conductor Splice ................................................................................................................................ 78
Figure 22 Crimping Tool ................................................................................................................................................... 78
Figure 23 Electric Heat Gun .............................................................................................................................................. 79
Figure 24 Wireline Guidance System ................................................................................................................................. 79
Figure 25 Wireline System Layout ..................................................................................................................................... 80
Figure 26 Tooling .............................................................................................................................................................. 80
Figure 27 Down Hole (Mud) Motor .................................................................................................................................. 81
Figure 28 Steering ............................................................................................................................................................. 81
Figure 29 Control Console General Arrangement (Inside Optional Cabin) ................................................................... 82
Figure 30 Ends of Control Console ................................................................................................................................... 82
Figure 31 Rotary Carriage Disable .................................................................................................................................. 83
Figure 32 Battery Box ........................................................................................................................................................ 83
Figure 33 Table to Convert PSI Reading to Rotary Torque .............................................................................................. 84
Figure 34 Table to Convert PSI Reading to Thrust/Pullback Force ................................................................................ 85
Figure 35 Table to Convert PSI Reading to Wrench Force ............................................................................................... 86
Figure 36 Maintenance Schedule ..................................................................................................................................... 87
Figure 37 Approved Replacement Fluids .......................................................................................................................... 87
Figure 38 Volume of Soil Formula..................................................................................................................................... 88
Figure 39 Steering Radius ................................................................................................................................................. 88
Figure 40 WiggleSteer™ Codes ........................................................................................................................................ 89
Figure 41 Drill Rig Nomenclature ..................................................................................................................................... 90
Figure 42 Upper and Main Control Console .................................................................................................................... 91
Figure 43 Air Cleaner ........................................................................................................................................................ 92
Figure 44 Manual Crank ................................................................................................................................................... 92
Figure 45 Tie Down Chain ................................................................................................................................................. 93

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Page 10 Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
1. GENERAL INFORMATION
1.1 USE AND MAINTENANCE MANUAL
1.1.1 DATA OF MANUAL
TITLE: Operation & Safety Instruction Manual,
Model DD-440 Trailer Mounted Directional
Drill
EDITION: 2002
Part number: 44DD10000
1.1.2 CONTENTS OF MANUAL
Section 1 General Information
Section 2 Description
Section 3 Storage and Transport
Section 4 Use
Section 5 Maintenance
Section 6 Diagnostic
Section 7 Demolition
1.1.3 WHO SHOULD USE THIS MANUAL
1.1.3.1 TRANSPORTER
The transporter is not authorized to handle the
machine nor start the engine. Only trained personnel
having a written authorization are allowed to load
and unload the machine from the transport vehicle
(see Section 1.1.3.2, USER). Relevant parts of the
manual are in Section 3, STORAGEAND
TRANSPORT.
1.1.3.2 USER
At consignment of the machine, a technician
either from the authorized dealer or fromAmerican
Augers is available for training one or more opera-
tors. Only trained personnel are qualified to operate
and maintain the machine.
We recommend following the procedure of the
acceptance and test-run certificate, which must
always come with the machine together with the
manual for any other subsequent training. The
authorized dealer is always available for any further
information or instruction. The user must read and
follow the manual.
1.1.3.3 MAINTENANCE TECHNICIAN
The technician in charge of maintenance must get
acquainted with operation and handling of the
machine, he must be able to check that there are
no faults in order to carry out maintenance work
with adequate equipment and protection. In case
the technician is not qualified, he must inform a
qualified person so that skilled personnel are called
for special work (example: adjustment of Caterpillar
engine, welding, etc.). The technician must
read and follow the manual.
1.1.4 OWNERSHIP OF INFORMATION
AmericanAugers, Inc. reserves all rights to the
information in this manual. The manual cannot be
reproduced or photocopied in part or in whole
without previous written authorization fromAmeri-
can Augers, Inc.
The use of the manual is restricted to the cus-
tomer who received it and only for purposes of
installation, use, and maintenance of the relevant
machine.
AmericanAugers declares that the information
contained in this manual fits the technical and safety
specifications of the machine.AmericanAugers
disclaims responsibility for direct or indirect dam-
ages to persons or property caused when the
manual or the machine are used in violation of the
information contained herein.
The information contained in the manual refers
only to the machine mentioned in Section 1.3,
MACHINE IDENTIFICATION DATA. American
Augers reserves the right to modify or improve the
manual and the machines without notice.
1.2 MANUFACTURER IDENTIFICATION
DATA
AMERICAN AUGERS, INC.
135 U.S. Rt. 42, P.O. Box 814
West Salem, Ohio 44287 USA
Tel. [phone] • Fax [phone]
www.americanaugers.com