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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THIS PAGE LEFT BLANK INTENTIONALLY

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

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1.3 MACHINE IDENTIFICATION DATA
Type: Directional Drill
Model: DD-440
Serial number: ..........
Year of manufacture: ...........
Location of identification plate: see illustration on
page 2.
1.4 DECLARATION OF EC CONFORMITY
If required, the declaration of EC conformity is
issued at consignment of the machine together with
the manual. EC conformity is not required in North
America.
1.5 GENERAL INFORMATION ON
SAFETY
1.5.1 SAFETY STANDARD
In designing and construction of the machine,
standards have been adopted in order to satisfy
essential safety requirements with subsequent
modifications under applicable directives. In par-
ticular, suitable measures to prevent risks for opera-
tors during transport, use, maintenance, and demoli-
tion of the machine have been completed.
The complete documentation of the measures
adopted for safety purposes is contained in the
technical file of the machine, registered by the
manufacturer.
The detailed analysis of risks carried out by the
manufacturer are intended to eliminate most of the
risks connected with the conditions of use of the
machine, both foreseen and reasonably foreseeable.
The manufacturer recommends that the user
carefully follows instructions, procedures, and
advice contained in the manual and the laws in force
on the work site, as well as the use of all protective
equipment, both integrated in the machine and
personal protective equipment.
1.5.1.1. SAFETYAWARENESS PROGRAM
Understanding Operation Safety
All references throughout this manual are to
current models of the DD-440 directional drill.
Please callAmericanAugers if you encounter
problems not addressed in this manual.
BE AWARE OF SAFETY INFORMATION.
This is the safety alert symbol. This
symbol is placed in the manual to alert you to the
potential for bodily injury or death.
UNDERSTAND SIGNAL WORDS
Signal words are used to identify safety infor-
mation within the text of this manual, and are used
on the hazard alert signs used on the machine.
DANGER
indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious personal injury.
WARNING
indicates a potential hazard or unsafe
situation which, if not avoided, could
result in death or serious personal injury.
CAUTION
indicates a potential hazard or unsafe
practice which, if not avoided, may result in
minor personal injury or product or property
damage.
If you are the owner, operator, or the helper
using anAmerican Directional Drill, it is important
that you recognize that your drill is a powerful piece
of construction equipment. (IT MUST BE OPER-
ATED WITH RESPECT AND CAUTION.)
All operators or trainees must carefully read
and thoroughly understand this Operation Manual
before starting or using this machine. Thorough
training of both operators and helpers is essential for
the safe operation of this equipment.
Never allow inexperienced personnel to
operate or work near the machine unless they are
carefully supervised during training. In the United

Page 12 Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
States, workplace safety is regulated by the Occu-
pational Health and SafetyAdministration (OSHA).
OSHA regulations are found in the Code Of Fed-
eral Regulations, Chapter 29. This is known as
29CFR1910. Information can be obtained from
your Regional U.S. Department of Labor Office.
Please note the limited warranty included in this
manual. If you have questions on the warranty or
about any part of the machine operation, please
contactAmericanAugers.
NOTICE
Location of Hazard Alert Signs
The drawings on Figures 7, 8, and 9 show
the locations of hazard alert signs as they are
placed on the DD-440. These hazard alert signs
are placed on the machine to inform your
operator and other personnel of potential
hazards that exist while these machines are in
operation. These signs must be kept clean and
legible. Replacement signs are available from
American Augers.
NOTICE
American Augers disclaims any responsibility
for damages to persons or property caused by
operation in violation of safety advice
contained in the manual.
1.5.2 QUALIFICATION OF PERSONNEL
If skilled personnel operate the machine accord-
ing to the advice and instructions supplied in the
manual, the machine will operate safely.All the
operations of transport, use, and maintenance must
be carried out only by skilled and authorized per-
sonnel, after studying and understanding the instruc-
tions supplied by the manual.
NOTICE
American Augers disclaims any responsibility
for damages to persons or property caused by
the operation of the machine by untrained
personnel.
1.5.3 USE OF PERSONAL PROTECTIVE
EQUIPMENT
WARNING
If personal protective equipment is not used,
serious injury or death of personnel can occur.
The operator and all other personnel on the
worksite must use proper protective equipment
according to their duties.
In addition to safety shoes, helmets, and safety
glasses, it is necessary to wear hearing protection.
The driller, locating device operator, and others
in contact with the machine should wear electric
insulating boots in case of striking a buried electric
cable.
1.5.4 DANGEROUS ZONES—SAFE
DISTANCES
Any zone inside or near the machine where the
presence of a person means a risk for his health and
security.
All the areas concerned with handling of parts or
machine.
During transport, keep a distance of at least 4.2
m (13 feet, 6 inches) away from the drill.
While drilling, some drilling fluid can be sprayed
from the cutting head.
In addition, in case of striking a buried electric
cable, the earth around the drill can become electri-
cally charged. Keep spectators at least 8 m (25 feet)
from the drill and associated equipment.
During maintenance, use adequate supports
before releasing bolts, pins, valves, pipes, and
pistons.
Safety distances during transport: 4.2 m (13
feet, 6 inches)
Safety distances during moving: 4.2 m (13 feet,
6 inches)
Safety distances during use: 8 m (25 feet)
Safety distances during maintenance: 8 m (25
feet)

Page 13
Refer to the Safety Awareness Program in this manual before attempting to operate this machine
1.6 JOBSITE SAFETY
Horizontal Directional Drilling (HDD) safety
requires essentially the same philosophy as
construction. Safety must start at the management
level, and every employee must be committed to the
safety program if it is to be effective. Each HDD job
is different, but all must be approached with safety
as the primary consideration.Awell-planned effort
by trained personnel allows construction to continue
profitably without compromising safety. The
manufacturer’s operator’s manual is the main source
for information on specific HDD equipment and
must be followed during all operations. This section
summarizes general job-site safety.
1.6.1 SAFETY PLAN AND CHECKLIST
Each company should have a safety manual that
includes the following:
• Operations and maintenance procedures
that comply with applicable regulations
• Emergency procedures for utility strikes
• Emergency procedures for other high risk
activities
• Detailed emergency evacuation plan
• Employee training program
• Records of incidents, accidents, and
training
As with any operation, it is important to work
safely and have procedures and contingency plans in
place to handle emergencies. Safety and
communication procedures should be well
established and all personnel on site should be
instructed on protocol. The following is a list of
issues that should be addressed when designing a
safety program and contingency plans:
• Safety starts at the top
• Identify the chain of command
• Clearly outline corporate safety philosophy
and develop safe work procedures
• Require participation by all salary and
wage personnel
• State the Personal Protective Equipment
policy
• Every employee has the right and obliga-
tion to refuse dangerous work
• Orientation of new employees is essential
• A Competent Person and trained first aid
personnel are required on every site
• First aid equipment and fire extinguishers
must be available at an identified location in
every commercial vehicle and on site
• Provide location and access to local
emergency facilities
• Communicate effectively
The following is a list of issues that should be
addressed when developing safety procedures for
specific activities:
• Identify and define the activity
• Identify related safety hazards
• Develop written step-by-step procedure
for performing the activity
• Eliminate, isolate, or control the identified
hazards with procedures
• Continuously monitor for changing haz-
ards
• Review and revise procedures when an
incident or accident occurs
• Closely supervise new, inexperienced
employees
The following is a list of issues that should be
addressed before starting work at a new location.
These issues should be reviewed with everyone
present at the beginning of each shift:
• Discuss specific hazards and procedures
• Discuss location of emergency facilities
• Discuss evacuation plan and emergency
procedures
• Brief all personnel, subcontractors, and
visitors as they arrive
• Record discussions and attendees
It is imperative that site-specific hazards are
identified and appropriate safety procedures are
discussed, as every site has unique safety issues that

Page 14 Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
need to be addressed. Crews should be aware of
specific safety and emergency procedures.
1.6.2 RESPONSIBLE PERSONNEL
1.6.2.1 COMPETENT PERSON
The Competent Person is responsible for
ensuring that a safety briefing is provided for all
authorized jobsite personnel prior to beginning
operations and periodically during the project, and
to assign duties to suitably qualified personnel. The
Competent Person is also responsible for ensuring
that generally accepted construction safety practices
and suitable procedures are understood and
followed by all personnel.
1.6.2.2 OPERATORS
Operators of drilling, tracking, and support
equipment must be deemed competent by the
Competent Person, or supervised by a qualified
operator. Operators must have continuous 2-way
radio contact with the drill locator and product side
personnel to coordinate the drilling operation.
Backup radios or spare batteries should be
available.
1.6.2.3 SUPPORT
Support personnel should be briefed by the
Competent Person upon arrival, and must follow
and maintain all safety procedures throughout the
job. Support personnel and visitors must be
informed of hazards, their responsibilities, and any
restrictions of activities.
1.6.3 HAZARDS
Prior to commencement of any boring activity, a
hazard analysis should be performed to identify all
perceived hazards. Procedures should then be
created to remove, isolate, or otherwise control the
identified hazards.As with any construction
operation, compliance with all OSHA, State, and
Local Regulations is required, regarding general
safety practices for activities including:
• Vehicle operation
• Mobile equipment operation
• Noise
• Traffic control
• Verification of utilities
• Security of jobsite and isolation of hazards
• Manual lifting
• Trench Shoring and Sloping
• Confined-space Entry
• Hand tools
• Power tools
• Fall protection
• Material handling
Activities that are specific to HDD must also be
addressed including:
• Rig operation
• Pilot bore tracking
• Utility clearances
• Electrical strike protection
• Rotating drill pipe
• Drilling fluid system operation
• Working on product side
• Communications
• Handling loose drill pipe
• Making/breaking tool joints
1.6.3.1 UNDERGROUND
Underground hazards to consider include:
• Electrical power cables, which can cause
serious injury or electrocution if connected
• Fluid and gas pipes, which may transport
asphyxiating, toxic, flammable, and/or
explosive gases or liquids
• Fiber optic cables carry laser light signals,
which can cause eye damage
• Low-pressure sewage and storm water
lines. These pose a unique hazard potential
if an HDD gas or electric line installation
has been installed that has interested the
sewage line without detection. Subsequent
maintenance or repair activity could cause a
gas leak, explosion, or electrocution.

Page 15
Refer to the Safety Awareness Program in this manual before attempting to operate this machine
1.6.3.2 SURFACE
The job site surface should be thoroughly
evaluated for indications of possible underground
hazards.
• Transformer boxes should be checked by a
qualified utility worker to determine the number and
orientation of lines entering the box. Ground grids
should also be checked.
• Manholes within the drill area should be
opened and inspected, without entry, to determine
the underground utility it services. The direction of
flow in a sewer should be checked to determine the
approximate grade. This information can be used to
project depth of the utility where the bore is being
made.
• Wire attached to poles should be assumed to
be live.
• Water and gas shutoff depths should be
confirmed to provide initial confirmation of the depth
of the pipe and facilitate the potholing process. A
minimum of 150 to 200mm (6" to 8") should be
added to depths for valves going to house services.
Additional clearance may be required for large
valves. This information can be used to facilitate
potholing, and is not by itself a safe method of
verifying the depth or location of the utility before
construction.
• Out buildings (i.e. storage sheds) should be
checked to determine if they have electrical wires or
other utility services that may not be marked on any
plans.
• Gas barbeque grills, outdoor lighting, etc.
should be identified and services confirmed.
• Ditch line depressions in the landscape or
obvious changes in vegetation may reveal previous
excavation and should be investigated.
• Road repairs may indicate the presence of
recently installed or repaired utilities.
• Marker signs or casing vents at or near
property lines indicate underground hazards.
• Private utilities and utilities that do not sub-
scribe to the one-call system are not marked by One
Call operators. The Contractor should check State
and local regulations and Contract Documents to
determine responsibility for verifying locations of
unmarked utilities.
1.6.3.3 OVERHEAD
Overhead lines must be avoided. Overhead
lines are of particular concern during mobilization/
demobilization, while handling drill pipe, or loading
and unloading heavy equipment. If the voltage is
unknown, always maintain at least 6m (20ft.) of
separation between equipment and power lines. If
the voltage is known, OSHA regulations outline the
required minimum separation. If necessary, place
highly visible markers on either side of the overhead
hazard or designate an individual to notify equipment
operators as they approach.
1.6.4 VERIFY UTILITY LOCATES
The location of all identified utilities must be
verified using non-destructive methods of
excavation. The bore profile must be designed to
maintain acceptable clearances between
underground utilities and structures, and the final
reamed hole. Possible migration of the back reamer
from the pilot bore toward the utility, due to
excessive steering or a tight radius, must be carefully
considered when establishing clearances.As
easements become increasingly congested, it may be
necessary to increase the easement widths to
accommodate demand for new utilities.
If there is any risk to the utility from the drilling
activity, a ‘window’must be excavated at or near
the utility to visually monitor the potentially hazard-
ous situation.Avacuum unit is required to remove
the drilling fluid during the process, and high pres-
sure drilling fluid hazards must be addressed. If the
bore passes closely by a utility, it may be necessary
to continuously monitor the separation after the drill
head or reamer passes the ‘window’, as the drill
string or product pipe may subsequently contact the
utility during the completion of the installation.
Communication is a critical ingredient of any
successful horizontal directional drilling project. It is
imperative that the drill locator and the drill rig
operator have an understanding of the job prior to
commencement of the work. They should walk the
planned bore path with the tracking equipment to
evaluate any potential fields of electromagnetic
(active) interference and look for signs of reinforced

Page 16 Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
concrete or other possible passive interference that
may hinder the operation, and discuss the identified
hazards.
During the actual boring process, if abnormal
readings are found with the tracking equipment, the
contractor should stop, back up, and verify previous
readings prior to commencing the bore. This is
critical; as deviation from the planned bore profile
could result in underground utility strike. Care must
also be taken during the pullback to ensure that
utilities are not damaged due to the upsizing by the
enlarged back reamer and possible straightening of
the bore during back reaming and product installa-
tion.
1.6.5 TRAFFIC CONTROL (PEDESTRIAN
AND VEHICLE)
Necessary traffic control must be maintained
throughout the project. Typically, mobilization,
demobilization, material handling, and intermittent
movement of mobile equipment require traffic
control if the activity conflicts with vehicle or pedes-
trian traffic. Traffic control includes permits, plan-
ning, notification, flag persons, warning signs, and
barricades. The work area, particularly around the
drill rig and entrance/exit pits, must also be secured
to prevent unauthorized entry. Emergency vehicles
and buses must have access during construction.
1.6.6 SAFE PRACTICES, SAFETY
EQUIPMENT
Safe practices must include identification of
hazards, as well as isolation, control, or removal of
hazards. Personal protective equipment that is
required on an HDD job-site is similar to that
required on other construction job-sites. Examples
include:
• Hard hat meeting OSHA criteria
• Safety glasses, goggles, or face shields
meeting OSHA criteria
• Hearing protection
• Highly visible reflective clothing
• Work boots
• Work gloves
• Any other safety equipment mandated by
other rules or required by the Owner or
regulatory agency
• Dielectric boots and gloves
• Suitable communication devices
• Remote break out wrenches for working
on the drill string
If the drilling unit is equipped with an Electrical
Strike Sensing System, its use should follow
manufacturer’s recommendations. The system may
include audible and visual warning alarms, grounding
mats, and personal protective equipment. Electrical
sensing stakes must be driven into the ground and
the strike alert system tested prior to operation.
1.6.6.1 DRILLING PRECAUTIONS
The following precautions should be observed
during the drilling operation:
• If a hazardous situation is suspected, work
should be stopped until an evaluation is made and
appropriate corrective action taken.
• Potential “pinch points” on the drill rig and
support equipment must be identified and avoided.
• Safe clearances (at least 900mm (3ft.) or as
specified by regulatory authorities) must be main-
tained between the bore and all utilities. The mini-
mum clearance must take into consideration the final
reamed diameter and the bend radius of the pilot
bore.
• Workers must stay clear of the rotating drill
string.
• The drill must not be operated when person-
nel are working on or near the drill string.
• The drill must not be operated without
positive communication with the drill locator or exit
side personnel.
• The manufacturer’s specified maximum
torque and thrust/pullback capacity of the drill pipe
must not be exceeded.
• Remote breakout wrenches must be used
safely. Drilling machine torque or backhoes with
wrenches should never be used to make or break
tool joints.

Page 17
Refer to the Safety Awareness Program in this manual before attempting to operate this machine
1.6.6.2 REAMING AND INSTALLATION
PRECAUTIONS
The following precautions should be observed
during reaming and product installation:
• Two-way radio communication must be
maintained at all times between the entry and exit
sides
• The drill pipe must not be rotated until all
personnel have been notified and acknowledge-
ment has been made by all personnel
• Workers must never step over rotating drill
pipe and must maintain a safe distance when work-
ing near rotating drill pipes
• When crossing existing underground utilities,
the utility must be exposed at the crossing location
and monitored during the crossing.
1.6.7 RESPONSE TO EVENTS
If an existing utility is struck during the boring
operation, emergency procedures must be initiated
to reduce the likelihood of human injury. Procedures
to follow in the event of utility strikes are summa-
rized below by type of utility.
1.6.7.1 ELECTRICAL STRIKE
If an electrical strike occurs, workers should
not move. The voltage difference between the
equipment and the ground, or between a person’s
feet may be sufficient to cause injury or death. Do
not touch the machine, drill pipe, water system,
mud-mixing system, or anything connected to the
drill as these items may be highly charged. The drill
operator should remain calm and reverse the direc-
tion of advance in an attempt to break contact with
the electrical line. The electrical utility company must
be contacted immediately. The drill operator should
follow the manufacturer’s procedure to determine if
the drill is electrically charged before attempting to
dismount the drill.
1.6.7.2 GAS STRIKE
If a gas line strike occurs, evacuate the area
immediately. The drill operator should shut down all
engines and under no circumstance should the
operator attempt to reverse the bore to break
contact as further movement may cause a spark.
Emergency services and the gas utility company
should be contacted immediately.
1.6.7.3 FIBER OPTIC STRIKE
If a fiber optic strike occurs, workers must not
look into the cut ends of the cable, which can cause
severe eye damage. Drilling must stop immediately
and the utility owner must be contacted.
1.6.7.4 COMMUNICATIONS LINE STRIKE
If a communications line strike occurs, drilling
must stop immediately and the utility company
should be contacted.
1.6.7.5 SANITARY/STORM SEWER AND
WATER STRIKE
If a water or sewer line strike occurs, drilling
should be stopped immediately and all bystanders
should be warned that a strike has occurred and that
they should stay away. Medical attention should be
obtained for personnel who have come into contact
with sewage.As with any strike, the utility owner
should be contacted immediately.
1.6.8 CONCLUSION
Hazards that are specific to HDD include the
rotating drill string, making up and breaking out of
tool joints, and unknown utility strike potential.
However, the most common incidents and accidents
on an HDD site are those that are common to other
construction activities including slips, trips, and falls,
excavation cave-ins, pinched fingers and toes,
vehicle accidents, and back injuries. The common
hazards and hazards specific to HDD equipment and
operation must be identified and isolated or removed
to avoid incidents and accidents.
The investment of time and money in training or
hiring an experienced crew is minimal when com-
pared to the cost of injuries or damaged utilities.

Page 18 Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
Safety procedures must be followed throughout the
job to reduce the likelihood of incidents or acci-
dents. For more information on safety consideration
in HDD, safety videos and written procedures
developed by drill rig manufacturers and the Equip-
ment Manufacturers Institute should be reviewed.
1.6.9 REFERENCES
Directional Crossing Contractor’sAssociation
(DCCA), 2000. “Horizontal Drilling Safe Opera-
tions Guidelines.”
Equipment Manufacturers’ Institute (EMI),
2000. “Safety Manual: Directional Drilling Tracking
Equipment”, and “Safety Video: Save Operations of
Directional Boring Equipment,” EMI, 10 S. River-
side Plaza, Chicago, IL. Both the manual and video
are available from Hubbard Publishing (Phone:
[phone]).
1.7 USES ALLOWED
Work allowed:
1) Installation of drill pipe into the earth.
2) Rotation of drill pipe.
3) Use of bentonite fluid to create the pilot
bore.
4) Removal of drill pipe from the earth.
5) Use of bentonite fluid to back ream the
bore.
6) Pulling a reamer through the pilot bore.
7) Pulling product pipe or cable through the
bore.
1.7.1 FEATURES OF THE SOIL TO BE
DRILLED
1.7.1.1 TYPE OF GROUND
The machine is suitable for working in the
following types of soil:
-Sand -Gravel -Loam -Clay -Shale -Rock
1.7.1.2 GROUND LEVELING
Maximum transversal inclination (lateral) :10°
Maximum longitudinal inclination (frontal): 15°
1.7.1.3 AMBIENT CONDITIONS
Allowed temperature between -15°C and
+40°C [5°F and 105°F] (with oils and coolants
recommended).
For temperature lower than 0°C [32°F], RE-
FER TO Section 4.23, OPERATION UNDER
AMBIENT TEMPERATURES BETWEEN -40°C
AND -15°C [-40°F AND +5°F]. For temperatures
not included in this range, contactAmerican Augers.
Relative humidity allowed during work: 100%
Maximum altitude: 2000 m [6500 feet] above
sea level (with adjustment to engines)
Atmospheric conditions must allow adequate
visibility within the safety area.
It is inadvisable to use the machine during rainy
conditions where lightning is present.
1.7.2 FEATURES OF TRANSPORT
The machine must be transported on a truck
trailer, according to the Highway laws in force in the
relevant country. The wrenches and front foot must
be removed out of concern for overall weight.
The thrust frame must be in the retracted posi-
tion. REFER TO: Section 3, STORAGE AND
TRANSPORT.
If the drill exceeds overall dimensions allowed, it
is necessary to flag it according to the Highway laws
of the countries involved in the transport.
1.7.3 MACHINE HANDLING PROCEDURES
1.7.3.1 TRANSPORT
Position the carriage midway on the thrust frame
to balance the load on the trailer axles. Most drillers
record the position of the carriage so its position can
be repeated in the future.
Remove the wrenches and front foot before
moving the drill on the highway.
1.7.3.2 USE
When the machine is used, only one operator is
allowed to operate the drilling functions for safety
reasons. Other trained personnel may work near the
drill if they are wearing personal protective equip-
ment.

Page 19
Refer to the Safety Awareness Program in this manual before attempting to operate this machine
1.7.3.3 MAINTENANCE
During maintenance with the machine running,
only one qualified technician is allowed to operate
the controls for safety reasons.
For maintenance operations with the machine
off, other trained personnel may work on it.
1.8 USES NOTALLOWED
The machine is not designed and built for any
uses not specified in Section 1.7, USES AL-
LOWED.
In particular, the uses not allowed are the
following:
1) Drilling on sandy, collapsing, or incoherent
ground.
2) Drilling on boggy ground or with too
much water that compromises the grip or the
support of the machine.
3) Use of the machine for pulling or pushing
other machines.
4) Movement of the machine pulled or pushed
by other machines.
5) Use of the machine in explosive and/or
inflammable areas.
6) Use the front foot to lift the tie down stakes
out of the earth.
7)Any time when there are vibrations which
compromise the safety of the operator or the
integrity of the machine.
8) Use when other persons different than the
operator are present within the dangerous zones
indicated in Section 1.5.4, DANGEROUS
ZONES—SAFE DISTANCES.
CAUTION
It is the responsibility of the user to decide
whether to use the drill in conditions which can
cause excessive wear or damage to the
machine.
CAUTION
Stop working when any situations compromise
the safety of the operator or the integrity of the
machine.
NOTICE
American Augers does not bear any
responsibility for damages caused by the
incorrect use of the machine, nor for wear and
damage caused by the particular quality of the
drilled material.
1.9 WARRANTY
1.9.1 GENERAL CONDITIONS
Any warranty is subject to the conditions
specified in the warranty certificate. Except for the
specified exclusions and limitations, the warranty
certificate covers all the material supplied for a
period of 365 days after the factory shipment date
to the initial purchaser, or 1000 hours of operation,
whichever occurs first. Extensions can be granted
only by the President ofAmerican Augers and must
be signed and enclosed with the certificate con-
signed at the time of sale. No extension can be
granted after sale.
1.9.2 LIMITATIONS OF WARRANTY
The warranty for all the components bought and
not produced by American Augers directly are
subject to the original warranty of suppliers/manu-
facturers and therefore defects in materials or
workmanship are considered valid only if they are
recognized by the same suppliers/manufacturers. In
particular, the warranty on the Caterpillar engine is
supplied by the Caterpillar dealer in the area where
the drill is sold.
1.9.3 LIMITED WARRANTY CERTIFICATE
See Figure 2.

Page 20 Refer to the Safety Awareness Program in this manual before attempting to operate this machine.
1.9.4 REQUEST FOR SERVICE SUPPORT
For any request of service support in or out of
the warranty period, contact your authorized dealer.
Have available model number, serial number of the
machine, and working hours indicated on the
instrument located on both the main junction box
(Figure 14, EngineAand B Engine Management
System) and on the main control console (Figure 42,
EngineAand B Engine Management System).
1.9.5 WARRANTYAND SERVICE FOR
CATERPILLAR ENGINE
The local Caterpillar dealer normally solves
problems related to the Caterpillar engine. The
Caterpillar warranty is valid worldwide. Only
Caterpillar dealers are authorized to perform repairs
under warranty and supply service and spare parts.
1.10 SERVICEAGREEMENT
Contact the local dealer.
NOTICE
This manual must be kept for the entire lifetime
of the machine so that it can be easily found if
needed. If the machine is sold, the manual must
be provided to the new owner.
1.11 CONVENTIONS
1.11.1 CONVENTIONS OF TERMINOLOGY
As the directional drill is not a conventional
construction machine, we list some terms normally
used in the text with their description.
FRONT is the end with the wrenches and foot.
LEFT or RIGHT as seen standing behind the
machine facing FRONT (downhole).
1.11.2 TYPOGRAPHIC CONVENTIONS
In the manual, different typographic notes have
been used for identifying dangerous conditions.
For example:
NOTICE
Notices, cautions, and warnings including
important information are set apart from the
text.
REFER TO: Section 1.5.1.1, SAFETY
AWARENESS PROGRAM.
2. DESCRIPTION
2.1 PARTS OF THE MACHINE
The machine consists of the following assemblies
(REFER TO: Figures 41).
2.2 DESCRIPTION OF THE DIRECTIONAL
DRILL
Which consists of the operator’s console,
engine, hydraulic system, and fuel tank.
2.2.1 TRUCK TRAILER
Which supports the drill and permits the
assembly to be transported over the highway.
2.2.2 THRUST FRAME
Which supports the carriage.
2.2.3 CARRIAGE
Which imparts thrust and pullback force, and
rotary motion to the drill pipe.
2.2.4 FIXED WRENCH
A hydraulic clamp for holding the pipe during
tightening or loosening of the joints.
2.2.5 BREAKOUT WRENCH
A moveable wrench that applies enough force to
loosen pipe joints.