ASTEC EarthPro DD-3238 User manual

DD-3238 EarthPro
Directional Drill
Operators Manual
AU108850
D7A

Safety Decals on this machine use the words Danger, Warning or Caution, which
are defined as follows:
•DANGER: Indicates an immediate hazardous situation which,
if not avoided, will result in death or serious injury.
The color associated with Danger is RED.
•WARNING: Indicates a potentially hazardous situation which,
if not avoided will result in serious injury.
The color associated with Warning is ORANGE.
• CAUTION: Indicates a potentially hazardous situation which,
if not avoided, may result in minor or moderate injury.
It may also be used to alert against unsafe practices.
The color associated with Caution is YELLOW.
© 2007 Astec Underground AU103897
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY
MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL,
CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO
THE POSSIBILITY OF PERSONAL INJURY OR DEATH.
IMPROPER OPERATION OF THIS MACHINE CAN CAUSE INJURY OR DEATH.
BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY OPERATOR:
• Is instructed in safe and proper use of the machine.
• Reads and understands the Manual(s) pertaining to the machine.
• Reads and understands ALL Safety Decals on the machine.
• Clears the area of other persons.
• Learns and practices safe use of machine controls in a safe, clear area
before operating this machine on a job site.
It is your responsibility to observe pertinent laws and regulations and
follow Astec instructions on machine operation and maintenance.

i AU108850 D7A
TABLE OF CONTENTS
TO THE OWNER . . . . . . . . . . . . . . . . . . . . . . . . . 1
DD-3238 EARTHPRO DIRECTIONAL DRILL . . . . . . . . 1
RIGHT, LEFT, FRONT AND REAR OF MACHINE . . . . . 2
IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . 3
MACHINE COMPONENTS . . . . . . . . . . . . . . . . . . . . 4
SAFETY/DECALS/HAND SIGNALS . . . . . . . . . . . 5
SAFETY MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . 5
PERSONAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . 5
SAFETY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . 5
UTILITY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ELECTRIC STRIKE ALERT SAFETY . . . . . . . . . . . . . . 6
ELECTRICAL LINE SAFETY . . . . . . . . . . . . . . . . . . . 6
GAS LINE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . 7
WATER LINE SAFETY . . . . . . . . . . . . . . . . . . . . . . . 7
COMMUNICATION LINE SAFETY . . . . . . . . . . . . . . . 7
BEFORE OPERATIONS . . . . . . . . . . . . . . . . . . . . . . 7
NOISE LEVEL SAFETY . . . . . . . . . . . . . . . . . . . . . . . 8
MACHINE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . 8
FAILURE IN OPERATION . . . . . . . . . . . . . . . . . . . . . 9
PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . 9
CAST DUCTILE IRON . . . . . . . . . . . . . . . . . . . . . . . 9
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
BATTERY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . 10
PRESSURIZED HYDRAULIC FLUID AND GREASE . . . 10
HYDRAULIC HOSE WEAR AND TEAR . . . . . . . . . . . 10
HAZARDOUS CHEMICALS . . . . . . . . . . . . . . . . . . . 10
FIRE OR EXPLOSION PREVENTION . . . . . . . . . . . . 11
ROLL-OVER PROTECTION . . . . . . . . . . . . . . . . . . . 11
FIRE EXTINGUISHER . . . . . . . . . . . . . . . . . . . . . . 11
READ OPERATOR’S MANUAL . . . . . . . . . . . . . . . . . 11
SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTRUMENTS AND CONTROLS . . . . . . . . . . . . 21
LEFT CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . 21
RIGHT CONTROL PANEL . . . . . . . . . . . . . . . . . . . . 24
REAR CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . 26
TRAVEL CONTROL PENDANT . . . . . . . . . . . . . . . . . 27
LIFE JACKET PENDANT . . . . . . . . . . . . . . . . . . . . . 28
DD-3238 OPERATORS DISPLAY . . . . . . . . . . . . . . . 29
SYSTEM BOOT SCREEN . . . . . . . . . . . . . . . . . . . . 30
MAIN OPERATING SCREEN . . . . . . . . . . . . . . . . . . 31
DRILL OPERATING SCREEN . . . . . . . . . . . . . . . . . 32
DRILL FORCE SCREEN . . . . . . . . . . . . . . . . . . . . . 33
ADDITIONAL INFORMATION SCREEN . . . . . . . . . . 34
MACHINE INFORMATION SCREEN . . . . . . . . . . . . . 35
GENERAL SYSTEM HELP SCREEN . . . . . . . . . . . . . . 36
READ ERROR CODES SCREEN . . . . . . . . . . . . . . . . 37
DIAGNOSE AND UPDATE SCREEN . . . . . . . . . . . . . 38
ERROR CODE DESCRIPTIONS . . . . . . . . . . . . . . . . 39
OPERATORS SEAT AND PLATFORM . . . . . . . . . . . . 40
HOOD LATCHES . . . . . . . . . . . . . . . . . . . . . . . . . . 40
BATTERY DISCONNECT SWITCH . . . . . . . . . . . . . . 40
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . 41
ZAP-ALERT ELECTRIC STRIKE ALARM SYSTEM . . . . 41
ZAP-ALERT ALARM INSTALLATION . . . . . . . . . . . . . 41
ZAP-ALERT ALARM TESTING . . . . . . . . . . . . . . . . . 41
es!lok® MACHINE LOCKOUT SYSTEM . . . . . . . . . . 42
INSTALLATION/CONFIGURATION . . . . . . . . . . . . . . 42
SPECIFICATIONS R130 RECEIVER/T50 TRANSMITTER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
DIAGNOSTICS - T50 TRANSMITTER . . . . . . . . . . . . 46
UNDERSTANDING DIRECTIONAL DRILLING . . . . . . 51
HOLE LENGTH/DEPTH CHART . . . . . . . . . . . . . . . . . 53
DRILL TRACKING ELECTRONICS . . . . . . . . . . . . . . 54
ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . 55
RUN-IN MAINTENANCE SCHEDULE . . . . . . . . . . . . 56
OPERATING IN HOT WEATHER . . . . . . . . . . . . . . . 56
OPERATING IN COLD WEATHER . . . . . . . . . . . . . . 56
STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . 57
ENGINE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . 57
BOOSTER BATTERY CONNECTIONS . . . . . . . . . . . 57
PARKING AND STOPPING THE ENGINE . . . . . . . . . 58
HYDROSTATIC BRAKES . . . . . . . . . . . . . . . . . . . . 58
MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . 58
MOVING THE MACHINE . . . . . . . . . . . . . . . . . . . . 58
TRANSPORTING THE MACHINE . . . . . . . . . . . . . . 59
MOVING A DISABLED MACHINE . . . . . . . . . . . . . . 59
ELECTRONIC TRACKING SYSTEM . . . . . . . . . . . . . 60
DATA LOGGING . . . . . . . . . . . . . . . . . . . . . . . . . 60
HYDRAULIC OIL WARM UP . . . . . . . . . . . . . . . . . . 60
TESTING INDICATOR LAMPS . . . . . . . . . . . . . . . . 60
ZAP ALERT STROBE . . . . . . . . . . . . . . . . . . . . . . . 61
THRUST FRAME POSITION AND DRILLING LOCATION
61
POWER STAKEDOWN . . . . . . . . . . . . . . . . . . . . . 62
CHANGING PIPE CARRIER . . . . . . . . . . . . . . . . . . 62
PIPE LOADER OPERATION . . . . . . . . . . . . . . . . . . 63
CHANGING PIPE STACKING ROWS . . . . . . . . . . . . 63
LOADING PIPE CARRIER . . . . . . . . . . . . . . . . . . . 63
ACCESSORIES AND OPTIONAL EQUIPMENT . . . . . . 64
LOADING DRILL PIPES TO DRILL . . . . . . . . . . . . . 64
INSTALL DRILL HEAD AND FIRST DRILL PIPE . . . . 64
OPERATIONAL HOOKUP CONNECTION . . . . . . . . . 65
DRILLING PRECAUTIONS . . . . . . . . . . . . . . . . . . . 65
POWER WRENCH OPERATION . . . . . . . . . . . . . . . 65
PILOT BORE OPERATION . . . . . . . . . . . . . . . . . . . 66
BORE ENTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
HORIZONTAL REACH BORING . . . . . . . . . . . . . . . 67
BACKREAMING AND PULLBACK . . . . . . . . . . . . . . . . 67
PRESSURE WASHING THE MACHINE . . . . . . . . . . . 69
UNLOADING DRILL PIPE DURING BACK REAM / PULL
BACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . 71
GENERAL SAFETY BEFORE SERVICING MACHINE . . 71
PLASTIC AND RESIN PARTS . . . . . . . . . . . . . . . . . 71
ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 71
ENGINE HOURS . . . . . . . . . . . . . . . . . . . . . . . . . 71
CAPACITIES AND LUBRICANT SPECIFICATIONS . . . 72
LUBRICATION/MAINTENANCE CHART . . . . . . . . . . 73
OIL VISCOSITY/TEMPERATURE USAGE CHART . . . 74
ENGINE OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
AIR FILTERING SYSTEM . . . . . . . . . . . . . . . . . . . . 76
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
HYDRAULIC OIL SYSTEM . . . . . . . . . . . . . . . . . . . 79
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . 80
TRACK PLANETARY DRIVE . . . . . . . . . . . . . . . . . . 82
DRILL FLUID PUMP OIL LEVEL . . . . . . . . . . . . . . . 83
ROTARY DRIVE GEARBOX . . . . . . . . . . . . . . . . . . 84
ADJUSTMENT/MAINTENANCE . . . . . . . . . . . . . 85
FASTENER INSPECTION . . . . . . . . . . . . . . . . . . . . 85
SHUTDOWN MAINTENANCE . . . . . . . . . . . . . . . . . 85
POWER WRENCH INSPECTION . . . . . . . . . . . . . . . 85
TRACK TENSION AND ADJUSTMENT . . . . . . . . . . . 85
HYDRAULIC HOSES AND FITTINGS INSPECTION . . 86
FIRE EXTINGUISHER . . . . . . . . . . . . . . . . . . . . . . 86
ROTARY DRIVE SPINDLE SAVER SUB . . . . . . . . . . 86
PRESSURE WASHING THE MACHINE . . . . . . . . . . . 86

TABLE OF CONTENTS
AU108850 D7A ii
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . 89
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 91
BASIC MACHINE DIMENSIONS . . . . . . . . . . . . . . . 91
ENGINE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
DRILLING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . 91
ROTARY DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . 91
CARRIAGE DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . 91
PIPE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
DRILLING FLUID PUMP . . . . . . . . . . . . . . . . . . . . . 91
DRILL PIPE (optional) . . . . . . . . . . . . . . . . . . . . . . 91
PROTECTIVE EQUIPMENT . . . . . . . . . . . . . . . . . . . 91
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . 92
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1

1 AU108850 D7A
TO THE OWNER
DD-3238 EarthPro Directional Drill
3238003
This manual contains important information about the
safe operation, adjustment and maintenance of your
Astec EarthPro Horizontal Directional Drill. Refer to the
Index at the end of this manual for locating specific items
about your equipment. This equipment conforms to
current safety regulations.
Do NOT operate or permit anyone to operate or
service this equipment until you or the other
persons have read and understand the safety,
operation and maintenance instructions in this
manual. Use only trained operators who have
demonstrated the ability to operate and service
this equipment correctly and safely.
This equipment, with standard equipment and authorized
attachments, is intended to be used for underground
drilling and pullback operation for installation of utility,
communication and cable television cable, tubing, etc.
Make sure that the equipment is properly equipped and
follow the instructions and safety precautions in this
manual.
Do Not use this machine for any application or
purpose other than those described in this manual.
Consult an authorized Astec dealer on changes, additions
or modifications that can be required for this equipment
to comply with various country regulations and safety
requirements. Unauthorized modifications will cause
serious injury or death. Anyone making such unauthorized
modifications is responsible for the consequences.
Make sure this manual is complete, in good condition and
available to the operator for reference. Contact your
dealer to obtain additional manuals. Contact your dealer
for any further information or assistance about your
equipment. Your dealer has Astec-approved service parts.
Your dealer has technicians with special training that
know the best methods of repair and maintenance for
your machine.
Use this manual as a guide. Your machine will remain a
reliable working tool as long as it is kept in good working
condition and serviced properly.

TO THE OWNER
AU108850 D7A 2
RIGHT, LEFT, FRONT AND REAR OF MACHINE
Right-hand and left-hand, when used in this manual, indicate the right and left sides of the machine as seen from the
operator’s seat facing the drilling platform and with the engine in the rear.
3238003
DD-3238 Directional Drill viewed from right (operator’s) side.
FRONT
REAR

3 AU108850 D7A
IDENTIFICATION NUMBERS
Write your machine Product Identification Number (P.I.N.) and Serial Numbers on the lines provided below. If needed,
give these numbers to your dealer when ordering parts or requesting information or assistance for your machine.
Make a record of the numbers and keep in a safe place. If the machine is stolen, report the numbers to your local law
enforcement agency.
MACHINE MODEL NUMBER: DD-3238 EarthPro Horizontal Directional Drill
1. PRODUCT IDENTIFICATION NUMBER (P.I.N.) ________________________________________________________
2. ENGINE SERIAL NUMBER ________________________________________________________
3238002
1. PRODUCT IDENTIFICATION NUMBER
3238001
2. ENGINE SERIAL NUMBER
1

IDENTIFICATION NUMBER
AU108850 D7A 4
MACHINE COMPONENTS
3238003
8
1
7
2
4
5
6
3
9
1. DRILL PIPE CARRIER 4. BATTERY COMPARTMENT 7. OPERATORS SEAT
2. CONTROL PANEL 5. ENGINE COMPARTMENT 8. POWER WRENCH
3. ZAP ALERT BEACON 6. TRACK/UNDERCARRIAGE 9. STAKEDOWN PLATE/ANCHORS

5 AU108850 D7A
SAFETY/DECALS/HAND SIGNALS
SAFETY MESSAGE
This machine has been designed and built to meet or
exceed current safety regulations and standards.
However, this does not completely exclude the risk of
accidents. It is therefore essential to follow basic safety
rules and procedures.
The strict execution of the instructions provided in this
manual will help prevent accidents during machine use,
maintenance and repair operations.
These instructions will only be effective if the machine
r e c e i v e s p r o p e r m a i n t e n a n c e . A n y d e f e c t s o r
abnormalities must be repaired immediately.
Do not use the machine for applications other than those
which are described in this manual.
In the event of a particular problem, requiring some
intervention or application not described in this manual,
contact your Astec dealer immediately.
Your safety and the safety of others are measured by how
you maintain and operate this machine. Most accidents
involving machine operation and maintenance can be
avoided by following basic rules and precautions. Know
the positions and operations of all controls before you try
to operate this machine. Read and understand all the
safety messages in this manual, and the safety signs on
the machine before you operate or service the machine.
See your Astec dealer if you have any questions.
READ THIS MANUAL COMPLETELY and make sure you
understand the characteristics of speed, stability, steering
and load characteristics of this machine. The machine
must be used only by trained operators. MAKE SURE THE
OPERATORS MANUAL IS AVAILABLE TO THE OPERATOR
AT ALL TIMES, and in complete and good condition. See
your dealer for additional manuals. Also see the inside of
the rear cover of this manual.
The safety information given in this manual does not
replace safety codes, insurance regulations, or local laws.
Make sure your machine has the correct equipment
according to these rules or laws.
IMPORTANT:
Safety messages in this section point out
situations which can be encountered during the normal
operation and maintenance of your machine. These safety
messages also give possible ways of dealing with these
conditions. Additional safety messages are used in the
text of the manual to show specific safety hazards.
PERSONAL SAFETY
Safety Decals on this machine use the words Danger,
Warning or Caution, which are defined as follows:
• DANGER: Indicates an immediate
hazardous situation which, if not avoided,
will result in death or serious injury. The color associated
with Danger is RED.
• WARNING: Indicates a potentially
hazardous situation which, if not avoided
will result in serious injury. The color associated with
Warning is ORANGE.
• CAUTION: Indicates a potentially
hazardous situation which, if not avoided,
may result in minor or moderate injury. It may also be
used to alert against unsafe practices. The color
associated with Caution is YELLOW.
ISO two panel pictorial symbol decals are shown in both
vertical and horizontal configurations and are defined as
follows:
•The Signal panel indicates the nature of the hazard.
•The Message panel indicates the appropriate avoidance
of the hazard.
•Background color is YELLOW.
•Prohibition symbols such as and if
used are RED.
SAFETY EQUIPMENT
•Different jobs may require different protective
equipment. Items such as hard hats, protective shoes,
heavy gloves, reflector type vests, respirators and ear
protection may be required. Know and use the
equipment that is required before you start the job.
•The Machine Grounding System includes a
grounding rod which is located at the operator’s
station. Insulated rubber gloves and boots are
available. These items are used to protect against
serious injury, death and other dangers of electrical
shocks and burns.
UTILITY SAFETY
Safety precautions MUST be followed when working near
buried utility lines
During operation it is likely that you will be working
around or near buried utility lines which may include, but
are not limited to:
•Electrical Power Line
WARNING:
This safety alert symbol
indicates important safety messages in this
manual. When you see this symbol, carefully
read the message that follows and be alert to
the possibility of personal injury or death.
STOP

SAFETY
AU108850 D7A 6
•Gas Line
•Water Line
•Communication Line - Telephone or Cable Television
•Sewer Line
Before beginning any drilling or other construction
work it is your responsibility to be aware of all
such utility lines buried in the area of your project
and to avoid them.
ALWAYS have all local utility companies mark the location
of their lines.
In U.S.A. and Canada call one of many “One Call System
Directory” services. If you do not know the local number,
call the national number (U.S.A. and Canada only): 1-888-
258-0808.
Check with local authorities for laws, regulations
and/or strict penalties requiring you to locate and
avoid existing utilities.
RH99G001
CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU TRENCH
Know the utility color code (U.S.A. and Canada):
Electric .......................................................... Red
Gas, Oil or Petroleum.................................. Yellow
Communication, Telephone, Television ........ Orange
Water ................................................. ..........Blue
Sewer.............................................. Green/Brown
Proposed Excavation.................................... White
Surveying ..................................................... Pink
Reclaimed Water and Slurry ........................ Purple
After locating the utility lines, carefully dig a hole by hand
and/or automatic vacuum equipment to the utility line to
verify the location and depth of the line.
ELECTRIC STRIKE ALERT
SAFETY
A Zap-Alert Electric Strike alarm has been installed on this
machine. It is located to the left of the operator and
under the engine cover. In the event of an electric strike
that charges the machine, this alarm will sound a loud
audible signal for as long as the machine is charged with
power. Follow the instructions in the Alarm Operation
section of this manual for operation and testing of the
alarm.
As part of your machine job site operation, drive the Zap-
Alert grounding rod into the ground.
NOTE:
It is possible to hit a power line without the
machine becoming charged.
NOTE: Rubber insulating gloves and boots should be
worn by any person working around the machine. These
items are used to protect the system users from serious
injury, death and other dangers of electrical shocks or
burns.
ELECTRICAL LINE SAFETY
If you ever make contact with a power line, the Zap-Alert
alarm system will sound if the machine becomes charged.
For information on grounding the machine and testing/
use of the Zap-Alert system, refer to OPERATION section
of this manual.
Follow the instructions listed below. Your life may be in
DANGER; failure to follow proper safety precautions may
result in serious injury or death.
•The Zap-Alert alarm will sound upon contact with an
electrical power source. The alarm will continue to
sound until contact with electrical line is disconnected.
•Do not panic.
WARNING:
Always contact your local One-
Call system and any utility companies which
do not subscribe to One-Call before the start
of your digging project.
WARNING: The Zap-Alert Electric Strike
alarm system will NOT sound if grounding rod
is not in the ground. ALWAYS have grounding
rod in the ground before operating the
stakedown or starting to drill.
WARNING: The Zap-Alert alarm will not be
set off by coming near a power source. It only
sounds the alarm after electrical contact has
been made and machine is charged. Safe
work procedures, safety equipment and
clothing must be used at all times to protect
operators. Failure to do so may result in
serious injury or death.