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.

SAFETY
7 AU108850 D7A
•It is likely (but not always the case) that the power
source interrupter or breaker will be tripped, but to be
safe you should consider that the directional drill may
be conducting electricity.
•Do not attempt to get off the machine. You are safe as
long as you stay in place.
•Touching any part of the machine with any part of your
body may ground you.
•Your greatest danger is from handling the grounded
drill pipe or from contact with any part of the machine.
•Do not allow any person to touch or approach the
machine.
•Immediately contact emergency number(s) to alert the
public safety authorities to secure the area, then
contact the proper utility authorities.
•When the proper utility authorities verify that the
power is disconnected and the work area is safe, you
may get off the machine.
•The Zap-Alert alarm may be activated if you break a
communication line; but until you are sure, you must
consider the alarm to be an electrical strike. Follow the
above procedures and wait for verification from the
proper utility authorities.
GAS LINE SAFETY
If you ever damage a gas line, there is an immediate
explosion and fire hazard. Escaping gas is both
flammable and explosive.
Follow the instructions listed below. Failure to do so may
result in serious injury or death.
•Do not panic.
•Extinguish all flame and sparks immediately.
•Shut OFF the directional drill immediately and remove
the key.
•Clear the work area of all people.
•Immediately contact emergency number(s) to alert the
public safety authorities to secure the area, then
contact the proper utility authorities.
•Stay clear of the work area and keep any person from
entering the danger area.
WATER LINE SAFETY
If you ever damage a water line, there is an immediate
flood hazard.
Follow the instructions listed below. Failure to do so safety
may result in serious injury or death.
•Shut OFF the directional drill immediately and remove
the key.
•Clear the work area of all persons.
•Immediately contact emergency number(s) to alert the
public safety authorities to secure the area, then
contact the proper utility authorities.
•Stay clear of the work area and keep any person from
entering the danger area.
COMMUNICATION LINE
SAFETY
If you ever damage a communication line, follow the
instructions listed below.
•Treat the strike as an electrical strike and follow
procedure for an electrical line contact until
verified that the strike is not electrical. If verified to be
a communication line strike, do the following:
•Immediately shut OFF the directional drill and remove
the key. Lines can become entangled in the drill pipe
and tooling.
• Do not look into fiber optic cable. A high intensity
light passes through the fiber optic cable and can
damage your eyes.
•Immediately contact emergency number(s) to alert the
public safety authorities to secure the area, then
contact the proper utility authorities.
BEFORE OPERATIONS
•Do not operate or service this machine unless you have
read and understood the operators manual and have
been properly trained in the machines operation.
•Do not allow inexperienced persons to operate this
machine.
•This machine requires an operator at all times. Never
leave the machine running and unattended.
•Always make sure working area is clear of other
persons before you start operating this machine. Never
allow anybody in your work area during machine
operation.
•Check that all connections, hydraulic fittings, nuts and
bolts are tight before operating the machine. Replace
all missing parts.

SAFETY
AU108850 D7A 8
•Avoid loose fitting clothing, loose or uncovered long
hair, jewelry and loose personal articles.
•Do not smoke while operating or servicing this
machine. Do not operate this machine while under the
influence of alcohol or drugs.
•Be prepared for emergencies. Always have a first aid
kit and a good fire extinguisher close by and know how
to use each.
•After servicing this machine, always replace the guards
and shields. Check that all guards, covers and safety
decals are installed correctly or closed. NEVER operate
the machine without guards in place.
•Foreign material such as ice or grease on the controls
or in the operators area can cause an accident. Keep
these areas clean.
•Remove all loose objects from operators area and from
the machine. Loose objects can jam controls and cause
accidents.
•Make sure all persons are away from the machine
before you start the engine.
•Before you start each day, walk around the machine
and check for oil or fluid leaks. Replace all broken,
loose, worn or missing parts and do the required
lubrication and maintenance as shown in this manual.
•Engine exhaust fumes can cause death. If you operate
this machine in an enclosed area, use good ventilation
to replace the exhaust fumes with fresh air.
•Know the rules, laws and safety equipment necessary
for transporting this machine on a road or highway.
Rotating beacon, backup alarm, SMV and other safety
equipment items are available from you dealer.
•Make sure the parking brake is engaged and that all
controls are in neutral before starting the engine.
•As part of your machine job site operation, drive the
Zap-Alert grounding rod into the ground.
• IMPORTANT: Always make sure machine is properly
earth grounded and ZAP-ALERT alarm has been tested
and is properly grounded before starting drilling
operation.
NOISE LEVEL SAFETY
•Operator’s station sound level is 96dB, and sound level
is not to exceed 104db at any position around the drill.
Exposure to high noise level may cause hearing loss;
hearing protection is required during use.
MACHINE SAFETY
•Check all controls in a clear area and make sure the
machine is operating correctly.
•Dust, fog, smoke, snow, etc., may decrease your vision
and cause an accident. Stop the machine or decrease
the speed until you can see everything around you in
the work area.
•Contact with high voltage power lines, underground
cables, etc., can cause serious injury or death from
electrocution.
•Before you operate in an area with high voltage lines or
cables, contact your utility companies or one of the
Digging Hot Line numbers. You MUST HAVE THE
POWER DISCONNECTED OR KEEP A SAFE
WORKING DISTANCE from the lines or cables. You
must know the safe working distance from the high
voltage power equipment and must know any federal,
state/provincial or local safety codes or regulations that
apply to the job site.
•If this machine turns over, you can be injured or killed.
Do not operate if weather, road or earth conditions will
not permit safe operation on a hill, ramp, or rough
ground.
•Stay away from hazardous areas such as ditches,
overhangs, etc. Walk around the work area before you
start and look for hazards.
•Be alert and always know the locations of all workers in
your area. Keep all other persons completely away
from your machine. Injury or death can result if you do
not follow these instructions.
•If your view of the work area is not clear, always have
a signal person direct your movement.
• DO NOT operate this machine while under the
influence of alcohol or drugs.
• NEVER allow anyone in the trench while digging.
WARNING:
Hearing protection required
when operating this machine.

SAFETY
9 AU108850 D7A
FAILURE IN OPERATION
•In the event of poor performance or machine failure,
stop the machine immediately and report the matter.
Take measures to prevent further use until the
malfunction is corrected (Place a DO NOT OPERATE
tag on the control panel, remove the key, turn off all
power sources, etc.) Before working on any hydraulic
or electrical circuits, refer to the maintenance sections
in this manual.
•Support or lower all attachments to the ground before
leaving or servicing the vehicle.
PARKING THE MACHINE
•When you park the machine, select level ground
whenever possible. If you must park on a slope or
incline, position the machine at right angles to the
slope.
•Before you leave the operators area, apply the parking
brake, stop the engine and remove the key.
CAST DUCTILE IRON
•Before you weld, cut or drill holes in a part on this
machine, make sure the part is not cast ductile iron.
See your dealer if you do not know if a part is cast
ductile iron.
•Unauthorized modifications to cast ductile iron parts
can cause injury or death. Welding, cutting or drilling
can cause cast ductile iron to break. Do not weld, cut
or drill to repair or to attach items to cast ductile iron
parts on this machine.
MAINTENANCE
•Always keep safety and informational decals clean and
visible. Replace decals that are damaged, lost, painted
over or cannot be read. Replacement decals are
available from your Astec dealer.
•Before you service the machine, park on a level
surface.
•Do not wear jewelry or loose fitting clothing that may
get caught in moving parts. Always wear close fitting
clothing. Keep hands, feet, clothing and hair away from
moving parts.
•Before you service the machine, put a Do Not Operate
tag on the control panel. A Do Not Operate tag (Part
Number AU103157) is included with each new
machine. Extra tags are available from your dealer.
PIC00056
•Improper service or repair can cause injury or death. If
you do not understand a service or adjustment
procedure, see the Service Manual for this machine or
see your dealer.
•Unauthorized modifications to this machine can cause
injury or death. Do not make unauthorized
modifications to this machine. Always see your dealer
before you weld, cut or drill holes in your machine.
•When you service this machine, wear protective
clothing and personal safety devices that are necessary
for the particular procedure. Some personal safety
devices that may be necessary are face and/or eye
protection, protective shoes, hard hat, heavy and/or
rubber gloves, filter mask and hearing protection.
•Never attempt to clear obstructions or objects from the
machine while the engine is running.
•Always stop the engine and remove the key from the
key switch when leaving the operator’s seat or the
machine.
•If you must service this machine with the engine
running, have another person help you. Follow the
instructions in this manual.
•Before servicing the machine, make sure machine has
cooled down. Hydraulic components, engine, radiator
and exhaust system can get hot enough to cause
serious injury.
•If shields or guards are removed or opened for service,
always replace them before resuming operation of the
machine. Never operate the machine with missing or
open shields or guards.
•When you replace parts on your machine, always use
Astec parts. See your dealer.
WARNING:
Shut off engine and remove key
before performing any maintenance or repair
work.

SAFETY
AU108850 D7A 10
•Keep the area used for servicing the machine clean and
dry. Wet or oily floors are slippery. Wet spots can be
dangerous when working with electrical equipment. Be
sure all electrical outlets and tools are properly
grounded.
BATTERY SAFETY
•Do not make sparks or use an open flame near the
battery.
•When disconnecting battery terminals, remove the
Negative (-) cable first; then remove the Positive (+).
When connecting cables, connect the Positive (+) first;
then connect the Negative (-).
•Battery acid causes severe burns. Batteries contain
sulfuric acid. Avoid contact with skin, eyes, or clothing.
Antidote - EXTERNAL: Flush with water. INTERNAL:
Drink large quantities of water or milk. Follow with milk
of magnesia, beaten egg or vegetable oil. Call a doctor
immediately. EYES: Flush with water for 15 minutes
and get prompt medical attention.
•When the battery electrolyte is frozen, the battery can
explode if, (1) you try to charge the battery, or (2) you
try to jump start and run the engine. To prevent the
battery electrolyte from freezing, try to keep the
battery at full charge. If you do not follow these
instructions, you or others in the area can be injured.
PRESSURIZED HYDRAULIC
FLUID AND GREASE
•Hydraulic, drilling fluid and pressure washer systems
are HIGH PRESSURE. Make sure all lines and fittings
are tight and in good condition. These fluids escaping
under pressure can have sufficient force to penetrate
skin and cause serious injury. Failure may result in
serious injury or death.
•NEVER check for leaks by using any part of your body
to feel for escaping fluid. Keep your hands and body
away from any pressurized leak. If fluid is injected into
your skin, get medical attention immediately and have
the fluid removed.
HYDRAULIC HOSE WEAR AND TEAR
Hydraulic hoses have a finite life as they are constantly in
motion. As equipment moves, hoses are subject to wear
and abrasion that leads to hydraulic hose failure. Wear of
a hydraulic hose can lead to the failure of a fluid power
system. Bad seals on pistons, dirt and debris that enters
the hose from its manufacturing process or from
contaminated hydraulic fluid (as well as using the wrong
viscosity) can also cause premature hose or system
failure. Hoses are tracked by a manufacturer’s date code
which is marked on the metal ferrule. An example of the
date code is HY6F09. The manufacture date of this Hose
would be the Year 2006, the 6th month (F), and the 9th
day, June 9, 2006. Inspect hoses daily for cracks, leaks,
tears, or dry rot and replace as necessary.
HAZARDOUS CHEMICALS
•If you are exposed to or come in contact with
hazardous chemicals you can be seriously injured. The
fluids, lubricants, paints, adhesives, coolants, etc.,
used with your machine can be hazardous.
•Material Safety Data Sheets (MSDS) provide
information about the chemical substances within a
product, safe handling procedures, first aid measures
and procedures to be taken when the product is
accidentally spilled or released. MSDS are available
from your dealer.
•Before you service your machine, check the MSDS for
each fluid, lubricant, etc., used in this machine. This
information indicates what the risks are and how to
service the machine safely. Follow this information
when servicing the machine.
•Before you service this machine and before you
dispose of the old fluids and lubricants, always
remember the environment. DO NOT put oil or fluids
into the ground or into containers that can leak.
•Check with your local environmental or recycling center
or your dealer for correct disposal information.
WARNING:
Before welding, first make sure
all electrical connections are unhooked.
Damage can occur to processor and electrical
system if this is not followed.
WARNING: Battery acid may cause burns.
Avoid contact.
WARNING: Fluid under pressure can pierce
skin and cause injury or death. Stay away.
WARNING: Improper handling or use of
chemicals may result in illness, injury, or
equipment damage. Follow instructions on
labels and in material safety data sheets
(MSDS).

SAFETY
11 AU108850 D7A
FIRE OR EXPLOSION
PREVENTION
•Engine fuel can cause an explosion or fire. Do not fill
the fuel tank with the engine running, if you are near
an open fire, or if you are welding, smoking, etc.
•Use nonflammable cleaning solvent to clean parts.
•Sparks or flame can cause the hydrogen gas in a
battery to explode. To prevent an explosion, do the
following:
1. When disconnecting the battery cables, disconnect
the negative (-) cable first; when connecting the
battery cables, connect the negative (-) cable last.
2. When connecting jumper cables to start the engine,
use the procedure shown in this manual. See Booster
Battery Connections in this manual.
3. Do not short circuit the battery posts with metal
items.
4. Do not weld, grind, or smoke near a battery.
•Sparks from the electrical system or engine exhaust
can cause an explosion and fire. Before you operate
this machine in an area with flammable dust or vapors,
use good ventilation to remove the flammable dust or
vapors before you start.
•Remove all trash or debris from the machine. Make
sure that oily rags or other flammable materials are not
stored on the machine.
•A fire can cause injury or death. Always have a fire
extinguisher close by. Make sure the fire extinguisher is
serviced according to the manufacturers instructions.
•Check for fuel, oil, and hydraulic fluid leaks. Replace
worn or damaged hoses or lines. After repairs are
made, clean the machine before you operate.
ROLL-OVER PROTECTION
•Operating this machine on steep grades may result in a
machine overturn. It is the operator’s responsibility to
make a judgement regarding weather, road or ground
conditions will permit safe operation on a hillside,
ramp, ditch or rough ground.
FIRE EXTINGUISHER
Fire Extinguisher
A fire extinguisher of the type shown is available on your
machine. This dry chemical fire extinguisher is approved
for Class B and C type fires.
153L95
READ OPERATOR’S MANUAL
Decals which display the “Read Operators Manual” symbol
are intended to direct the operator to the Operators
Manual for further information regarding safety,
maintenance, adjustments and/or procedures for specific
areas of the machine. When a decal displays the following
symbol refer to the Operators Manual.
237187A1
“READ OPERATORS MANUAL”
WARNING: Fire or explosion possible.
Fumes could ignite and cause burns. No
smoking, no flame, no spark.

SAFETY
AU108850 D7A 12
SAFETY DECALS
•Make sure that you read all safety and instruction
decals. Check these decals every day before you start.
Clean these decals if you cannot read the words.
•When you clean the decals, use only a cloth, water and
mild soap. Do not use solvent, gasoline, etc.
•You must replace a decal if the decal is damaged,
missing or cannot be read.
•If a decal is on a part that is replaced, make sure you
install a new decal on the new part. See your dealer for
new decals.
3238011
3238005
DECAL READ MAN
1. This decal is located near the front and rear operator
controls.
3238023
DECAL IMPACT HAZ
2. This decal is located near the front of the machine by
the power wrench.
ATTENTION: Injury or death can result if you
cannot read a safety decal or if a safety decal is
missing. Replace any missing or damaged safety
decal and keep all safety decals clean. See your
Astec dealer for new safety decals.
1
1
1
1
2
2

SAFETY
13 AU108850 D7A
3238021
3238010
3238011
3238012
3238013
3238014
3
3
3
3
3
3

SAFETY
AU108850 D7A 14
3238015
3238016
3238017
3238008
3238019
3238020
3
3
3
3
3
3

SAFETY
15 AU108850 D7A
DECAL MOVING PARTS
3. This decal is located at 12 locations near all moving
parts.
3238007
3238008
DECAL ROTATE DRILL
4. This decal is located in 2 locations by the rotating drill
pipe.
3238024
DECAL EXP HAZ
5. This decal is located in the engine compartment near
the battery.
3
4
4
4
5
5

SAFETY
AU108850 D7A 16
3238029
3238012
DECAL ELECT HAZ
6. This decal is located near the front and rear operator
controls.
3238021
3238036
3238037
6
6
6
7
7
7