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Preface
Thank you for selecting XZ320 horizontal directional drill produced by
Xugong Road Construction Machinery Co., Ltd.
The machine can operate effectively with longer service life by accurate
usage and maintenance. Please read and understand the manual
especially safety notices and operate according to regulations before usage.
Manual shall be placed with equipment together for reference at any time.
The manual includes structure, performance, operation, lubrication,
maintenance, storage and transportation. Please refer to attached
instructions for usage instructions and maintenance of engine, hydraulic
pump, motor, speed reducer and guide detector, etc.
Warning!Reconfiguration may cause dangers without
manufacturer’s permit before usage. Please consult to
manufacturer or designated dealer before reconfiguration or
manufacturer has no responsibility for any consequence caused
by impermissible reconfiguration.
Note: XZ320 horizontal directional drills have gained many patent licenses
issued by the State Intellectual Property Office (SIPO) (with ZL patent No.:
031428282, 02288040.2, 02283784.1 and 02288046.1). Anybody who
counterfeits it will be prosecuted for his legal responsibility.
We may modify description and technical specification of the manual at any
time. We have rights to improve and create the equipment. Please contact
Xugong Road Machinery Co., Ltd, dealer or log on WWW.XCMGJC.COM to
query relational information if you want to know the latest information.
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Contents
I n t r o d u c t i o n … … … … … … … … … … … … … … … … … … … … … … … . . …… … … 1
Structure, performance and main parameters………… …………………………..3
Operating principle and structure…… …… ………………… ………………… .. 5
Safety requirements… …… …… …………… …… …… …… …… … …. .… …… .. 1 6
Usage and operation … …… ……… …… …… …… …… …… …… …. .…… …..21
Lubrication, repair and maintenance…………… …………………………………45
Transportation, storage and protection ………………………… ………………52
Appendix A: Mud cons u m p t i o n ………… … … … … … ……… … …… … … … 56
Appendix B: N o zzl e f low … … … ………… … … ………………………………57
Appendix C: The maximum diameter and length of tow pipe…………………58
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I. Introduction
XZ320 horizontal directional drills (hereinafter referred to drills) are a kind of
construction machine to set various underground utilities without excavating
the earth’s surface. They are widely used to set pipes which pass across
highways, railways, buildings, rivers, downtown area, historic district, crop
and vegetation protection zones which are difficult to excavate as well as
water supply, coal gas, power supply, telecommunication, natural gas and
petroleum pipes. Drill bit plates and re-expanding hole with different models
shall be selected according to pipe diameter. They have characteristics
such as compact structure, high rotation speed of power heads, large torque
and push-pull effort, quick driving speed, flexible operation, quick
construction speed, low comprehensive expense and high economic and
social benefits.
1. Designation:
XZ 320
Pull-back force: 320kN
Horizontal directional drill
2. Applicable scope
It is suitable to sandy soil, clay and pebble, etc. Most of non-hard rocky
zones in China can be constructed and ambient temperature is between
-10℃ and +45℃.
3. Product characteristics
3.1 Reliable power
Total power is 140kW for water-cooled vortex pressurized engine with 6
cylinders. It can provide torque of 12,000N·m and pull-back force of 320kN
(which can reach 400kN if driven by oil cylinder).
3.2 Large-flow mud
Mud pump can provide mud with sufficient flow during synchronous pushing,
pulling or back rotation during drill operation.
3.3 High rotation speed of power head
Main axle of power head can drill with high speed to increase operating
efficiency when drilling and towing auger stem. Power head also can rotate
with high speed to increase operating efficiency when drilling pivot holes
and small-diameter holes.
3.4 Floating strong auger stem holder
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The most advanced jaw vice and double-floating-gear of power head in the
world shall be selected and specific patent technique, namely, floating
strong auger stem holder shall be adopted when assembling drilling stems.
It has large shackle torque, quick and reliable holding and simple
maintenance. Double-floating-gear can be adopted to reduce thread
abrasion in 2 ends of auger stem effectively and prolong service life of
auger stem so as to reduce construction cost as well as rupture risk of auger
stem.
3.5 Rubber crawler
Hydraulic rubber crawler has the minimum damage to side pavement, lawn
and beauty spots.
3.6 (Optional) hydraulic anchor devices
Hydraulic drive with high efficiency can be selected to position drills quickly,
reliably and stably.
3.7 (Optional) auxiliary loading/unloading device of auger stem
Auxiliary loading/unloading device of auger stem can be selected to reduce
operator’s effort.
3.8 Hydraulic power assisting device
Hydraulic power assisting device shall be provided for complex stratums
with jamming of a drilling tool. The maximum back-pull force can reach
40kN to reduce construction risks effectively.
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II. Structure, Properties and Main Parameters
1. Please refer to Figure 1 for outline dimension of drills.
Figure 1 Outline drawing of drill
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Item
Unit
Parameter
The maximum
back-tow/feeding force
kN
320(400)/200
The maximum operating
speed of power head
m/min
20
The maximum torque of
power head
N·m
12000
Rotation speed of power
head
r/min
0～140
Bore diameter
mm
Φ127
The maximum diameter of
re-expanding hole
mm
Φ800
Length of (single) auger
stem
m
3
Diameter of auger stem
mm
Φ73
(Extreme) bending radius of
auger stem
m
65
The maximum mud flow
L/min
320
The maximum mud pressure
MPa
8
Engine model
D6114ZG
Rated power
kW/r/min
140/2300
Driving speed
km/h
3
The maximum climbing
gradient
％
30
Machine weight
kg
10500
Outline
dimension
(under
transportation
status)
Length
mm
7100
Width
mm
2250
Height
mm
2450
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2. Please refer to Table 1 for main performance and parameters.
Table 1
III. Operating principle and structure
1. Operating principle
XZ320 horizontal directional drills mainly consist of upper directional drill
part and lower traveling part. Engine of lower part drives oil pump to
provide power to motor then drive driving wheel by driving speed reducer
to realize rotation and brake functions of chassis.
Drilling: Drilling inclination shall be adjusted firstly and the machine shall be
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fixed by anchor device. The probe shall be installed into the drill bit to
connect drill bit body, auger stem and power head for drilling. Mud pump
also shall pump mud during synchronous drilling for soil cutting and heat
dissipation of protective wall and drill bit during drilling or back towing.
Position of drill bit shall be measured by receiving signals issued by probe
in the wireless probe through earth’s surface receiver. Power head shall
stop rotation and adjust inclined drill bit plate toward required direction if
necessary. Ground receiver will monitor feeding direction when pushing
power head without rotation. Drilling shall be continued after defining
accurate direction. Direction can be adjusted for many times during drilling
until ending.
Pipe layout: Different re-expanding hole drill bits shall be used after drilling
according to pipe diameter and category for once or multiple back drilling to
reach required aperture. Power divider can be connected to set pipe during
the final back drilling and towing until all pipes are positioned. Mud shall be
supplied during the entire process.
2. Main structure
XZ320 horizontal directional drill is an integral drilling device. It mainly
consists of chassis, power head, drilling rig, engine system,
semi-automatic access assembly of auger stem, jaw vice, anchor device,
drilling tool, hydraulic system, electric system and mud system, etc.
2.1 Chassis
Chassis mainly consists of automatic chassis, left and right driving devices.
Hydraulic leg is supplied in the rear of automatic chassis.
Driving device consists of crawler tension device, rubber crawler, drive
wheel, guide wheel, supporting wheel and driving speed reducer, etc.
Embedded planetary reducer (including motor) shall be provided for driving
speed reducer.
Crawler tension device consists of tension oil cylinder, guide wheel and oil
cup, etc. It is used to maintain certain tensity of crawler by adopting
lubricating grease.
2.2 Engine system
As power source of the entire system, engine system includes engine,
water heat dissipater, air filter and muffler, etc. D6114 pressurized
water-cooled engine of Shanghai Diesel Engine Co., Ltd shall be selected
and its rated power is 140kW/2300r/min.
2.3 Power head
As a main operating mechanism of machine, output axle of power head
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shall be driven by hydraulic motor. Drill bit shall be mainly driven for
revolution, drilling and back towing and hollow hole of drill collar is the mud
channel to enter into auger stem.
2.4 Drilling rig
As a sliding & supporting device of power head, drilling rig shall slide on the
guide rail by push-pull mechanism of oil cylinder to bear push-pull and
rotation torque of the entire machine.
2.5 (Optional) auxiliary loading/unloading device of auger stem
Auxiliary loading/unloading device of auger stem shall be used to lighten
operator’s intensity and accelerate construction schedule.
2.6 Strong auger stem holder
It includes upper and lower jaw vices and it is in the previous part of sliding
support. Upper jaw vice has clamping and rotation motions. Upper and
lower jaw vice will coordinate with motion of power head to screw down or
loosen threads of auger stem. Special buffer device of our company shall
be used to reduce thread abrasion and prolong service life of auger stem.
2.7 (Optional) anchor devices
Ground anchor is used for anchorage of the entire machine. It is located in
the front end to increase stability. It shall be pressurized by oil cylinder for
drilling in/out of anchor rod driven by low-speed and large-torque motor.
2.8 Vehicle-mounted mud system
Large-flow mud pump of 320L/min shall be adopted for vehicle-mounted
mud system. Horizontal reciprocating single-effect piston pump with 3
cylinders shall be used as mud pump which is driven by hydraulic motor to
provide pressure mud for drill.
2.9 Electric system
Electric system of horizontal direction drill mainly consists of engine
monitoring, mud pump control, jaw vice control, high-speed driving control
and high-speed push-pull control of power head, etc.
2.9.1 Engine part and lamp alarm:
DC 24V single-line power shall be adopted for the machine with negative
electrode ground system. Power shall be generated by 2 series storage
batteries of 12V and power generator. Storage battery shall supply power
during vehicle startup and power generator shall supply DC 24V to the
machine power utilization system and charge storage battery at the same
time after operation.
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·Water temperature gauge
Water temperature gauge of engine is used to display temperature of
cooling liquid of engine. Water temperature alarm switch is off and indicator
lamp is on when water temperature is higher than setting value and
shutdown is required for inspection.
·Oil pressure gauge
Oil pressure gauge is used to display pressure of power generator oil. Oil
pressure alarm switch is closed and indicator lamp is on when oil pressure
is less than setting value and shutdown is required for inspection. (Indicator
lamp will be on if power generator stops operation.)
·Fuel oil gauge
Fuel oil level indication of engine: Oil shall be added in a timely manner if
fuel oil level is super-low.
·Hourly rotation speed list
To record operating hours and current rotation speed of power generator.
·Voltmeter
The list is to measure voltage of electric system.
·Jamming alarm of hydraulic filter
Indicator lamp is on to indicate that oil filter shall be cleaned due to
jamming.
2.8.2 Mud pump control
Mud pump switch is used to control mud pump and mud pressure can be
displayed by mud pressure gauge. Mud pressure variation shall be
monitored carefully during operation. Check if mud channel is jammed or
not if mud pressure is high and operation speed of piston reduces.
2.8.3 Jaw vice control
·Rotation switch of post-jaw vice
The switch is used for clockwise or counter-clockwise rotation of post
wrench.
·Clamp switch of post jaw vice
The switch is used to control clamp of post jaw vice.
·Clamp switch of front jaw vice
The switch is used to control clamp of front jaw vice.
2.8.4 Double-speed control of power head
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Push-pull speed of power head is controlled by one switch. Push-pull
speed of power head will be doubled by pressing high-speed push-pull
switch of power head and normal speed will be restored by loosening the
switch. High-speed push-pull can be adopted to save auxiliary period
during drilling or back towing if main axle is not connected to auger stem.
(Mud pump will stop operation automatically when using high-speed
push-pull function.)
High-speed rotation of power head shall be controlled by manual valve on
power head box. Manipulation rods of the valve shall be placed in different
positions to guarantee different rotation speed of power head. (Please do
not use high-speed rotation function of power head during large-aperture
construction.)
2.9 Principle of hydraulic system is shown in Figure 2.
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Figure 2 Principle diagram of hydraulic system
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Figure 3 The 1st schematic diagram of electric system
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2.9 Principle of electric system shown in Figure 3
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Figure 3 The 2nd schematic diagram of electric system
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Figure 3 The 3rd schematic diagram of electric system
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Figure 3 The 4th schematic diagram of electric system
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Figure 3 The 5th schematic diagram of electric system
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Figure 3 The 6th schematic diagram of electric system
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IV. Safety Requirements
Severe casualty may be caused if not abiding by danger, warning or
Attention shown in the manual and safety label of drills.
Danger: Death or severe injury may be caused due to direct dangers
if not abiding by danger, warning or note shown in the manual and
safety label of drills.
Warning: Death or severe injury may be caused due to potential
dangers if not abiding by danger, warning or note shown in the manual
and safety label of drills.
Attention: Slight or medium injury may be caused due to potential
dangers if not abiding by danger, warning or note shown in the manual
and safety label of drills.
Warning： Please read and master the manual before startup to
operate equipment according to regulations. The manual shall be
placed in convenient locations with timely supplementation or
replacement if it is lost, damaged or difficult to read.
1 Please read following content carefully on the construction site
before operating the equipment：
1.1 Only trained operators with rich experience can operate the drill. Be
sure to read the manual and accept operation training before operation.
1.2 Please contact local utility pipe company before construction for
assistance with position detection and mark of original underground pipes
and cables along the route. Please contact relevant departments in a
timely manner if pipes are damaged during construction.
1.3 Construction site shall be divided according to underground dangerous
articles to select suitable tools, equipment, safety facilities and construction
methods.
1.4 Construction scope shall be marked obviously and irrelevant persons
can not enter into it within construction scope.
1.5 Construction staff shall wear suitable safety protection clothes such as
rubber insulation gloves and shoes, etc.
1.6 Inspect underground dangerous articles, safety situations and
emergency measures carefully before formal bootstrap. Responsibility of
every worker also shall be defined definitely.
1.7 Equipment shall be operated carefully with instant shutdown for
inspection under abnormal conditions.
1.8 Confirm all pipes are connected reliably to avoid severe casualty
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caused by leakage of hydraulic oil, drilling liquid and washing system with
high pressure.
1.9 Be sure not to operate the machine in locations with combustible gas or
dangers may be caused.
1.10 Please contact local dealer if there is any doubt for equipment
operation, maintenance and usage.
2 User’s facilities
2.1 Fire extinguisher
Be sure that fire extinguisher can extinguish fire caused by oil or power.
2.2 Lighting lamp
Other lighting lamps shall be provided if necessary.
3 Classification of underground dangerous articles
3.1 Power wire 3.2 Natural gas pipe
3.3 Optic fiber cable 3.4 Water pipe
3.5 Blow-off pipe 3.6 Pipes to convey other chemicals, liquid or gas
4 Electric shock knowledge
4.1 Current will be conveyed to underground by various ways besides
channel of the minimum resistance.
4.2 Current also can be conveyed to equipment by cables of auger stem,
hose and machine.
4.3 Casualty or death may be caused by low-voltage current.
4.4 Electric shock shall be assumed under following circumstances：
4.4.1 Power failure 4.4.2 Smoking
4.4.3 Explosion 4.4.4 Crack noise
4.4.5 Electric arc
5 Operation during electric shock:
5.1 Remain on our respective positions on the drill or grounding cushion.
5.2 Anybody is strictly prohibited to contact or access drill.
5.3 Contact relevant power departments instantly.
5.4 Do not touch auger stem and drill body by hand or tool.
5.5 Drill operator can not leave the machine until power department
confirms power cutoff and safety of work zone.
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Construction zone
Category
Within scope of 3m
away from power
wire
Power
Within scope of 3m
away from natural
gas pipes
Natural gas
Within scope of 3m
away from other
dangerous articles
Others
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5.6 Re-drilling or entry into the site is not allowed without permission of
power department.
6 Operation when fuel gas pipes are broken by drilling：
6.1 Close the engine and eliminate various fire sources instantly.
6.2 Leave the construction site as soon as possible.
6.3 Alarm other persons that fuel gas pipes are broken by drilling so that
they can leave the site as soon as possible.
6.4 Contact local utility pipeline departments.
6.5 It is not allowed to enter into the site randomly without permission of
utility pipeline departments.
7 Operation when optic fiber cables are broken by drilling：
7.1 Close the drill and contact local utility pipeline department instantly.
7.2 Do not look broken ends of optic fibers or unknown cables directly into
our eyes to avoid impairment of vision.
8 Operation when tap water pipes are broken by drilling：
8.1 Close the drill and contact local utility pipeline department instantly.
8.2 Anybody is strictly prohibited to access the dangerous zone.
9 Division and precaution measures of construction site
9.1 Please refer to Table 2 for category division according to existing
underground dangerous articles.
Table 2 Division List of Construction Site
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9.2 Detail precaution measures of various kinds of construction sites
9.2.1 Detail precaution measures of power site
Take one or all methods as follows:
9.2.1.1 Electric wires shall be exposed by manual excavation.
9.2.1.2 Power failure during construction: Power department shall inspect
power wires before restoring power supply.
9.2.2 precaution measures of natural gas site
9.2.2.1 Drill shall be installed toward upwind direction of natural gas pipes.
9.2.2.2 Electric wires shall be exposed by manual excavation and bore
track shall be traced by probe carefully.
9.2.2.3 Gas supply cutoff during construction: Fuel gas department shall
inspect pipes before restoring gas supply.
9.2.3 Other site protection measures
Different methods may be used to prevent us from other underground
dangerous articles. Please contact responsible person of dangerous articles
to define protection measures.
9.3 Safety warning classification
Such illustrations are used to prompt danger to you, surrounding persons
and equipment. Please read such warnings or illustrations carefully with
strict execution.
Do not touch it before cooling.
Keep far away from it due to possible severe
winding and injury.
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Keep far away from it due to possible casualty
even death by touching electrified body.
Keep far away from it due to possible severe casualty caused by movable
parts.
Use suitable process, procedure
and facility or keep far away from it
due to possible casualty even
death caused by protrusion.
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V. Usage and operation
1 Functional instructions of switch, handle or instrument
1.1 Please refer to Figure 4 for operation panel of left console and Table
2 for detailed functions.
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No.
Name
Function
1
Front jaw vice switch
To control clamping or loosening of front jaw vice
2
Post jaw vice switch
To control clamping or loosening of post jaw vice
3
Rotation switch of jaw
switch
Used for rotation control of post jaw vice
4
Rotation handle
To control rotation of power head
5
Jamming alarm of
hydraulic oil filter
Filter core of hydraulic oil filter shall be replaced if
indicator lamp is on.
6
Machine oil warning lamp
of engine
Machine oil shall be added if indicator lamp is on.
7
Charging indicator lamp of
engine
Power generator shall supply power to battery if
indicator lamp is off.
8
Hydraulic oil temperature
alarm
Temperature of hydraulic oil is super-high if
indicator lamp is on.
9
Water temperature alarm
of engine
Cooling liquid temperature of engine is super-high
if indicator lamp is on.
10
High-speed driving switch
Driving speed of drill will be doubled by pressing
the switch.
11
Loudspeaker switch
To control operation and shutdown of loudspeaker
12
Rotation lamp switch
To control opening/closing of rotation lamp
13
Working lamp switch
To control opening/closing of working lamp
14
Mud pump switch
To control opening/closing of mud pump
15
Back tow switch with
auxiliary power assistance
To control protrusion/shrinkage of oil cylinder with
auxiliary power assistance
16
High-speed push-pull
switch
Operation speed of power head will be doubled.
17
Lifting switch of auger
stem
(Optional function) to control
ascending/descending of auger stem
18
Tongs switch
(Optional function) to control opening/closing of
tongs
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Figure 4 Operation panel of left console
Table 2 Left console switch
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1.2 Please refer to Figure 5 for operation panel of right console and
Table 3 for detailed functions.
Figure 5 Operation panel of right console
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No.
Name
Function
1
Shutdown switch of engine
To control engine shutdown
2
Startup switch of engine
To control engine startup
3
Front jaw vice switch
To control clamping or loosening of front jaw
vice
4
Backup switch
Backup switch
5
Rotation switch of jaw vice
Used for rotation control of post jaw vice
6
Post jaw vice switch
To control clamping or loosening of post jaw
vice
7
Pushing handle
To control push-pull of auger stem
8
Push-pull pressure gauge
To display pressure of push-pull motor
9
Rotary pressure gauge
To display pressure of rotary motor of power
head
10
Installation plate of guide
instrument
Guide instrument shall be installed here.
11
Mud pressure gauge
To display pressure of mud system
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Table 3 Right Console Switch
1.3 Please refer to Figure 6 for operation panel of auxiliary console and
refer to Table 4 for detailed functions.
Figure 6 Operation panel of auxiliary console
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No.
Name
Function
1
Power switch
Main power switch of the system
2
Key switch
Used for engine startup and
system electrification
3
Machine oil
pressure gauge
To display engine oil pressure
4
Fuel oil gauge
To display fuel oil quantity
5
Water temperature
gauge
To display temperature of cooling
liquid of engine
6
Voltmeter
To display system voltage
7
Hourly rotation
speed list of engine
To display rotation speed and
working hours of engine
8
Control handle of
accelerator
To control engine accelerator
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Table 4 Function of auxiliary console
1.4 Please refer to Figure 7 for operation panel of post console and refer
to Table 5 for detailed functions.
Figure 7 Operation panel of post console
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No.
Name
Function
1
Liquid control handle
of left leg
To control expansion/retraction of
left leg
2
Liquid control handle
of right leg
To control expansion/retraction of
right leg
3
Inclined liquid control
handle of drilling frame
To control expansion/retraction of
inclined oil cylinder of drilling frame
4
Crash stop switch
Crash stop switch of engine
5
Right driving liquid
control handle
To control forward/backward
motion of right crawler
6
Left driving liquid
control handle
To control forward/backward
motion of left crawler
7
Driving acceleration
switch
To control driving speed
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Table 5 Operation panel of post console
Note：Driving acceleration position must be in non-acceleration position
after finishing movable machines or power head can not be pushed or
pulled.
2 Preparation
2.1 Data collection
Successful construction begins from bore and existing documents of
the project and construction site shall be read firstly.
2.1.1 Contact utility pipeline company to position and mark existing
underground utility pipes.
2.1.2 Ask for pipe sample and detect weight and rigidity. Contact material
manufacturing department to consult to bending radius. Check if we have
suitable back tow facilities or not.
2.1.3 Contact local management department and discuss with relevant
safety measures if construction site is close to highway or other traffic
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zones.
2.1.4 Provide phone numbers of local rescuing and medical departments
as well as phones.
2.2 Site exploration
Construction site shall be inspected as follows before equipment
positioning：
2.2.1 Overall flatness and slope of construction site
2.2.2 Height drop of construction site such as hill and valley, etc;
2.2.3 Obstacles such as building, railway and river, etc;
2.2.4 Mark of underground pipelines (shown in Safety Protection Part)
2.2.5 Traffic circumstances
2.2.6 Entry route
2.2.7 Soil quality and geologic conditions
2.2.8 Water supply situations
2.2.9 Trace and position disturbance source such as reinforcement iron bar
and steel rail, etc of the system.
2.2.10 Select points and collect soil samples along bore track to define drill
bits for drilling and re-expanding.
2.3 Verification of dangerous articles
Please refer to “Safety Protection” for verification of underground
dangerous articles and division of site category.
Note: Use equipment by abiding by operation regulations accurately and
maintain necessary safety protection facilities because underground
dangerous articles may cause death or casualty.
2.4 Position selection of perforation and final hole
Consider following circumstances when selecting perforation
positions.
2.4.1 Slope
Mud mixing station shall be in horizontal position and perforation angle
shall be considered to avoid influence to drill installation and prevent mud
from flowing out of the hole due to bent auger stem.
2.4.2 Traffic
Locomotives and pedestrians must be out of safety distance of
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construction site with buffer zone of at least 3m away from equipment.
2.4.3 Space
Check if perforation and final hole have sufficient space to guarantee
gradual bending of auger stem. Please refer to “The minimum angle
buildup distance” in the chapter to check if there is sufficient operation
space or not.
2.4.4 Amenity
Strive to drill toward downslope direction by considering shade, wind
direction, smoke, smog and other site characteristics so that mud will not
flow to drill.
2.5 Design bore track
Bore track shall be designed from perforation to final hole before
drilling.
Bore track can be marked on the ground by painting, flagging or marking
on the paper for operator’s reference.
For complex bore:
Consult to engineers for site evaluation and calculation of bore track. Be
sure to notify engineer of the minimum perforation angle, bending extreme
of auger stem, back tow materials, length of auger stem and positions of
various underground pipelines.
Four parameters shall be considered before drilling for simple
bore.
It is suggested to consider bending extreme of auger stem, perforation
angle, the minimum angle buildup distance and the minimum depth.
Suggested bending extreme shall be considered for every bent auger stem
besides perforation.
Attention: Auger stem can be bent but invisible damage
may be caused if exceeding suggested bending extreme.
Auger stem may be invalid suddenly after long-term damage
accumulation.
2.5.1 Definition of perforation angle
Perforation angle refers to relative included angle between drill and ground.
It can be gained by following methods:
2.5.1.1 Deviation survey probes shall be placed on the ground and drill
respectively to measure ground inclination and drill inclination. Difference
of drill inclination and ground inclination is equal to perforation angle.
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2.5.1.2 “A” and “B” refer to height of carrier front end and post end to the
ground. “C” refers to horizontal distance of front and post ends and formula
of perforation angle is follows:（（ B-A）/C）×100
（Please refer to Figure 8.）
Figure 8 Definition of perforation angle
Bore can be under the horizontal status as early as possible by little bore
bending if perforation angle is relatively smaller. Bore track and depth will
be increased if perforation angle is relatively larger.
2.5.2 Definition of the minimum angle buildup distance
The minimum angle buildup distance refers to horizontal projected distance
of bore from drilling to horizontal status. Bore slope will exceed bending
extreme of auger stem with damage if angle buildup distance is
excessively small.
The minimum angle buildup distance can be defined by known perforation
angle according to bore depth requirements to the ground.
2.5.3 The minimum hole location depth
Auger stem must be bent stably so bore depth to the ground under
horizontal status shall be defined by perforation angle and bending
extreme of auger stem. Depth is in inverse proportion of perforation angle.
Depth will be increased by increasing perforation angle and angle buildup
distance.
Corresponding angle buildup distance and perforation angle can be
calculated by required hole location depth.
2.6 Equipment preparation
Note: Inspect equipment carefully before daily or shift equipment
startup.
2.6.1 Inspect liquid level and volume including fuel oil, hydraulic oil, cooling
liquid of engine, electric quantity of storage battery and machine oil.
2.6.2 Check if status and function of equipment parts are normal without
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loose bolts or not.
2.6.3 Check if there is oil, water or gas leakage or not.
2.6.4 Check if display of various manipulation instruments is normal or not.
2.6.5 Check if assorting facilities are complete or not.
2.6.5.1 2 sets of new batteries shall be provided for receiver, transmitter or
tracer.
2.6.5.2 Probe shall have new and backup batteries.
2.6.5.3 Wireless interphone shall have new and backup batteries.
2.6.5.4 Quick wrench
2.6.5.5 Backup drill bit, filter net and nozzle
2.6.5.6 Small flag or paint for mark
2.6.5.7 Water and backup hose
2.6.5.8 Fuel oil (according to engineering quantity)
2.6.5.9 Bentonite, polymerizer, water processor and other additives
2.6.5.10 Fuse
2.6.5.11 Re-expanding probes, rotary connectors and back tow facilities;
2.6.5.12 Hose and water gun for washing
2.6.5.13 Pipe tape
2.6.5.14 Thread dope and brush
2.6.5.15 Insulation shoes and gloves
2.6.5.16 Tally book and pen
2.7 Site preparation
Note：Such sites shall be classified into power type site if there
is any doubt for category division or there are possible power wires
without mark. Cables shall be cut off and exposed to facilitate
monitoring before drilling.
2.7.1 Bore track mark
Design bore track or original underground pipelines shall be marked by
small flag or paint.
Bore preparation point
As shown in Figure 9, the 1st auger stem must be straight to guarantee
successful drilling. Please excavate a beginning hole on the ground to
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avoid bending and distortion of auger stem.
Figure 9 Beginning pit
2.7.2 Bore path record
Record actual bore path after construction. List skewness, depth of every
auger stem and describe the construction process integrally. In addition,
construction sketch shall be mapped to record back tow depth and
approximate position.
2.8 Machine startup
2.8.1 Various manipulation rods and switches shall be placed in the middle
position before engine startup.
2.8.2 Switch on power switch and rotate key switch or press startup button
then start up the engine.
Please refer to engine manual for startup and usage of engine.
2.8.3 Low-speed no-load operation for 5 minutes is required after engine
startup for pre-heating.
2.9 Drill positioning
2.9.1 Drill shall be positioned according to soil insertion pint.
2.9.2 Rack shall be inclined to reach required soil insertion angle according
to demand.
2.9.3 Post leg shall be lowered to the ground.
2.10 Assembly of drilling rig
2.10.1 Selection of nozzle and drill bit.
2.10.1.1 Selection of nozzle and drill bit: There are many kinds of nozzles
and drill bits and they shall be selected according to detailed construction
conditions and required mud flow.
2.10.1.2 The nozzle shall be installed on the probe container tube.
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2.10.1.3 (As shown in Figure 10), the probe shall be connected to
container tube.
Figure 10 Assembly of drilling rig
2.10.1.4 Transmitter installation：
Replace old battery, place signal rod in its accurate position and use guide
instrument accurately according to manual.
Note：Battery of signal rod must be replaced before daily operation.
2.10.2 Connection of buffer rod
2.10.2.1 Slide bushing components of auger stem shall be detached.
2.10.2.2 Buffer rod shall be placed in the front jaw vice.
2.10.2.3 Close the jaw vice.
2.10.2.4 Lubricate the connector.
2.10.2.5 Connector shall be tightened by machine torque.
2.10.3 Connect probe container tube.
2.10.3.1 Drilling rig shall be placed in the front jaw vice.
2.10.3.2 Close the jaw vice.
2.10.3.3 Connector shall be tightened by machine torque.
2.10.4 (Optional) connection of drilling rig by combination pliers
2.10.4.1 Drilling tool shall be connected to the 1st auger stem and tightened
by hand.
2.10.4.2 Special combination pliers shall be connected in the accurate
positions.
·(As shown in Figure 11), combination pliers shall be placed around
pipes after opening special pliers(2).
·Pipes shall be clamped by the combination pliers (1).
·As shown in the figure, special pliers(2) shall be placed in the other
end of pipes.
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·Pull-rod axles (3) (4) shall be screwed down to rotation body (5).
·Rotate special pliers to insert pull-rod axles (3) (4) into special pliers
(1) (2) then into elastic pins (6) (7) respectively.
·Pipes shall be clamped by rotating special pliers (2).
Figure 11 (Optional) special pliers
2.10.4.3 Connector shall be tightened by marking-on process.
2.10.4.4 Screws shall be tightened for 2 circles inversely to release
pressure then components of combination pliers shall be detached.
2.10.5 Marking-on process (shown in Figure 12)
Figure 12 Marking-on processes
2.10.5.1 Slag shall be removed from wrench and connector thoroughly.
2.10.5.2 A line shall be marked to divide 2 ends of partition line.
2.10.5.3 The 2nd line shall be marked to be about 9.5mm away from the 1st
line toward inverse tightening direction in one end of movable connector.
2.10.5.4 Rotate the handle and tighten connector so that the 2nd line is
connected to the 1st line.
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2.10.6 Connect the 1st auger stem.
2.10.6.1 Start up the engine.
2.10.6.2 Align buffer rod of the front wrench.
2.10.6.3 Clamp the drilling rig by front wrench.
2.10.6.4 Load the auger stem.
2.10.6.4.1 Lubricate main axle connector thread of power head.
2.10.6.4.2 Lubrication front threads of auger stem.
2.10.6.4.3 Lifting device switch of auger stem shall be used to convey
auger stem to the main axle. Pay attention to relative position of auger
stem to front jaw vice and drill collar (and mark clamping positions of every
auger stem) to guarantee accurate position of auger stem.
2.10.6.5 Connection of auger stem
2.10.6.5.1 Power head shall move forward until main axle connector is
closed to threads of auger stem.
2.10.6.5.2 Power head shall continue to move forward until auger stem is
inserted into main axle connector.
2.10.6.5.3 Power head shall move forward until auger stem terminal is
aligned to thread of buffer rod.
2.10.6.5.4 Use the pushing/rotation controller to rotate the main axle and
auger stem slowly then install them to threads of the buffer rod.
2.10.6.5.5 Open the holder clamp.
2.10.6.5.6 Decline the lifting device of auger stem to the greatest extent.
2.10.6.6 Screw down the auger stem.
2.10.6.7 Loosen the front jaw vice then move power head to the rear of drill
rack.
2.10.6.8 Power off the engine.
2.10.7 Connection of mud system
Mud hose shall be connected from mud mixing system to mud pump.
Guide drilling
Warning：Inaccurate operation may cause death or casualty.
Shutdown is required for inspection if failing to operate
according to manual.
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Note：Drills shall be anchored accurately before perforation.
3.1 Operation of feeding & revolution handle
Feeding & revolution handle has 2 operation locations to allow
complex effect of 4 basic motions. Please refer to Figure 13 for
function and position of operation handle.
Please refer to following figure for possible functions when control handle
is in the composite position.
Auger stem will rotate positively (and shackle) when power head moves
forward.
Auger stem will rotate inversely (and shackle ) when power head moves
forward.
Auger stem will rotate inversely (and shackle ) when power head moves
backward.
Auger stem will rotate positively (and shackle ) when power head moves
backward.
3.2 Drilling the 1st rod
3.2.1 System startup
3.2.1.1 Start up drill and mud device to pre-heat 2 engines. Please refer to
usage manual of mud mixing system for operation.
IMPORTANT：Be sure that mixed liquid can meet drilling
conditions.
Auger stems, drilling rigs and short connectors of different
factories can not be mixed.
3.2.1.2 Adjust accelerate switch of engine so that it can be opened
completely.
3.2.1.3 Pressure the charging mud pump switch so that auger stem is full
of mud with increased mud pressure.
Note：Everybody shall be at least 3m away from rotary auger stem.
Feeding auger stem can not operate forcefully or it may be bent. Do
not use bent auger stems.
3.2.2 Inspect flow of drilling liquid by visual observation.
3.2.3 Select position of time clock.
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3.2.4 Power head shall move forward slowly. Strive to drill the 1st auger
stem straightly.
3.2.5 Monitor various surveying meters.
3.3 Add auger stems
Warning： Please keep far away from rotary axle due to
possible death or casualty.
3.3.1 Adjust accelerator switch so that rotation speed of engine can be
about 1,900 r/min.
3.3.2 Cut off auger stem connector in main axle thread.
Attention：Do not hold recessed end of auger stem to avoid
damage. Strive to be close to front jaw vice (2) and close the mud
pump if connector is between jaw vices.
Figure 14 Holding the auger stem
3.3.2.1 Loosen the manipulation rod when auger stem connector in main
axle thread is between front jaw vice (2) and post jaw vice (1).
3.3.2.2 Start up the front jaw vice (2) until auger stem is clamped with
increased pressure.
3.3.2.3 Main axle shall be rotated counter-clockwise until threads are
loosened.
3.3.2.4 Lubricate the main axle thread.
3.3.2.5 Stop rotation and move the power head to the rear end of rack.
3.3.3 Add auger stems.
3.3.3.1 Decline the lifting device of auger stem then open the clamp switch
of holder.
3.3.3.2 Place one auger stem in the clamp.
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3.3.3 Close clamp switch of holder.
3.3.4 Rotate the lifting device to move the auger stem to its axle.
3.3.5 Lubricate front threads of auger stem.
Note：Thread oil shall be brushed on threads of auger stem and short
connector when installing the auger stem.
3.4 Connect the auger stem.
3.4.1 Power head shall be pushed forward until main axle thread contacts
auger stem.
3.4.2 Continue to push power and rotate main axle until main axle thread is
installed on the auger stem.
3.4.3 Power head shall move forward slowly until new auger stem contacts
front auger stem threads.
3.4.2 Push the power head and rotate the main axle until new auger stem
is tightened with front auger stem.
3.4.3 Loosen the front jaw vice.
3.4.4 Press the holder switch then open the holder.
3.4.5 Rotate lifting device switch for declination.
Note：Be sure that lifting device of auger stem is in the lowest position
before pushing power head forward. Guarantee sufficient free motion
distance between power head and carriage during loading/unloading
of auger stem.
3.5 Pressure the charging mud pump switch so that auger stem is full of
mud with increased mud pressure.
Note：Adjust speed control handle of mud pump and set pressure
suitably. Gear can not be changed during operation of mud pump.
Gear variation operation of mud pump: It is the easiest to change gears
within 10 seconds after closing the mud pump because transmission gear
is still in operation.
Please refer to operation manual of mud pump for operation.
3.6 Rotate the main axle and drill slowly then adjust rotation speed
according to dimension of drill bit and soil conditions.
Attention： Be sure to rotate it clockwise unless connector of
auger stem is cut off. Connector will be loosened by
counter-clockwise rotation.
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3.7 Monitor various surveying instruments and shutdown is required for
inspection if any is any problem.
3.8 Drill bit shall be positioned by guide instrument after drilling for at least
half of length of auger stem.
4 Correction direction
4.1 Correction direction is operator’s technique gained by experience
to equipment and soil conditions.
Basic operation steps are as follows:
4.1.1 An operator shall position drill bit by guide instrument and issue
operation instructions to drill operator during directional drilling.
4.1.2 Drill bit shall be traced during correction to compare current position
with drilling plan and steer drill bit according to demand.
4.1.3 Basic principle to consider during correction is as follows:
4.1.3.1 Steering ability depends on soil conditions, used drill bit, nozzle,
surveying data of drill bit and non-rotation pushing distance.
4.1.3.2 All machines shall be corrected gradually. Please refer to bending
extreme of auger stem. Excessive correction may damage auger stem and
cause difficult drilling and back towing so it is required to straighten as early
as possible for correction.
4.1.3.3 Do not push the entire auger stem into the ground if it does not
rotate because auger stem may be damaged by exceeding the bending
radius.
4.2 Positioning of drill bit
4.2.1 Drill bit parameters which can be gained by guide instrument include
depth, inclination, angle of tool and temperature, etc.
4.2.2 Compare with positions shown in drilling plan to define direction of
drill bit.
4.2.3 Rotate the power head until required time clock position is displayed
on the guide instrument;
4.3 Steering steps:
4.3.1 Adjust angle of drill bit.
4.3.2 Push the auger stem if power head does not rotate.
4.3.3 Check if direction can meet requirements or not by display data of
guide instrument. Stop operation then drill with rotation once reaches
required angle. (Steering of auger stem can not exceed permissible
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bending angle of single auger stem or it may be damaged.)
Attention：Stop operation and find out reasons instantly if
single auger stem has larger angle variation within shorter
distance. Auger stem, drill bit, beginning rod, pivot plate even
probe rod may be damaged if continuing to operate the machine.
Do not push the power head forcefully if it is difficult to change
pushing direction of auger stem to avoid bending. Auger stem can be
close to steering direction for slow rotation and pushing within scope
of 45° sector.
5 Design notice of guide hole
Guide holes shall be designed to evade underground pipelines and remain
sufficient safety distance. Measured depth of underground pipes deviates
from actual depth and detected and measured values are different
especially under large disturbance. Therefore, sufficient safety distance
shall be remained when designing the guide hole. In general, safety
distance shall be 1m during actual construction and it must reach 0.5m.
Guide hole below the water level shall be designed to horizontal hole as
practicable as possible when passing across the river. In general, guide
hole shall be at least 3m away from bottom of river bed because pipes may
float due to super-small distance. In the meanwhile, guide hole is difficult to
construct due to small distance of river bottom and complex soil quality.
Guide hole shall be at least 4m away from road base when passing across
railway or highway. Depth shall be increased if expanding diameter is
larger. Various conditions on the site shall be collected completely when
passing railway and highway to guarantee safety of guide operators.
In general, depth of guide hole shall be not lower than 5m when setting
pipes below floors. Depth of guide hole shall be increased if expanding
diameter is large with soft stratum.
Points shall be set when passing across routes for construction site with
poor vision to control guide precision and define soil exit hole positions.
Auger stems of every factory have different bending radius and they may
be invalid due to early rupture even major loss if actual bending radius
exceeds permissible bending radius.
Be in accordance with three requirements at the same time when
designing the guide hole. That is, it is required to meet owner’s
requirements and construction process and evade underground hidden
articles. Coordinate with entrusting party to check if construction route can
be changed or not if construction location can not meet above conditions at
the same time. Project of which route can not be changed is preferred to
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reject due to super-low success rate.
6 Soil exit of drill bit
Drill bit shall be led to target pit or protrude out of the ground upward. Pay
attention that deformation of auger stem shall be within the minimum
bending radius. Mud pump switch shall be closed instantly once drill bit is
exposed.
Warning：Ask drill operator to close the engine then replace
the drilling tool when using the combination pliers. It is
strictly prohibited to start up the engine when connecting
and replacing drilling rigs.
7 Re-expanding and back towing
Bore can be expanded and materials shall be drawn after finishing
directional drilling.
Warning：All persons shall keep far away from materials and
movable parts which are in installation. Re-expanding or
back towing is not allowed until confirmation that
re-expanding head is installed and relevant persons are far
away from them. Back towing is required firstly until drill bit begins to
enter into the soil then it shall be rotated slowly.
7.1 Re-expanding steps
7.1.1 Selection of re-expanding device: Selection of re-expanding drill bit
may be influenced by dimension of pivot hole, back towing materials and
soil conditions so please contact dealer or factory for details.
Ideal final bore aperture is approximately 1.3 to 1.5 times of pipe diameter
or sum of pipe diameter and 200mm. Suggested expanding aperture is
sum of pipe diameter and 200mm if pipe diameter exceeds 600mm.
Re-expanding head is suggested to be the smaller value of 1.2 to 1.5 times
of outer diameter or sum of outer diameter and 200mm during practice to
form a circular space, remove mud or drilling debris and reduce resistance
of back towing pipes with suitable bending for pipes.
7.1.2 Define mud flow requirements.
7.1.3 Select the back towing device.
7.1.4 Transmitter installed in the re-expander shall be used for
re-correction if re-expanding hole is traced by transmitter.
7.1.5 Set mud flow reasonably.
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7.1.6 Ensure that mud can be jetted from all nozzles.
7.2 Re-expanding prompt
7.2.1 Strive to straighten drilling route during plan.
Inspect bending extreme of back towing materials for gradual bending.
Mud quality is important for re-expanding so it is required to know soil
quality, underground water, additive and mixed mud. Re-expanding needs
more mud by comparing with pivot hole drilling.
7.2.2 Definition of mud requirements
Re-expanding is not successful until there is sufficient mud. Required mud
consumption depends on dimension of re-expanding hole, drawn materials
and soil conditions.
The section is to describe how to define the minimum mud consumption
under ideal conditions. Mud consumption during actual construction shall
be larger than suggested consumption or re-expanding hole may be dry
and unsuccessful.
7.2.2.1 Define dimension of re-expanding hole and outer diameter of drawn
materials shall be defined and required mud consumption can be known
according to Appendix A.
For instance, a re-expanding hole of 15.2 cm (namely, 6 inches) needs at
least 19L/m (1．47 gallon/foot) while a back towing material of 7.6cm needs
at least 5L/m (0.37 gallon/foot).
7.2.2.2 Mud consumption required by every foot or meter of re-expanding
can be calculated by difference of mud consumption required by
re-expanding hole and volume of back towing materials. For instance,
drilling for 1m needs at least 14L mud (and every foot needs 1.1 gallons).
7.2.2.3 Mud consumption required by the hole can be estimated by
multiplying result by re-expanding length.
7.2.2.4 Pressure estimation
Required mud flow and pressure can be defined according to nozzle
diameter shown in Appendix B.
Actual mud flow and pressure relate to nozzle quantity of re-expanding
heads.
8 Disassembly of auger stem
Warning!Do not hold the head of auger stem or it may be
damaged. Hold the auger stem and strive to close to front jaw
vice (2) when connector is between wrenches. Please refer to
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Figure 15 for clamping.
Figure 15 Clamping diagram of auger stem
8.1 Stop the power head and hold the auger stem when connector is
between front and post jaw vices.
Press clamping switch of front jaw vice (2) until auger stem is clamped with
certain pressure.
Press clamping switch of post jaw vice (1) until auger stem is clamped with
certain pressure.
8.2 Cut off the front connector.
Press rotation switch of post jaw vice (1) and rotate the post jaw vice
counter-clockwise then cut off the connector.
Open the post jaw vice then rotate it clockwise so that it can return to its
original position.
8.3 Separate the front connector.
8.3.1 Clamp the auger stem by post jaw vice；
8.3.2 Rotate the power head counter-clockwise and loosen the connecting
thread；
8.3.3 Rotate auxiliary loading/unloading device of auger stem and clamp
the auger stem so that post jaw vice can loosen the auger stem;
8.3.4 Rotate the main axle slowly and counter-clockwise, move power
head backward, detach the auger stem then rotate auxiliary
loading/unloading device of auger stem and detach the augers tem. (Pay
attention to relative position of auger stem and jaw vice to avoid collision of
rotary auger stem and jaw vice or bonding with connecting thread of drill
collar.)
8.4 Connect it to the next auger stem.
8.4.1 Move the power head forward until main axle pin contacts auger
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stem.
8.4.2 Rotate the main axle and move the power head forward. Connect
main axle pin to the box of auger stem then screw down the connector.
8.4.3 Open the front jaw vice to loosen the auger stem.
8.4.4 Open the mud pump for continued re-expanding or back towing.
8.5 Shutdown
8.5.1 Low-speed no-load operation for 5 minutes is required for engine
before shutdown for cooling.
8.5.2 Toggle key switch to shutdown position or pressure the button then
remove the startup switch key.
8.5.3 Power off the main switch then remove the power switch key.
9 Technical difficulties during construction
9.1 Jamming of a drilling tool
Jamming of a drilling tool is a common technical difficulty during
re-expanding and reasons shall be defined for troubleshooting.
9.1.1 Retract the drill bit, auger stem and move drill to drill the guide hole
again if there is jamming with underground pipelines.
9.1.2 Jamming of bricks or stones in the soil: Loosen the torque and rotate
the drill bit for slow expanding. Jamming of large stone or concrete in the
soil: Strive to retract the drill bit and move drill for re-drilling or excavate
stones for continued expanding. Do not operate forcefully or auger stem
may be broken and drill is lost in the hole.
9.1.3 Slow down expanding speed and increase mud consumption if there
is frequent jamming for large-diameter expanding in hard clay layers.
Sometimes 40 minutes shall be required for back towing of an auger stem.
9.1.4 Loosen the torque and re-expand slowly if jamming is caused by
collision of drill bit and root. Root shall be crushed to avoid obstacles if
re-expanding is required.
9.2 Hole shrinkage
Hole shrinkage may be caused in the hole during re-expanding in soft soil
layer. Water in the hole will flow out of the auger stem inversely after
disassembling the auger stem to indicate severe hole shrinkage. Pipes
may be protruded with deformation even jamming under severe hole
shrinkage.
Solid mud protective wall shall be selected for severe hole shrinkage to
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maintain balanced pressure in the hole or drill bit of larger diameter shall be
adopted for expanding, borehole cleaning and pipe layout. PE or PVC
tubes with higher hardness and strong resistance pressure shall be used
and pipes with slight hole shrinkage generally can be set after borehole
cleaning.
9.3 Hole collapsing
Expanding holes in sandy clay, sand and loose backfill soil layers are easy
to collapse and pavement crack may sink due to hole collapsing, burial or
jamming of a drilling tool.
Solid mud or heavy gum solid mud protective wall can be selected to avoid
hole collapsing effectively. Continued expanding is not allowed until
removing rock blocks if hole collapses in storage yard of rock blocks.
9.4 Bore expansion
Clay expands after water absorption so set pipes are easy to be flat with
increased debris and reduced aperture after forming.
High-quality solidfree protective wall can be adopted to reduce contact
between hole wall and water and reduce water loss. Expanding diameter
can be added with multiple borehole cleaning to avoid stratum expansion
and protrusion to set pipes effectively.
9.5 Mud loss
Mud in loose backfill soil layers such as sandy silt, clay, sand layers and
soft soil layers on the bottom of river bed will lose from the hole due to
lower underground water level.
Mud concentration and viscosity can be added to form a skin on the hole
wall to avoid mud loss effectively. Mud still will lose when hole passes
across the river.
9.6 Mud effusion
Mud will effuse from hole to ground during expanding and back towing of
pipes and reasons are as follows:
9.6.1 Bore will be jammed due to excessive debris in the expanding hole
and mud will effuse from the ground due to high pressure in the hole.
9.6.2 Loose stratum will reserve an effusion channel for mud.
In general, it is insignificant if mud effuses from the ground. Pay attention to
it under specific conditions.
9.6.3 Mud can not effuse from residential houses, fish, shrimp or crab
ponds.
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9.6.4 Mud effusion prevention measures
9.6.4.1 Design bore depth shall be added from 6m to 9m and original depth
can be added from 9m to 12m.
9.6.4.2 Improve the drill bit structure to strive to mix mud in the bore into
mud.
9.6.4.3 Add mud viscosity, concentration, flow and floating and debris
removal ability of protective wall properly. A complete channel shall be
formed in the bore so that mud can effuse from the hole freely.
9.7 Continue to pump mud even if drill stops operation.
Drill stops operation due to various reasons during back towing and pipe
layout. Pipes which shall be welded and protective layers which shall be
repaired in the halfway may be disturbed by municipal administration. Mud
can not be pumped if drill bit stops operation if back towing and pipe layout
are required. Mud shall circulate in the hole to prevent from increasing
back towing force of set pipes and avoid burial. Mud pumping can not be
stopped especially for sandy stratum. Stop pumping dense mud before drill
stops operation under emergency conditions then mud shall be pumped for
10 minutes after re-drilling so that mud can exit the hole for back towing
and pipe layout.
9.8 Expanding efficiency
Torque and rotation speed of drill are in direct proportion of expanding
efficiency. Expanding efficiency relates to expanding soil layer, drill bit, mud
quality and mud consumption directly under rated torque and rotation
speed of drill. Clarify soil layer structure and soil quality composition, select
high-efficiency drill bit to cut the soil layer, mix mud and define mud
consumption to increase expanding efficiency.
9.9 Quick sand
Complete holes can not be formed after expanding of quick sand layer.
Quick sand has absorption force to bring resistance to set pipes. Heavy
gum solid mud will be used to slow down expanding speed so that mud
and quick sand can emulsify thoroughly. Quick sand will be floated in the
hole to eliminate absorption force. Quick sand will flow out of the bore with
mud during pipe layout.
9.10 Pipe deformation
Clay will form blocks for residue in the hole in high-viscosity stratum and it
is difficult to mix into mud. Mud blocks will be protruded and pipes will be
protruded with deformation during pipe layout. Pipes shall be set before
layout after multiple borehole cleaning to guarantee little deformation.
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Pipes with large deformation shall be repaired or they shall be rejected.
9.11 Pipe jamming
Pipes may be jammed in the hole due to many residual mud blocks, hole
collapsing and hole shrinkage. Back tow pressure gauge will increase
gradually before jamming. Back towing speed shall be paused or reduced
and mud consumption shall be added when reading increases to avoid
pipe jamming. Pipes can be retracted by bulldozer and excavator for
re-borehole cleaning and pipe layout.
10 Add antifreeze fluid into the drill
Drill can operate in the night under low temperature by using approved
antifreeze fluid.
Steps to add antifreeze fluid：
10.1 Connect one end to mud pump by a hole and the other end shall be
placed into the antifreeze fluid.
10.2 Adjust the mud pump to the minimum flow gear.
10.3 Start up the device and set the accelerator to the slow speed position.
10.4 Open the mud pump switch and start up the mud pump.
10.5 Until antifreeze fluid flows out of main axle.
10.6 Close the mud pump.
10.7 Remove the hose and keep it properly.
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VI. Lubrication, repair and maintenance
1 Operation and maintenance of rubber crawler
1.1 Tension force of rubber crawler
Tension force of rubber crawler must be adjusted before operation of
driving device. (Rubber crawler has been adjusted before leaving the
factory.) It must be adjusted if crawler has large pendant length during
operation. Adjustment method is as follows: Grease shall be added into the
tension device by grease gun until rubber crawler can meet tension
standards.
Tension standard of rubber crawler is as follows: The maximum pendant
length of rubber crawler between 2 upper supports is less than or equal to
10mm.
1.2 Ground
Rubber crawler is strictly prohibited to use for following pavement because
texture may be damaged. Sharp turn shall be evaded with super-low speed
for operation under following conditions:
1.2.1 Grit road
1.2.2 Stone road
1.2.3 Steps
1.3 Warning :
1.3.1 Driver shall drive it slowly and carefully on the rough pavement to
avoid damage to wheel and crawler.
1.3.2 Strive to avoid abrasion between rubber crawler and cement wall
during driving to avoid rim crack of rubber crawler.
1.4 Driving technique of driver will influence service life of rubber crawler
greatly.
1.4.1 Driver shall turn in times with low speed during operation. Driving
speed shall be changed gradually during driving to avoid crash and
emergency stop.
1.4.2 Avoid sharp turn on the cement pavement and avoid damage to
wheel or crawler.
1.4.3 Driving rubber crawler shall not contact salt or salt fog because it may
influence bonding of rubber and metal parts. It shall be washed by water
after contacting salt.
1.4.4 Driving rubber crawler shall not contact fuel oil or hydraulic oil. Stain
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shall be removed instantly or service life of crawler may be damaged.
Warning:Rubber crawler damaged by improper operation is not
within regulated scope of “three warranties” of the machine.
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Task
Period
(hour)
Oil product
Inspection of machine oil
10
Please refer to
engine operation
instructions.
Replacement of machine oil
and filter (for the 1st time)
50
Please refer to
engine operation
instructions.
Replacement of machine oil
and filter
100
Please refer to
engine operation
instructions.
Task
Period
(hour)
Grease
Lubrication chain
10
SAE 30W
Grease nozzle of lubrication
jaw vice
10
Calcium soap grease
Sliding rail of lubrication
power head
If necessary
Calcium soap grease
Sliding rod axle of lubrication
jaw vice
If necessary
Calcium soap grease
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2 Equipment lubrication and maintenance
·Check if various connectors are tightened and pipelines are damaged or
not before operation of lubrication system.
·Leakage of hydraulic oil is difficult to inspect by visual observation. It is
preferred to inspect by a hard paperboard or wooden pieces.
·Wear protection clothes and glasses.
·Cure injured anybody instantly.
Attention！Maintenance and repair shall be under closing
status of engine unless otherwise specified.
2.1 Engine maintenance shown in Table 7
Table 7 Engine maintenance
2.2 Sliding rack lubrication shown in Table 8
Table 8 Sliding rack lubrication
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Lubrication item
Hour
Lubrication oil
Inspection of lubrication oil in
power head
50
L-CKD220
Inspection of driving speed
reducer oil (in 2 locations)
50
SHELL OMALA EP150
Caltexoils Meropa 150
Replacement of lubrication oil in
power head
1000
L-CKD220
Replacement of driving speed
reducer oil (in 2 locations)
1000
SHELL OMALA EP150
Caltexoils Meropa 150
Item
Hour
Hydraulic oil
Inspection of hydraulic oil
10
L-HM46
Replacement of oil filter (for the 1st
time)
50
Replacement of oil filter
250
Replacement of hydraulic oil and
filter core
1000
Lubrication item
Hour
Lubrication oil
Inspection of machine oil in mud
pump
50
SAE30W
Replacement of machine oil in the
pump
250
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2.3 Maintenance of power head shown in Table 9
Table 9 Maintenance of power head
2.4 Maintenance of hydraulic system shown in Table 10
Table 10 Maintenance of hydraulic system
2.5 Maintenance of mud pump shown in Table 11
Table 11 Maintenance of mud pump
2.6 Maintenance of drilling tool
Joint threads shall be used for drilling rig connectors and lubrication auger
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Interval
(hour)
Item
Ordinary
Inspection of tensity of feeding
chain
Inspection of tensity of crawler
10
Inspection of various pipes
Leakage inspection of gear box
and motor
25
Inspection of radiator
50
Inspection of storage battery
Belt inspection
Replacement of oil filter (for the
1st time)
100
Inspection of drilling tool
250
Replacement of oil filter
2000
Washing & cooling system
If necessary
Replacement of air filter
Replacement of sliding plate of
power head or clamp holder
Replacement of wearing parts
such as short connector of auger
stem, power divider, re-expander
and torque sleeve, etc
Muffler inspection
Item
Interval (hour)
Pipeline inspection
10
Inspection of radiator
25
Inspection of storage
battery
50
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stem with special lubrication grease before usage for the 1st time and after
drilling.
2.7 Ordinary inspection shown in Table 12
Table 12 Ordinary inspection
2.8 Ordinary maintenance shown in Table 13
Table 13 Ordinary maintenance
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Belt inspection
50
Replacement of short
connector
If necessary
Replacement of sliding
plate of power head
If necessary
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Warning!Close engine and manipulate various handles for
unloading and descend, lock or support various ascending
devices before cutting off hydraulic pipes. Various connectors
shall be covered by thick cloth and loosened by connector nuts to
release residual pressure. Discharged hydraulic oil shall be contained
by container.
2.8.1 Storage battery
Attention! Storage battery shall be cut off during repair, welding
and long-term storage. It shall be inspected every 50 hours.
Keep the storage battery clean without corrosion and brush a
layer of lubrication grease in the cable connectors.
2.8.2 Pipeline inspection
All pipelines shall be inspected every 10 hours to check if there is leakage
or loose connection or not.
2.8.3 Engine belt
The transmission belt drives AC power generator, cooling fan and water
pump. Operating conditions of tension device and idle pulley shall be
inspected every 50 hours to check if belt is in accurate position with
abrasion or not.
2.8.4 Radiator
Check if there are sundries, weeds or sundries or not by inspection every
25 hours. It shall be cleaned by compressed air or water spraying gun if
necessary. Pay attention to not damage cooling fins by high-pressure air or
water. It also shall be inspected constantly during construction under dirty
or weedy conditions.
It shall be cleaned by compressed air or sprinkling every 50 hours. Do not
damage vanes by high-pressure air flow or water flow. Screws can be
detached to remove weeds and dirt in the cover. Dirty engine end of heat
dissipater can be cleaned by cleaner of radiator.
Cooling liquid level of radiator shall be inspected every year or every 600
hours. Please refer to operation manual for engine operation.
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Item
Period (hour)
Replacement of machine
oil filter
Shown in “Lubrication”
chapter
Replacement of fuel oil
filter (for the 1st time)
50
Replacement of fuel oil
filter
150
Muffler inspection
If necessary
Replacement of air filter
If necessary
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2.8.5 Short connector
2.8.5.1 Replace short connector of drill collar if necessary.
2.8.5.2 Unload thread connection of drill collar and short connector.
2.8.5.3 Replace old short connectors and brush thread adhesive on
threads.
2.8.5.4 Install new short connectors with tightening by jaw vice.
Note:Short connectors and jaw vices are wearing parts so they shall be
replaced in a timely manner after abrasion. Backup parts shall be supplied
to avoid influence to construction schedule.
2.8.6 Power head pulley
Check if power head pulley is abraded or not with replacement if necessary.
It can be adjusted by removing adjustment gaskets in phases. Removed
gaskets shall be reserved and installed again during pulley replacement.
2.9 Maintenance of filter core shown in Table 14
Table 14 Filter maintenance
2.9.1 Oil filter
Filter shall be replaced fore every 50 hours for operation period and after
future 150 hours. Filter shall be replaced constantly if added oil comes from
oil bucket.
2.9.2 Air filter
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Item
Period
(hour)
Feeding inspection of
feeding chain
Every day
Tensity inspection and
operating conditions of
crawler
Every day
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Air filter shall be replaced if yellow strip in repair indicator reaches red line
position or operation for 1,000 hours. It also shall be replaced constantly
during construction in dirty environment.
2.9.3 Muffler
It shall be replaced if necessary.
2.10 Inspection of power head shown in Table 15
Table 15 Inspection of power head
2.10.1 Crawler tensity
Crawler tensity shall be inspected if necessary. Calcium soap grease can
be added by oil nozzle to adjust tensity.
2.10.2 Tensity of feeding chain
Tensity of feeding chain shall be adjusted as follows if necessary:
2.10.2.1 Move power head to the rear end of sliding rack.
2.10.2.2 Loosen connecting rod nut below head support of drilling frame.
2.10.2.3 Screw down nuts clockwise to tighten chain then lock it by nuts.
2.11 Gear box and motor
Inspect gear box and motor every 10 hours to check if there is leakage or
not.
2.12 Maintenance of auger stem
Auger stem is important for drill so it shall be maintained periodically.
2.12.1 Please install the protective cover cap before long-term storage of
auger stem.
2.12.2 Threads shall be cleaned by high-pressure water and soap
according to demand. Do not use gasoline or similar solvent. Lubricate
threads and base by thread oil after cleaning. Special protective cap shall
be installed if it is not used for a long time.
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VII. Transportation, Storage and Protection
1. Transportation notice
Drill shall be transported by truck during distance transfer. It has a driving
chassis so it can move onto the vehicle by support (welded by
owner)without relying on crane.
Please refer to Figure 15 for support dimension.
Figure 15 Support dimension diagram
In the figure：”h” refers to height of transportation platform of vehicle to the
ground.α≤16.7° (namely, l≥3.3Xh).
Support shall bear weight of the entire drill with certain safety coefficient.
2. Drill transportation
Warning! Drill operator or other persons can not stay on the
drill to avoid falling off or accidents.
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Warning! Drill shall move forward during motion on the horizontal ground or
downslope pavement and retreat during upslope or moving to tow truck to
strengthen safety precaution measures and facilitate operation.
Please operate as follows when entering into the site or finishing drilling;
2.1 Remove residual mud in mud supply system by clean water then detach
the mud mixing device.
2.2 Wash equipment and auger stem by clean high-pressure water if
possible.
2.3 Retract anchor piles.
2.4 Separate all assorting devices such as mud mixing system and pipe
connector, etc.
2.5 Overturn the operation seat to the transportation position.
2.6 Rotate the guide rail to the horizontal position.
2.7 Engine shall operate with low speed so that drill can move to the tow
truck or auto truck with low speed.
Warning: Drill shall move forward during motion on the horizontal
ground or downslope pavement and retreat during upslope or
moving to tow truck to strengthen safety precaution measures
and facilitate operation.
2.8 Guarantee firm fixation when transporting drills by truck or tow truck.
IMPORTANT: Anchorage seat must be put down during
transportation (to avoid damage to angle adjustment oil
cylinder). It can not be tied by hoisting ring on left and right
sides of crawler support by chain or rope after placing on the
carriage floor of tow truck or truck stably.
Warning: Engine shall be under low-speed operation status
when drill moves toward tow truck or truck!
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VIII. Daily Storage and Protection
Anchorage seat must be placed on the ground thoroughly during drill
storage so that angle adjustment oil cylinder is not under the stress status.
Manipulation rods of various valve blocks shall be in middle positions.
Retract the key and power off main power switch then keep the key
properly.
Short-term storage
Short-term storage refers to storage period which does not exceed 2
months. Drill shall be kept in a garage with excellent ventilation and it shall
be far away from combustible, explosive and volatile articles. It must be
covered by firm and durable coverage if there is no garage.
Please refer to engine usage manual for maintenance.
Please refer to usage manual of mud pump for maintenance.
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Diameter of re-expanding drill bit (or
back towing pipe)
Gallon/foot
Liter/meter
5＇
12.70 cm
1.02
12.67
5.5＇
13.97 cm
1.23
15.33
6＇
15.24 cm
1.47
18.24
6.5＇
16.51 cm
1.72
21.41
7＇
17.78 cm
2
24.83
7.5＇
19.05 cm
2.29
28.50
8＇
20.32 cm
2.61
32.43
8.5＇
21.59 cm
2.95
36.61
9＇
22.86 cm
3.30
41.04
9.5＇
24.13 cm
3.68
45.73
10＇
25.40 cm
4.08
50.67
10.5＇
26.67 cm
4.5
55.86
11＇
27.94 cm
4.94
61.31
11.5＇
29.21 cm
5.4
67.01
12＇
30.48 cm
5.88
72.97
12.5＇
31.75 cm
6.37
79.17
13＇
33.02 cm
6.9
85.63
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Appendix A Mud Consumption
Guarantee sufficient mud in the hole during drilling and re-expanding for
smooth construction. Mud demand shall be determined according to
dimension of re-expanding hole, back towing materials and nozzle
dimension.
Please refer to following list for the minimum mud consumption required by
drilling under complete soil layer conditions. Mud consumption during
actual construction shall be larger than value in the list or construction may
be invalid due to poor cooling or lubrication in the hole.
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Diameter of re-expanding drill bit (or
back towing pipe)
Gallon/foot
Liter/meter
13.5＇
34.29 cm
7.44
92.35
14＇
35.56 cm
8
99.31
14.5＇
36.83 cm
8.58
106.54
15＇
38.1 cm
9.18
114.01
15.5＇
39.37 cm
9.8
121.74
16＇
40.64 cm
10.44
129.72
16.5＇
41.91 cm
11.11
137.95
17＇
43.18 cm
11.79
146.44
17.5＇
44.45 cm
12.79
155.18
18＇
45.72 cm
13.22
164.17
18.5＇
46.99 cm
13.96
173.42
19＇
48.26 cm
14.73
182.92
19.5＇
49.53 cm
15.51
192.68
20＇
50.8 cm
16.32
202.68
20.5＇
52.07 cm
17.15
212.94
21＇
53.34 cm
17.99
223.46
21.5＇
54.61 cm
18.86
234.23
22＇
55.88 cm
19.75
245.25
22.5＇
57.15 cm
20.65
256.52
23＇
58.42 cm
21.58
268.05
23.5＇
59.69 cm
22.53
279.83
24＇
60.96 cm
23.5
291.86
24.5＇
62.23 cm
24.49
304.15
25＇
63.5 cm
25.5
316.69
25.5＇
64.77 cm
26.53
329.49
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26＇
66.04 cm
27.58
342.53
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Appendix B Nozzle Flow
Nozzle dimension shall be selected according to mud pressure and the
minimum mud flow per minute. Actual mud flow shall be larger then the
minimum mud flow per minute.
Please refer to Figure 16 for pressure and flow curve with different nozzle
diameters.
B:Nozzle pressure; Unit: Kilogram/centimeter 2;
Please refer to following list for the maximum operating capacity of XZ320
Figure 16 Relation diagram of pressure and flow
In Figure 15: A:Flow of every nozzle; Unit: Liter/minute;
C:Nozzle diameter; Unit: Millimeter;
Appendix C The Maximum and Length of Tow Pipes
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Diameter of drill
bit, φ(mm)
The
maximum
length of tow
pipe (m)
63
1076
75
1068
90
1057
110
1038
125
1027
140
1006
160
982
200
927
225
891
250
853
315
756
400
636
500
514
630
392
800
281
1000
210
1200
205
Diameter of
drill bit, φ(mm)
The maximum
length of tow pipe
(m)
152
840
159
785
168
730
173
715
180
675
194
655
203
644
219
558
245
525
273
494
299
470
325
447
351
425
377
407
402
390
426
375
480
346
530
300
630
262
720
237
820
213
920
179
1020
133
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horizontal directional drill. (Actual capacity relates to soil quality and mud
greatly and the list is only for reference.)
Diameter of drill bit and the maximum length of tow pipe (or steel tube)
Diameter of drill bit and the maximum length of tow pipe (or plastic tube)
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徐州工程机械集团有限公司
XUZHOU CONSTRUCTION MACHINERY GROUP Co.,Ltd.
生产单位：徐州徐工基础工程机械有限公司
Xuzhou Xugong Foundation Construction Machinery Co.,Ltd.
地址：中国.江苏.徐州经济开发区驮蓝山路 36 号
Add：No.36 Tuolanshan Road, Economic Developing zone,Xuzhou JiangSu, China
全国统一客服热线：（Tel）： 400-110-9999
销售部电话（Tel）： 0516-87738167 87738169 87892612
传真（Fax）： 0516-87892627-103、104、109
服务处电话（Tel）： 0516-87892690 87738150
传真（Fax）： 0516-87738173
邮编（Postcode）：221004
网址：http：//www.xcmgjc.com
2011 年 10 月版
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