DD1100RS Operation and Safety Manual Rev 01

DD-1100 RST
Operation & Safety

Instruction Manual
WARNING
Unsafe use of this equipment could result in serious injury or death. This manual con-
tains important instructions for the safe operation and recommended maintenance of
your DD-1100 RST. All operators and ground personnel must carefully read and
understand this manual before starting the machine. Keep this manual available both
as a reminder for your experienced operator and as a training aid for your new staff.
Replacement manuals are available by calling American Augers.
Telephone: 419-869-7107 or 800-324-4930 (USA Toll Free)
Foreword DD-1100 RST Operators Manual
Introduction
Foreword
INTRODUCTION
Since 1970, American Augers has been a devoted manufacturer of trenchless technology equip-
ment; customers worldwide recognize the DD-1100 RST as a premier piece of directional drilling
equipment. American Augers provides its equipment with worldwide technical support, parts and
service. American Augers encourages customers to contact the factory with any operational or
assistance needs.
Every effort has been made to adequately cover the operation of the DD-1100 RST in this man-
ual. If you have any questions about any of the features of your specific machine, contact the fac-
tory (Telephone 419-869-7107 or 800-324-4930 (USA Toll Free)).
Specifications are subject to change without notice or obligation. American Augers will continue
to update its product manuals with current operational information, but some units maybe retrofitted
independently by the customer or by the manufacturer per a customer request at the factory, or
while in service, and the information herein may not reflect those changes.
Wiggle Steer, es!lok and Quiet-Pak are registered trademarks of American Augers, Inc.
Other trademarks are the property of their respective owners.
Original Instructions
Manual Part Number 50DD10100
Released January 2014 Revision 01
Page 2 Refer to the Safety Awareness Program in this manual before attempting to operate this machine
DD-1100 RST Operators Manual Foreword
Limited Warranty
Limited Warranty
This warranty is extended by American Augers, Incorporated in respect of equipment & products sold. American Augers warrants to the
initial purchaser that this Equipment will be free of defects in material and/or workmanship for a period of 2 years from date of shipment to the
initial purchaser, or 2000 hours of operation (Engines 2 years/3000 hours, Rack and Pinion 5 years/10,000 hours), whichever occurs first.
Once the equipment is placed into service as a retail sale, rental or lease, a properly completed Warranty Registration Certificate must be
submitted to American Augers to start and validate warranty coverage.
• The Limited Warranty does not include (1) batteries, lamp bulbs, fuses, various types of gaskets and packing, filter elements, oil
lubricants, fluids, track chain, track drive sprockets, Drill Pipe, Auger sections, die holders, wrench wear parts, guide bushings, shaft
seals, mud swivel assemblies, valves, piston liners, centrifugal pumps, shaker screens, and other normal wearing or aging parts, (2)
engines, (3) transmissions not manufactured by American Augers, and (4) down hole tools & accessories. American Augers extends
to the initial purchaser the benefits of any warranty (if any) of the manufacturers or suppliers of any of the excluded items.
• Claims for defects in material and workmanship shall be made in writing by the initial purchaser to American Augers within ten days
of defect discovery. American Augers reserves the right to send a service representative, contract an authorized representative, or
request that the equipment is returned to the factory for product inspections. Failure on the behalf of the purchaser to permit such
above action can cause a voiding of warranty coverage.
• Within the warranty period, American Augers will repair or replace, at its option, free of charge any portion of parts of the new Equip-
ment, which are found by American Augers to be defective in material or workmanship. Replacement or repaired parts provided
under the terms hereof are guaranteed in like fashion for the remainder of the warranty period. Any parts replaced under the terms
of this warranty become the property of American Augers and upon written request, must be returned, transportation prepaid, to
American Augers.
• In no event shall American Augers’ liability exceed the purchase price of the Equipment. American Augers reserves the right to fully
satisfy its warranty obligation by refunding to the Buyer the full purchase price of the Equipment upon the return of the Equipment by
the Buyer, transportation prepaid, to American Augers.
• This warranty applies only if the alleged defective Equipment has been properly maintained and operated as specified by American
Augers. This warranty will not apply if the alleged defect is attributable to an unauthorized modification or service repair made, a
component part installed, improper equipment storage, neglect or abuse of the equipment on the behalf of the purchaser or their
representatives, improper product operation or use of the product exceeding the design limitations, or an attachment supplied, by a
party other than American Augers or its subsidiaries, or the authorized representative of any of the foregoing.
• If any tests are conducted to ascertain or demonstrate defects in material or workmanship, such test shall be conducted after rea-
sonable notice to American Augers and upon conditions mutually agreed upon in advance of the test, and American Augers may be
represented at any test that shall be made. American Augers, at its option may charge the Customer for any tests performed by
American Augers at the request of the Customer in respect to the merchandise sold hereunder.
• THE REMEDIES IN THIS WARRANTY SHALL BE EXCLUSIVE AND SOLE REMEDIES OF THE BUYER.
THERE ARE NO OTHER WARRANTIES, EXPRESSED OR IMPLIED, OF ANY KIND, INCLUDING BUT WITH-
OUT LIMITATION, ANY WARRANTY THAT THE EQUIPMENT IS OF MERCHANTABLE QUALITY OR THAT
THE EQUIPMENT IS FIT FOR ANY PARTICULAR PURPOSE. AMERICAN AUGERS WILL HAVE NO MONE-
TARY LIABILITY WHATSOEVER FOR ANY DAMAGE, LOSS COSTS, OR EXPENSE (WHETHER GENERAL,
SPECIAL, INCIDENTAL, OR CONSEQUENTIAL) SUFFERED BY THE BUYER AS A RESULT OF OR CONNEC-
TION WITH THE EQUIPMENT, IN NO EVENT SHALL AMERICAN AUGERS BE LIABLE FOR INCIDENTAL OR
CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT LIMITED TO, FREIGHT CHARGES, TRANSPORTATION
CHARGES, DOWNTIME OR OTHER PARTS INCIDENTAL TO THE REMOVAL AND REPLACEMENT OF
PARTS REPAIRED OR REPLACED UNDER THIS WARRANTY.
• American Augers reserves the right to modify, alter, and improve any product or parts without incurring any obligation to replace any
product or parts previously sold with such modified, altered or improved product or parts.
• No person is authorized to alter or extend this warranty unless made in writing and signed by an officer of American Augers.
• Used products and equipment delivered by American Augers or picked up by American Augers are sold without conditions or war-
ranties, express or implied, “as is, where is”, unless there is a clear agreement with the Customer in writing to the contrary. The Cus-
tomer agrees to inspect all such equipment before purchase is completed and to accept same without any warranty of
merchantability or fitness for a particular purpose.
By acceptance hereof, the Customer covenants and agrees that in the event any products purchased hereunder are resold either in
their original form or as a component of another system, the LIMITED WARRANTIES provision set forth above will be included in all sales
documents by which the Customer resells any such products. In all such cases, the sales documents by which a purchaser from the Cus-
tomer purchases and accepts delivery of the products sold hereunder will include from such LIMITED WARRANTIES and prior to any such
sale or delivery and authorized representative of the subsequent purchaser will be made aware of the limitations on the warranty of American
Augers or other manufacturer of the products and that the disclaimers of American Augers apply to the resale of such products. The Cus-
tomer agrees to indemnify and hold harmless American Augers from any such loss, claim or damage. Including attorney’s fees and expenses
resulting from a breach of the foregoing covenant.
Refer to the Safety Awareness Program in this manual before attempting to operate this machine Page 3
Foreword DD-1100 RST Operators Manual
Machine Serial Number Locations
Driller’s Console - side view
Location of Machine Serial Number Plate
Machine Serial Number
DD-1100 RST Operators Manual Foreword
Safety Awareness Program

Understanding Operation Safety
This manual is part of the safety system of the equipment. Use it when training personnel who will oper-
ate the machine or work on the jobsite. Ensure that a copy is always available with the machine and that the
operators have read it, understand it and have access to it. Carefully follow the instructions, advice and pro-
cedures it contains. Safety is everyone’s responsibility.
Directional drills have a number of unavoidable hazards unique to their operation. Safety alert decals are
provided on American Augers’ equipment to alert the operator to hazards of the machines. The “Safety
Alerts” section beginning on page 33 shows these hazard alert signs.
Signal Words
Signal words are used to identify safety information within the text of this manual. They are reserved for
personal injury hazards.
is used for a hazard with a high level of risk which, if not avoided, will result in death or serious
injury.
is used for a hazard with a medium level of risk which, if not avoided, could result in death or
serious injury.
is used for a hazard with a low level of risk which, if not avoided, could result in a minor or
moderate injury.
NOTICE: Hazard alert signs are placed on the machine to inform your operator and other personnel of
potential hazards that exist while these machines are in operation. These decals should be kept clean
and legible. Replacement decals are available from American Augers (Telephone: 419-869-7107 or 800-
324-4930 (USA Toll Free)).
Notes DD-1100 RST Operators Manual
Notes
NOTES:
DD-1100 RST Operators Manual Forward
Revision Record
Revision to Manual
Revision Number Description of Change Date
00 New Release; Serial numbers under top level 50DD10002 from 8/8/2011
RS11000020111
01 Updated Approved Replacement Fluids table and engine maintenance 1/10/2014
items; revised Maintenance Schedule; added hydraulic pump drive
maintenance item; updated safety decals section and carriage
thrust/pullback chart
Forward DD-1100 RST Operators Manual
Revision Record
Revision to Manual, Continued

Revision Number Description of Change Date
DD-1100 RST Operators Manual Forward
To The Owner
To The Owner
Thank you for your purchase of the American Augers DD-1100 RST with optional carriage position sen-
sor. This directional drill, with standard equipment and authorized attachments, is intended to be used for
underground drilling and pullback operations.
This manual contains important information that will help you and your crew set up and safely operate
the DD-1100 RST. DO NOT operate or permit anyone to operate or service this machine until you have read
this Manual. Use only trained operators who have demonstrated the ability to operate and service this
machine correctly and safely.
DO NOT use this machine for any application or purpose other than those described in this Manual.
Consult the American Augers factory for changes, additions, or modifications that may be required for this
machine to comply with various safety requirements. Do not make unauthorized modifications. Unautho-
rized modifications could cause serious injury or death. Anyone making such unauthorized modifi-
cations is responsible for the consequences.
Make sure this Manual is complete and in good condition. Contact the American Augers factory to obtain
additional manuals and for further information about or assistance with your machine. Your American Augers
factory has approved service parts and technicians with special training that know the best methods of repair
and maintenance for your machine.
Forward DD-1100 RST Operators Manual
NOTICE
Before using this manual, familiarize yourself with
the “DD-1100 RST Components” section beginning
on page 17.
PERFORMANCE
Actual machine, accessory, and component performance, capacity, and results can be adversely
affected by or vary with such factors, as environmental conditions, weather, failing to exercise
proper maintenance, machine functionality not being utilized within suggested operating
levels, mechanical or component substitutions that may alter factory standards, operator
experience, or other unforeseen limitations not previously listed.
DD-1100 RST Operators Manual Table of Contents
Table of Contents
Forward ............................................................................................... 2
Introduction.................................................................................................................. 2
Limited Warranty ......................................................................................................... 3
Machine Serial Number Locations............................................................................... 4
Safety Awareness Program......................................................................................... 5
Revision Record .......................................................................................................... 7
To The Owner.............................................................................................................. 9
Overview ........................................................................................... 17
DD-1100 RST Components....................................................................................... 17
Operation and Maintenance Manual ......................................................................... 19
Ownership of Information .......................................................................................... 19
Manufacturer Identification Data................................................................................ 19
Machine Identification Data ....................................................................................... 19
Scope of Document ................................................................................................... 19
Qualification of Personnel.......................................................................................... 20
Declaration of Conformity .......................................................................................... 20
Use of Personal Protective Equipment...................................................................... 20
Legal Disclaimer ........................................................................................................ 20
Purpose of Machine................................................................................................... 20
Ground Leveling and Soil Conditions ........................................................................ 21
Ambient Conditions ................................................................................................... 21
Transport ................................................................................................................... 21
Operation................................................................................................................... 21
Warranty: General Conditions ................................................................................... 21
Limitations of Warranty.............................................................................................. 21
Request for Service/Support ..................................................................................... 21
Warranty and Service for Diesel Engine.................................................................... 22
Instruction Manuals ................................................................................................... 22
Safety Information ........................................................................... 23
Safety Regulations and Practices.............................................................................. 23
Emergency Procedures ............................................................................................. 23
Basic Safety Guidelines............................................................................................. 24
Utility Locations ......................................................................................................... 25
Table of Contents DD-1100 RST Operators Manual
Surface Examination ..................................................................................................26

Overhead Hazards .....................................................................................................26
References .................................................................................................................27
Exit Pit Construction ...................................................................................................27
Before Starting the Machine.......................................................................................27
Operating Precautions ...............................................................................................27
Operator’s Responsibilities.........................................................................................27
Material Handling Precautions; Crane Safety ............................................................28
Drilling Precautions ....................................................................................................28
Reaming and Installation Precautions........................................................................28
Maintenance Precautions...........................................................................................29
Transporting Precautions ...........................................................................................29
Welding Safety ...........................................................................................................29
Noise Level Safety .....................................................................................................30
Ladder Safety .............................................................................................................30
Hazardous Chemicals ................................................................................................30
Danger Zones -- Safe Distances ................................................................................31
Grounding ..................................................................................................................31
Safety Features - ZAPALERT™.................................................................................32
Safety Features - es!lok® Exit Side Lockout System.................................................32
Safety Features - Fire Extinguisher............................................................................32
Safety Alerts...................................................................................... 33
Machine Controls............................................................................. 37
Safety Switches..........................................................................................................37
Disable Switches ........................................................................................................40
Battery Switch and Light Switch .................................................................................41
Setup Box...................................................................................................................42
Radio Remote Transmitter .........................................................................................44
Typical Engine Control Panel .....................................................................................46
Driller’s Console Map .................................................................................................48
Pressure Gauges .......................................................................................................49
Carriage/Rotary/Wrench Operations Panel................................................................50
Engine/Wiggle Steer® Panel......................................................................................53
Various Functions Panel ............................................................................................55
Carriage Position Meter (Optional).............................................................................56
Driller’s Console .............................................................................. 57

Preparation....................................................................................... 59
Site Preparation......................................................................................................... 59
Site Layout................................................................................................................. 59
Cranes ....................................................................................................................... 60
Mats and Cribbing ..................................................................................................... 60
Protection of Wires, Cables and Hoses..................................................................... 60
Making Power Connections....................................................................................... 60
Crew .......................................................................................................................... 60
The Bore Path ........................................................................................................... 61
Guidance System ...................................................................................................... 61
Mud Recycling System .............................................................................................. 61
ZAPALERT™ Electric Shock Alarm .......................................................................... 61
es!lok® Exit Side Lockout System............................................................................. 62
Set Up ............................................................................................... 63
Set Up the Machine ................................................................................................... 63
Anchor the Machine................................................................................................... 69
Excavate the Entry Pit and Returns Pit ..................................................................... 71
Starting the DD-1100 RST ............................................................... 72
Starting the DD-1100 RST......................................................................................... 72
Operating the DD-1100 RST ........................................................... 74
Test the Indicators, Emergency Stop Buttons and all Controls ................................. 74
Attach the Drilling Fluid Supply Connections............................................................. 74
Power Wrench Operation .......................................................................................... 74
Checks During Operation .......................................................................................... 75
Thrust and Pullback Force Controls .......................................................................... 75
Converting Gauge Pressure to Torque and Force .................................................... 75
Using a Mud Motor .................................................................................................... 75
Fundamentals: Install Drill Pipe ................................................................................. 76
Turn on the Drilling Fluid ........................................................................................... 77
Make the Pilot Bore ................................................................................................... 78
End of Pilot Bore Drilling............................................................................................ 79
Pullback Operations ......................................................................... 80
Table of Contents DD-1100 RST Operators Manual
Backreaming and Pullback.........................................................................................80

Continue Backreaming ...............................................................................................83
Equipment Shutdown .................................................................................................83
Rig Down....................................................................................................................84
Operating in Different Climates ...................................................... 85
Operating in Hot Weather...........................................................................................85
Operating in Cold Weather.........................................................................................85
Engine Block Heater ..................................................................................................86
Engine Preheating Devices ........................................................................................86
Machine Storage and Transport...................................................... 87
Minimum Storage Space Required ............................................................................87
Storage Site Conditions .............................................................................................87
Preparations for Storage ............................................................................................87
Transportation ............................................................................................................88
Lifting the Machine .....................................................................................................88
General Maintenance....................................................................... 89
Qualification of the Technician ...................................................................................89
Cleaning .....................................................................................................................89
Welding ......................................................................................................................90
Diesel Engine Maintenance........................................................................................91
Approved Replacement Fluids ...................................................................................91
Scheduled Maintenance ...................................................................92
10 Hour Inspection and Maintenance.........................................................................93
After First 100 Hours of Operation ...........................................................................101
250 Hour Inspection and Maintenance.....................................................................102
500 Hour Inspection and Maintenance.....................................................................103
Specifications.................................................................................. 107
Machine Dimensions / Weight..................................................................................107
Power Supply Unit....................................................................................................107
Power Train ..............................................................................................................107
Drilling Unit ...............................................................................................................107
Rotary Drive .............................................................................................................107
Carriage Drive ..........................................................................................................107
Wrench Assembly.................................................................................................... 107

Drill Pipe .................................................................................................................. 108
Protective Equipment .............................................................................................. 108
Controls ................................................................................................................... 108
Appendix ......................................................................................... 109
Appendix A: List of Attachments ............................................................................. 111
Appendix B: Wiggle Steer and Wiggle Steer Codes ............................................... 113
Appendix C: Dual Power Units and ROOTS .......................................................... 115
Appendix D: Tables Converting Pressure to Torque and Force ............................. 117
Sample Declaration of Conformity ............................................... 123
Notes
NOTES:
DD-1100 RST Operators Manual Overview
Overview
Overview
DD-1100 RST Components
1
50dd10002-dxf-RIG
2
3
18 4
17 6
16
7
15
8
14
13 9
10
12
11
1. Auxiliary Power Unit 11. Front Foot

2. Rotary Gear Box 12. Cables (both sides of rig)
3. Carriage 13. Sliding Dolly
4. Spindle 14. Lifting Legs
5. Top Clamp 15. Rear Foot
6. Thrust Frame 16. Cross Bracing
7. Walkways and Handrails 17. Support Strut
8. Wrench Clamp 18. Hose Carrier
9. Fixed Clamp 19. Light Bar (not shown)
10. Guide Bushing
Overview DD-1100 RST Operators Manual
Overview
DD-1100 RST Components (Continued)
1430H-PowerTrl
2
1
7 6 5 4 3
Side Panels Removed for Clarity
1. Diesel Engine
2. Hydraulic Tank
3. Fuel Filler Pipe
4. Battery Box
5. Valve Bank
6. Filters
7. Electrical Box
Overview
Operation and Maintenance Manual
TITLE: DD-1100 RST Operation & Safety Instruction Manual
EDITION: 2013
Part Number: 50DD10100
Ownership of Information
American Augers, Inc. reserves all rights to the information in this manual.
The use of the manual is restricted to the customer who received it for purposes of installation, use, and
maintenance of the relevant machine. American Augers declares that the information contained in this man-
ual fits the technical and safety specifications of the machine. American Augers disclaims responsibility for
direct or indirect damages to persons or property caused when the manual or the machine are used in viola-
tion of the information contained herein.
The information contained in the manual refers only to the machine mentioned under “Machine Identifi-
cation Data” below. American Augers reserves the right to modify or improve the manual and the machines
without notice.
Manufacturer Identification Data

AMERICAN AUGERS, INC.
135 U.S. Rt. 42, P.O. Box 814
West Salem, Ohio 44287 USA
Tel. 419-869-7107 • Fax 419-869-7425
Web Site: www.americanaugers.com
Machine Identification Data

Type: Directional Drill
Model: DD-1100 RST (with carriage position sensor (optional))
Serial number: Found on identification plate
Year of manufacture: Listed on serial number plate
Location of identification plate: See drawing on page 3.
Scope of Document
This manual covers operation, safety and maintenance of the DD-1100 RST. Planning the bore path,
selecting drilling fluid, operating a drilling fluid recycling system and selecting and operating a guidance sys-
tem are outside the scope of this document. “Horizontal Directional Drilling; Good Practice Guidelines” by the
HDD Consortium1 provides information on these and other topics. Consult equipment suppliers, engineers
and the American Augers factory for additional assistance.
1. Available from the Association of Equipment Manufacturers, 6737 W. Washington Street, Suite 2400, Mil-
waukee, WI 53214-5647, phone: 414-272-0943 or through the association’s website: shop.aem.org.
Overview
Qualification of Personnel
Improper operation can result in serious injury, death and damage to the
equipment. Personnel should read and understand the manual and obtain
appropriate training based on their duties. Owner must ensure that all
personnel receive instructions about safety. Owner must review all warnings
on the machine with all personnel.
• Only skilled and authorized personnel should be permitted to transport, operate

and maintain the machine.
• Training is available by contacting the American Augers factory.
NOTICE: American Augers disclaims any responsibility for damages to persons or property caused by
the operation of the machine by untrained personnel or use of the machine in an unauthorized manner.
Contact American Augers if you have any questions about any aspect of machine operation or safety, if
you need further information or instruction, or if you need additional copies of the manual or replacement
decals (Telephone: 419-869-7107 or 800-324-4930 (USA Toll Free)).
Declaration of Conformity
If required, the Declaration of Conformity is issued at consignment of the machine. A sample document
is reproduced on page 123. The Declaration of Conformity is not required in most countries.
Use of Personal Protective Equipment
If personal protective equipment is not used, serious injury or death of

personnel can occur. The operator and all other personnel on the jobsite
should use proper protective equipment according to their duties.
Legal Disclaimer
the operation of this machine in violation of the instructions contained in this manual.
Purpose of Machine
The machine was designed solely for boring a circular section under the earth ready for positioning pipe
or cable, without the need for backfilling and compacting.
Overview
Ground Leveling and Soil Conditions
The DD-1100 RST can operate on surfaces with a maximum lateral inclination of 3° and a slope in the
running direction up to 5°. The machine is designed to work on solid ground that can support the load without
settling.
Ambient Conditions
Temperature limits: The machine, with factory fill of lubricants, is designed to work in temperatures from
+5°F and +110°F (-15°C and +43°C). For temperatures not included in this range, contact American Augers.
Refer to “Operating in Hot Weather” on page 85 and “Operating in Cold Weather” on page 85 for additional
information.
Relative humidity: 100%
Maximum altitude: 6500 feet (2000 m) above sea level
Atmospheric conditions should allow adequate visibility within the operating area.
The machine should not be operated when lightning is likely.
Transport
The machine should be transported by a truck tractor in accordance with local and national transporta-
tion laws.The wrenches may be removed and shipped separately to reduce transport weight.
Operation
It is recommended only one person operates the controls. Other trained personnel may work near the
DD-1100 RST if they are wearing appropriate personal protective equipment and follow the safety instruc-
tions in this manual. Further, the operator must remain aware of the location of all other personnel while
operating the machine.
Warranty: General Conditions

Warranty is provided with the understanding that all safety warnings and instructions will be reviewed by
all personnel. Warranty is subject to the conditions and limitations specified in the warranty certificate. The
warranty certificate is on page 3. If you have questions about the warranty or any part of the machine opera-
tion, please contact American Augers (Telephone: 419-869-7107 or 800-324-4830 (USA Toll Free)).
NOTICE: Modifications to the equipment made by the customer might reduce warranty coverage. See
“Limited Warranty” on page 3.
Limitations of Warranty
The warranty for all components that are not manufactured by American Augers are subject to the origi-
nal warranties of their manufacturers and not by American Augers.
Request for Service/Support

For service support in or out of the warranty period, contact American Augers. Provide machine model
number, serial number and number of operating hours.
Overview
Warranty and Service for Diesel Engine
The warranty on the engine is valid worldwide and is supplied by the engine dealer in the area where the
machine is sold. Only diesel engine dealers are authorized to perform repairs under warranty, provide ser-
vice and supply spare parts.
Instruction Manuals
Manuals for components not manufactured by American Augers (e.g., the diesel engine) are included as
attachments to this manual. For translations of any of the attachments to this Manual, contact the respective
equipment manufacturers.
DD-1100 RST Operators Manual Safety
Safety Information
Safety
Safety Regulations and Practices
This manual contains important information about the safety practices and safe operation of the
DD-1100 RST. All operators must read and understand the Operation and Safety Instruction Manual before
starting the machine. Careful adherence to the safety and operating instructions in this manual will help
ensure a safe and productive jobsite.
The safety information in this Manual does not replace safety codes, insurance needs, national, provin-
cial, state and local laws. Ensure that your machine has the correct equipment required by the local laws and
regulations. It is the responsibility of each person working with this equipment to learn and follow all applica-
ble local, state, provincial and national safety regulations.
operation in violation of safety advice contained in the manual.
Emergency Procedures
EMERGENCY SHUTDOWN: Push the red Emergency Stop button in one of the following locations:
• on the right control panel on the Driller’s Console
• near the outside hydraulic connections on each Power Supply Unit
• on the Engine Control Panel in the Power Supply Unit
All workers should know the locations of the Emergency Stop buttons before starting the machine on the
jobsite.
Response to Electrical Strike
Your DD-1100 RST is equipped with the ZAPALERT™ alarm system. If the drill makes contact with a
power line and becomes electrically charged, the ZAPALERT alarm system will sound a loud, audible signal.
The alarm will continue until contact with the electrical line is disconnected and the ZAPALERT is reset.
• If you are on the machine, stay on it.

• Remain calm.
• Reverse the direction of drill string advance in an attempt to break contact with the electrical line.
• If you are not on the machine, do not touch any part of the machine as it may be highly charged.
• Notify public safety authorities to secure the area.
• Notify the electric utility company immediately.
• When the proper utility authorities verify that the power has been disconnected and the work area is
safe, you may get off the machine.
Other workers in the immediate area of the machine should not move. The voltage difference between
the equipment and the ground, or between a person’s feet may be sufficient to cause injury or death. Do not
touch the machine, hoses, drill pipe, water system, mud mixing system or anything connected to the drill as
these items may be highly charged.
Safety DD-1100 RST Operators Manual
Safety Information
The ZAPALERT alarm may be activated if you break a communication line. However 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.
Response to a Gas Strike
If a gas line strike occurs, evacuate the area immediately. Shut down all engines. Extinguish all flame
and sparks immediately. Do not attempt to reverse the bore to break contact as further movement may
cause a spark. Contact emergency services and the gas utility company immediately.
Response to a Fiber Optic Strike
If a fiber-optic strike occurs, stop drilling immediately. Do not look into the cut ends of the cable. This can
cause severe eye damage. Notify the utility owner.
Response to a Communications Line Strike
If a communications line strike occurs, stop drilling immediately and notify the utility company.
Response to a Sanitary/Storm Sewer and Water Strike
If a water or sewer line strike occurs, stop drilling immediately. Warn all bystanders that a strike has
occurred and that they should stay away. Obtain medical attention for personnel who have come into contact
with sewage. Notify the utility owner immediately.
Basic Safety Guidelines
Jobsite hazards could result in serious injury or death. All personnel on the
jobsite should use proper protective equipment according to their duties.
1. Before using the DD-1100 RST, all operators should receive thorough training in the use of this equip-
ment. This manual should be used as a training tool.
2. A copy of this manual should remain with the machine and be accessible to all personnel at all times.
3. Personnel on the jobsite should receive training on safety practices, procedures, safety signs and haz-
ards. Operators, support personnel, repair technicians, and visitors should be aware of their responsibil-
ities and any restrictions to their activities.
4. All new or inexperienced employees should receive a complete orientation to the jobsite and thorough
training in their job duties. Never allow inexperienced personnel to operate or work near the machine
unless they are carefully supervised.
5. The meaning of the hazard alert signs on the equipment is explained in the “Safety Alerts” section begin-
ning on page 33.
Safety Information
6. Follow all national, state, provincial and local regulations regarding, but not limited to:
Rig operation Mobile equipment operation

Drilling fluid system operation Confined space entry
Rotating drill pipe Noise
Handling loose drill pipe Hand and power tools
Making/breaking tool joints Traffic control
Pilot bore tracking Communications
Location of utilities and utility clearances Fall protection
Electrical strike protection Security of jobsite and isolation of hazards
Vehicle operation Material handling and manual lifting
Trench shoring and sloping
In the United States, workplace safety is regulated by the Occupational Safety and Health Administration
(OSHA). OSHA regulations are found in the Code of Federal Regulations, Chapter 29. This is known as
29CFR1910. Information can be obtained from your Regional U.S. Department of Labor Office. In other
countries, the operator is responsible for determining which national, provincial, state and local laws govern
operations at the jobsite.
7. Use required or recommended protective equipment which meets applicable standards when operating
this machine:
• Hard hats
• Safety glasses, goggles, or face shields
• Work boots
• Work gloves
• Highly visible reflective clothing
• Hearing protection
• Boots and gloves having electrical insulation
• Any additional safety equipment mandated by other rules or required by the Owner or regulatory
agency
8. If a hazardous situation is suspected, stop work until appropriate corrective action is taken.
9. Use hand signals required for specific jobs. Know who has the responsibility for signaling.
10. Post the location and phone number of the nearest aid station or hospital. Have a fire extinguisher and
complete first aid kit on site. Have at least one of your workers trained in first aid.
Utility Locations
Electric shock and explosion hazard. Have all utility lines marked before you
begin to dig. Notify One Call (by calling 811) as well as utility companies that
do not subscribe to the One Call system.
• The One-Call system (dial 811 (US only) or 1-888-258-0808 (US and Canada
only)) is in place to facilitate identifying appropriate local utility contacts.
• It is the operator's responsibility to follow applicable laws and regulations which
govern locating and avoiding existing utilities.
Safety Information
Before beginning any drilling project, have local utility companies mark the location of utility lines buried
in the area. Design the bore profile to maintain acceptable clearances between underground utilities and
structures and the final reamed hole. Carefully consider possible migration of the backreamer from the pilot
bore toward the utility due to excessive steering or a tight radius when establishing clearances.
The One-Call system (dial 811 (US only) or 1-888-258-0808 (US and Canada only)) is in place to facili-
tate identifying appropriate local utility contacts. Additionally, the Pipeline Association for Public Awareness
website has several references for excavators at http://www.pipelineawareness.org/excavators. Their
“Excavation Safety Guide” describes best practices and contains a guide to state contacts and regulations.
It is the operator's responsibility to follow applicable laws and regulations which govern locating and
avoiding existing utilities.
The location of all identified utilities must be verified using non-destructive methods of excavation. Care-
fully dig a hole by hand and/or automatic vacuum equipment to the utility line to verify its location and depth.
If there is any risk to the utility from the drilling activity, an observation hole must be excavated at or near
the utility to visually monitor the potentially hazardous situation. A vacuum unit is required to remove the drill-
ing fluid during the process, and high pressure drilling fluid hazards must be addressed. If the bore passes
closely by a utility, it may be necessary to continuously monitor the separation after the drill head or reamer
passes the observation hole, as the drill string or product pipe may subsequently contact the utility during the
completion of the installation.
The drill locator and the drill rig operator should walk the planned bore path with the tracking equipment
to evaluate any potential fields of electromagnetic (active) interference and look for signs of reinforced con-
crete or other possible passive interference that may hinder the operation.
During the actual boring process, if abnormal readings are found with the tracking equipment, the con-
tractor should stop, back up, and verify previous readings prior to commencing the bore. This is critical; as
deviation from the planned bore profile could result in an underground utility strike. Care must also be taken
during the pullback to ensure that utilities are not damaged due to the upsizing by the enlarged backreamer
and possible straightening of the bore during backreaming and product installation.
Surface Examination
The job site and the surface along and around the path of the planned bore should be evaluated for indi-
cations of possible underground hazards. Transformer boxes, manholes, outbuildings and sheds, gas grills,
outdoor lighting, ditch line depressions and signs of recent road or utility repairs may indicate the presence of
additional buried utility lines. Confirm the depth of water and gas shutoff valves. Assume all wires attached to
poles are live. Be aware that private utilities and utilities that do not subscribe to the one-call system are not
marked by One-Call operators.
Overhead Hazards
Overhead lines must be avoided. Overhead lines are of particular concern during mobilization/demobili-
zation, loading and unloading heavy equipment and while handling drill pipe. If the voltage is unknown,
always maintain at least 20 feet (6 m) of separation between equipment and power lines. If the voltage is
known, OSHA regulations outline the required minimum separation in the United States. If necessary, place
highly visible markers on either side of the overhead hazard or designate an individual to notify equipment
operators as they approach.
Safety Information
References
Equipment Manufacturers’ Institute, “Directional Drilling Tracking Equipment Safety Manual”, 2000, Safe
Operation of Directional Boring Tracking Equipment Video”, 1999, and “Horizontal Directional Drilling Good
Practices Guidelines - PDF on CD”, 20012.
Exit Pit Construction

Drilling operations may require construction of a pit to receive the cutter or mud motor on the exit side of
the crossing. It is the responsibility of the crew to make a safe pit that is in accordance with the rules set forth
in the (OSHA) Code of Federal Regulations 29 or applicable regulations in other countries.
Before Starting the Machine

• Complete all servicing prescribed in this Operator’s Manual and Attachment A: Diesel Engine Manual.
• Securely connect all fluid lines before starting the machine.
• Check that all hydraulic fittings, bolts and nuts are tight.
• Remove all loose objects stored in or on the machine.
• Remove all objects which do not belong in or on the machine and its equipment.
• Ensure all protective guards, doors, etc. are in place.
• Ensure all safety devices are in place and in working order.
• Know the location of all personnel on the jobsite.
• Make sure the ZAPALERT system has been tested and is properly grounded. Follow procedures in
Attachment 3, “ZAPALERT™ Electric Shock Alarm Instruction Sheet.
Operating Precautions
• Place all machine controls in the neutral or off position before starting the engine.
• Do not start the machine until all personnel are away from rotating or moving parts.
• Check the operation of all machine controls before using the machine.
Operator’s Responsibilities
• It is the responsibility of the operator to read, understand and follow the Operator’s Manual and other
information provided and use the correct operating procedure. Machines should be operated only by
qualified operators and trained helpers.
• Ensure that all underground utilities have been located before the bore is started, and avoid them by
using proper drilling techniques.
• Assess the situation using common sense and the benefit of his/her experience and proceed if and
only if the work can be safely performed.
• Understand and obey all applicable national, provincial, state, and local codes and regulations.
• Point out each of the safety signs on the machine and ensure that the crew understand them.
• Make sure all operating personnel observe and use safe operating practices.
• Visually verify that all personnel and objects are clear of the machine before startup.
2. All are available from the Association of Equipment Manufacturers, 6737 W. Washington Street, Suite 2400,
Milwaukee, WI 53214-5647, phone: 414-272-0943 or through the association’s website: shop.aem.org.
Safety Information
• Make sure all personnel stay in their prescribed areas.
• Ensure that all personnel and objects stay away from rotating or moving parts.
• Walk around the drilling path prior to starting. Check for hazardous areas such as ditches and inclines.
Ensure that traffic and terrain will permit safe operation.
• Never leave the operator’s station while the engine is running.
• Do not operate the machine while under the influence of alcohol or drugs.
• Ensure all safety devices are in place and in working order.
• Turn off the machine at the first sign of malfunction or hazardous condition.
Material Handling Precautions; Crane Safety

• Use appropriate lifting equipment for the size of the load.
• Do not move loads that exceed the crane lift rating.
• Discard and replace damaged or worn lifting equipment (e.g., slings, chains, ropes, etc.)
• Use a tether line to stabilize the load and minimize twisting and turning.
• Stand away from suspended loads. Do not approach the load until it has been lowered to hand-height.
• Use proper hand signals and know who has the responsibility for signaling.
• Do not use to lift or move personnel.
• Make sure equipment is inspected regularly and maintained properly.
Drilling Precautions
• Identify and avoid potential pinch points on the drill rig and support equipment.
• Maintain safe clearances (at least 3 feet (900 mm)) or as specified by regulatory authorities) between
the bore and all utilities. Minimum clearance must take into consideration the final reamed diameter
and the bend radius of the pilot bore.
• Stay away from the rotating drill string at all times.
• Do not operate the drill when personnel are working on or near the drill string.
• Do not operate the drill without positive communication with the drill locator or exit side personnel.
• Use the es!lok® Exit Side Lockout System to prevent inadvertent movement or rotation of the drill pipe
and tooling.
• Operate within the drill pipe manufacturer’s specified maximum torque and thrust/pullback capacity of
the drill pipe.
• Do not use drilling machine torque to make or break tool joints outside the machine’s wrenches.
• Do not breakout tool joints with pipe wrenches.
• Use remote breakout wrenches safely.
Reaming and Installation Precautions

• Maintain two-way radio communication between the entry and exit sides.
• Notify and wait for acknowledgement from all workers before starting to rotate or move the drill pipe.
• When crossing existing underground utilities, expose the utility at the crossing location and monitor it
during crossing. A power line that was safely passed during drilling may be struck on reaming or pull-
back.
• Do not step over rotating drill pipe. Maintain a safe distance when working near rotating drill pipe.
Safety Information
Maintenance Precautions
• Eliminate all power sources (turn off machine and remove key) and relieve system pressures before
doing maintenance.
• Allow the machine to cool before servicing. Hydraulic components, engine, radiator and exhaust sys-
tems can get hot enough to cause serious injury.
• Use proper lock out and tag out procedures when doing maintenance.
• Follow manufacturer’s recommended maintenance procedures.
• Allow only properly trained personnel to perform maintenance activities.
• Do not modify the machine in any way.
• Repair or replace damaged or missing protective guards, doors, etc.
• Replace all missing, illegible, or damaged safety signs. Keep all safety signs clean.
• Use a piece of cardboard or wood to check for pressurized leaks to prevent fluid penetrating the skin.
• Seek medical attention immediately if hydraulic fluid escaping under pressure has penetrated the skin.
Even if the injury seems minor, prompt medical treatment by a physician familiar with this injury is
essential. This is a serious condition which can cause serious injury and possibly death.
Transporting Precautions
• Do not sit or stand on the machine while it is in motion.
• Inspect all tractor trailers being used to transport the machine, including but not limited to checking the
brakes, tires, tire pressure and lights.
• Remove or secure loose items so they cannot fall off during transport.
Welding Safety
Workers can encounter hot surfaces, fire, noxious fumes and other hazards
when welding.
These practices can help increase safety when welding:

• Follow established welding safety practices and regulations.
• Assign another worker to “fire watch”.
• Do not leave a welder alone.
• Wear appropriate protective equipment (face shield, fire resistant clothing, etc.).
• Ensure adequate ventilation.
• Have a first aid kit nearby.
• If welding in a confined space, follow all confined space regulations and proce-
dures.
Safety Information
Noise Level Safety
Exposure to high noise levels may cause hearing loss. Wear appropriate
hearing protection.
The sound pressure measured according to ISO 11202:1993, ISO 3746:1995, IEC 651:1979 and IEC
804:1985 is 102 dB(A).
Ladder Safety
Falls from heights can cause serious injury and death. Use required fall
protection equipment when working at heights above grade.
• When working at heights about 4-6 feet (1.2 to 1.8 m) other precautions may be
necessary.
• Follow established ladder safety practices and regulations.
• Do not use ladders during thunderstorm activity or if conditions are such that light-
ning could occur.
Hazardous Chemicals
Inhalation hazard. Dust from drilling fluid additives such as bentonite may
irritate the respiratory system or lungs. Prolonged exposure may damage the
respiratory system. Use respiratory protection and dust resistant safety
goggles.
Explosion hazard. Flammable solvents could ignite if placed near fire, sparks
or other ignition sources. Keep flammable solvents in closed containers and
away from fire, sparks and ignition sources.
IMPORTANT:
• Do not use containers that can leak.
• Do not drain fluids on the ground or dump them into sewage systems, streams, rivers, lakes or the
sea.
• Always follow laws and regulations for proper disposal of waste materials.
Safety Information
Danger Zones -- Safe Distances
Electrocution Hazard. Personnel are at risk of serious injury or death if an

electric line is struck during drilling. All personnel must wear appropriate
protective equipment (electrical insulating boots and gloves) on the job site.
A danger zone is any zone inside or near the machine where health, safety and security risks exist. All
personnel on the jobsite should be advised of these zones, the hazards they may encounter and the safety
precautions which are required or recommended.
Hazardous Area: All areas from which a person could touch parts of the machine when it is operating or
when maintenance is being performed. Wear appropriate protective equipment.
Electrically Charged Safe Distance: 25 feet (8 m) from the drill hole. Personnel in this zone during drilling
operations are at risk in the event an electric line is struck. On electrical jobsites, wear appropriate protective
equipment (insulated boots and gloves). All other personnel must stay out of this zone during drilling or back-
reaming or any time when an electric line could be struck. You may wish to set up a safety barrier around the
danger zone to prevent anyone who is not wearing appropriate safety gear from entering this zone.
Note that personnel on the exit pit side are also at risk for electric shock during an electric strike. As the
drill pipe approaches the exit pit, it could strike a buried power line. During backreaming, the diameter of the
original pilot hole is increased by the reamer which can contact a power line.
Grounding
Electrocution hazard. Improperly grounded components may become

electrically charged. Serious injury or death could occur. Bond all fixtures
together and ground to a single stake before starting the engine.
• . Follow all local codes and regulations with regard to bonding and grounding.
Metal components on a drill rig site can become electrically charged for a number of reasons: faulty or
damaged wiring, inductive capacitance from generators, motors, motor drives, transformers, contact with
local distribution wiring or underground cables etc. Care should be taken to avoid electrocution.
All metal components on a drill rig site should be bonded together as shown in the drawing below. Bond-
ing will reduce the electric potential difference between components with respect to any other components
on the site. Current will not flow between two sections that are at the same electric potential. All remote
equipment that is in close proximity to the drill rig must also be electrically bonded to the drill rig, i.e. pipe
racks, mud pumps etc. This will reduce the risk of shock to any personnel who might contact both the drill rig
and the remote equipment.
Safety Information
IMPORTANT: For additional information on electrical hazards, bonding and grounding, you may wish to
consult publications from the U.S. Occupational Safety and Health Administration.a b
a. Controlling Electrical Hazards, U.S. Department of Labor, OSHA 3075.
b. Protection from Step and Touch Potentials, 29CFR1910.269 Appendix C.
Bonding Cable
Dumpster
Crane
Mud System
Drill Pipe
Drill Rig
Pit
Bore Path
Power Supply Unit Cabin
Bonding Cable Bonding Cable
Ground Stake
Typical Bonding Scheme
Safety Features - ZAPALERT™

ZAPALERT™ is an electric sensing device used on equipment which has a high likelihood of striking an
underground energized power line. Refer to “ZAPALERT™ Electric Shock Alarm” on page 61 and Attach-
ment 3, “ZAPALERT™ Electric Shock Alarm Instruction Sheet” for complete information.
Safety Features - es!lok® Exit Side Lockout System

The es!lok® Exit Side Lockout system provides a way to disable thrust and rotation from a remote loca-
tion, such as the exit side of a directional bore. Refer to “es!lok® Exit Side Lockout System” on page 62 and
Attachment 2, “es!lok® Exit Side Lockout System Operation & Safety Instruction Manual” for complete infor-
mation.
Safety Features - Fire Extinguisher

A dry chemical fire extinguisher approved for Class B & C type fires should be either on your machine or
in the Driller’s Cabin.
Safety Alerts
Whole body entanglement in Electrocution hazard. If beacon is

machinery. Stay safe distance from hazard. flashing, stand back 8 meters (25 feet).
In case of an electric strike, do Keep hand and feet at a safe dis-

not move. Pull drill pipe away from power line. tance.
Diesel engine exhaust warning Read manual before lifting.
Safety Alerts
High Pressure Fluid. Read oper- Crushing of feet. Keep feet safe
ator’s manual for proper service procedures. distance from hazard.
Explosion hazard. Call 811 Electrocution/explosion hazard.

before you dig. Keep safe distance.
Read operator’s manual. Use proper lockout and tagout

procedures when performing maintenance work.
Safety Alerts
Stay safe distance from Body crush hazard. Stay safe dis-
machine. tance from machine.
Hot surface. Do not touch. Body crush hazard from side.

Stay safe distance from machine.
Notes
NOTES:
DD-1100 RST Operators Manual Controls
Machine Controls
Controls
Safety Switches
There are four push buttons which stop the diesel engines on the DD-1100 RST. These push buttons
stop the flow of fuel to the engine and shut down the power in a normal manner. Some movement or rotation
may occur due to residual hydraulic pressure or stored energy.
DD1M9716 EnginePanel
Diesel Engine Stop Push Buttons (2) on Driller’s Console

50dd1430C-hose connections
To turn off both diesel engines:
Push emergency stop button located

near the hose connections
Diesel Engine Stop Push Button near the outside hydraulic connections on each Power Supply Unit
Controls DD-1100 RST Operators Manual
Machine Controls
Diesel Engine Stop Push Buttons on Typical Engine Control Panels
Safety Switches - Auxiliary Power Unit
There are two push buttons which stop the auxiliary power unit engine.
SETUP
STOP STOP
n/min
50DD9790-Setup Box.tif
Auxiliary Engine Stop Push Button on the Setup Box
Machine Controls
8EE11201_2010May10-p8cervis-bwFACE.tif
MACHINE STOP
ASSOC
STORE
BOTH CYL UP
UP UP
TROLLEY RIGHT
TROLLEY LEFT
DOWN DOWN
LEFT CYL RIGHT CYL
BOTH CYL DOWN
Auxiliary Engine Stop Push Button on Remote Transmitter
Machine Controls
Disable Switches
DD1100 008-RotCarDisable-edited
Typical Location of Rotary/Carriage Disable

DD1M9736 DisableButton-a
ROTARY
CARRIAGE
DISABLE
The Rotary/Carriage Disable is a large, red push button located on the carriage. Push this button to:
• Lock the carriage brake

• Lock the rotary brake
• Disable makeup and breakout
• Disable wrench travel and wrench separate
• Disable the carriage and rotary joysticks
Machine Controls
Battery Switch and Light Switch
IMPORTANT:
• DO NOT disconnect the batteries while the engine is running.
• DO NOT try to stop the engine with this switch. You can damage the electrical system.
• During maintenance, turn the switch OFF and use proper lockout and tagout procedures.
The battery switches are located on the Power Supply Unit as shown in the drawing below. The switch
connects and disconnects the batteries from the electrical system. Rotate to the right to connect. Rotate left
to disconnect. The battery switch must be in the ON position before starting the engine. Turn the battery
switch OFF after you stop the engine and remove the key.
Typical Location of Battery Switch
Battery Box
bttery_box_line [Converted]
Light Switch
Machine Controls
Setup Box
50DD9790-Setup Box.tif
SETUP
3 n/min
STOP STOP 2
6 4
7
10 REMOTE
PENDANT 8
9 5
1. Hydraulic Oil Level Indicator 6. Engine Running Light

2. Carriage Position Indicator 7. Battery Charging Light
3. Throttle 8. Oil Pressure Warning Light
4. Emergency Stop Button 9. Preheat Light
5. Key Ignition Switch 10. Remote Pendant Plug
Machine Controls
Control Function
1. Hydraulic Oil Level Indicator Light on: Hydraulic oil level on the Auxiliary Power Unit is low
2. Carriage Position Indicator Light on: Carriage is not in proper position for thrust frame setup,
take down and rig transport
3. Throttle • Increase engine speed: turn control to the right

• Decrease engine speed: turn control to the left
4. Emergency Stop Button • Stop the Auxiliary Power Unit engine: push button
• Enable engine start: button must be pulled out
5. Key Ignition Switch • Stop: Turn the key straight up

• Run: Rotate key 45° to the right
• Start: Rotate key 90° to the right
6. Engine Running Light Light on: Auxiliary Power Unit engine is on
7. Battery Charging Light Light on: Battery not charging
8. Oil Pressure Warning Light Light on: Low engine oil pressure
9. Preheat Light Light on: Auxiliary Power Unit engine is preheating
10. Remote Pendant Plug Plug umbilical cord for radio remote transmitter in this plug to
operate the unit in the event radio communication is not function-
ing
Machine Controls
Radio Remote Transmitter
8EE11201_2010May10-p8cervis-bwFACE.tif
1
5
MACHINE STOP
ASSOC
6
STORE
BOTH CYL UP
UP UP
TROLLEY RIGHT
TROLLEY LEFT
DOWN DOWN
LEFT CYL
BOTH CYL DOWN
RIGHT CYL
7
4
2 3
1. Emergency Stop Button 5. Controller Setup Toggle Switch

2. Cylinder/Trolleya Joystick 6. Trigger
3. Right Cylinder Control 7. Umbilical Cord Connection (Optional)
4. Left Cylinder Control
a. The “trolley” on the DD-1100 RST is called a “dolly”.
Machine Controls
Refer to Attachment 5, “Cervis - Wireless SmaRT™ Engineered System Manual” for complete
instructions on replacing batteries and using the transmitter.
Control Function
1. Emergency Stop Button Stop the Auxiliary Power Supply engine

• Stop the engine: push button
2. Cylinder/Trolleya Joystick • Move dolly left (away from the drill hole): push joystick to the left
• Move dolly right (downhole): push joystick to the right
• Lift thrust frame with both cylinders: push the joystick away from
you
• Lower thrust frame with both cylinders: pull the joystick toward
you
3. Rightb Cylinder Control Use for making small adjustments in thrust frame position
• Move thrust frame up: push toggle away from you
• Move thrust frame down: pull toggle toward you
4. Left Cylinder Control Use for making small adjustments in thrust frame position
• Move thrust frame up: push toggle away from you
• Move thrust frame down: pull toggle toward you
5. Controller Setup Toggle Switch Refer to Attachment 5, “Cervis - Wireless SmaRT™ Engineered
System Manual” for instructions when it is necessary to re-associ-
ate the transmitter and receiver.
6. Trigger Squeeze the trigger for the cylinder control joystick to work.
7. Umbilical Cord Connection The umbilical cord can be used if the radio communication
between transmitter and receiver is not functioning.
a. The “trolley” on the DD-1100 RST is called a “dolly”.

b. Right and Left when looking downhole.
Machine Controls
Typical Engine Control Panel
5
4
5 6 3 2
2
3
1. Emergency Stop 5. Throttle

2. Key Ignition Switch 6. Engine Hours Meter
3. Yellow Diagnostic Warning Light 7. Display Screen
4. Red Diagnostic Warning Light
Machine Controls
Controls, gauges and displays on an engine panel vary depending on the manufacturer and model of
engine on your machine. Two different, typical control panels are pictured. Consult the Diesel Engine Manual
for your equipment.
Control Function
1. Emergency Stop Stop the engine of the corresponding Power Supply Unit
• Stop the drill and the engine: push button
2. Key Ignition Switch • Stop: Turn the key straight up

• Run: Rotate key 45° to the right
• Start: Rotate key 90° to the right
3. Yellow Diagnostic Warning Light If this light turns on, follow instructions in the Diesel Engine man-
ual or contact the engine manufacturer.
4. Red Diagnostic Warning Light If this light turns on, follow instructions in the Diesel Engine man-
ual or contact the engine manufacturer.
5. Throttle • Increase engine speed: push control up

• Decrease engine speed: pull control down
6. Engine Hours Meter Displays the number of accumulated hours on the engine.
7. Display Screen Displays engine information and diagnostic codes.
Machine Controls
Driller’s Console Map
Various Functions Pressure Gauges Engine & Wiggle Steer
DD1M9716-Control Panel
Operations
For a larger drawing, see “Driller’s Console” on page 57.
Machine Controls
Pressure Gauges
1 2 3 4 5
6 7 8 9 10 11 12 13
1. Top Clamp Pressure Gauge 4. Wrench Makeup Pressure Gauge

2. Carriage Pressure Gauge 5. Rotary Pressure Gauge
3. Wrench Clamps Pressure Gauge
Control Function
6. Top Clamp Pressure • Increase pressure: rotate control right

• Decrease pressure: rotate control left
7. Carriage Pressure - Thrust • Increase pressure: rotate control right

8. Carriage Pressure - Pullback • Increase pressure: rotate control right

9. Wrench Clamps Pressure - • Increase pressure: rotate control right

Wrench • Decrease pressure: rotate control left
10. Wrench Camps Pressure - • Increase pressure: rotate control right

Fixed • Decrease pressure: rotate control left
11. Makeup Pressure • Increase pressure: rotate control right

12. Rotary Pressure - Makeup • Increase pressure: rotate control right

13. Rotary Pressure - Breakout • Increase pressure: rotate control right

Machine Controls
Carriage/Rotary/Wrench Operations Panel
14 16 19 20 26 28
17 21 22 27
29
15
23 24 25
18
DD1M9716 OperationsPanel
14. Carriage Speed Select 22. Lower Pipe Support

15. Carriage Joystick 23. Wrench Clamp
16. Carriage Brake 24. Fixed Clamp
17. Wrench Speed 25. Wrench
18. Wrench Joystick 26. Rotary Brake
19. Power Unit Select 27. Rotary Speed
20. Signal Alarm 28. Rotary Speed Select
21. Upper Pipe Support 29. Rotary Joystick
Machine Controls
Control Function
14. Carriage Speed Select • Need maximum pullback force: set control to 1
• Need low pullback force: set control to 4
15. Carriage Joystick • Move drill string down (thrust): push joystick away from you
• Move drill string up (pullback): pull joystick toward you
16. Carriage Brake Hold the carriage in position during gear changes or transport
• Lock brake: rotate control to the right
• Unlock brake: rotate control to the left
17. Wrench Speed • Increase speed: rotate control to the right

• Decrease speed: rotate control to the left
18. Wrench Joystick • Move wrench down rack: push the joystick away from you
• Move wrench up rack: pull the joystick toward you
• Move the fixed clamp and the wrench clamp closer together:
move the joystick to the left
• Move the fixed clamp and the wrench clamp apart (a maximum
of 12 inches (305mm)): move the joystick to the right
19. Power Unit Select Select which Power Supply Unit controls pressure:
• Power Supply Unit A: rotate switch to the left
• Power Supply Unit B: rotate switch to the right
Remove key and store in a safe location. See “Appendix C: Dual
Power Units and ROOTS” section beginning on page 115.
20. Signal Alarm • Sound an audible alarm to alert workers that the engines are
about to be started or drilling is about to commence. Be sure all
workers on the job site are aware of the audible alarm and the
meaning of the signal.
21. Upper Pipe Support • Raise the pipe support: move the joystick to the left
• Lower the pipe support: move the joystick to the right
22. Lower Pipe Support • Raise the pipe support: move the joystick to the left
• Lower the pipe support: move the joystick to the right
23. Wrench Clamp Grip/Ungrip • Wrench clamp grip: rotate control to the right
• Wrench clamp ungrip: rotate and hold control to the left
• Wrench clamp off: move control to center
24. Fixed Clamp Grip/Ungrip • Fixed clamp grip: rotate control to the right
• Fixed clamp ungrip: rotate and hold control to the left
• Fixed clamp off: move control to center
Machine Controls
25. Wrench Make/Break • Wrench breakout: rotate and hold control to the right to break
the pipe joint
• Wrench makeup: rotate and hold control to the left to make the
pipe joint
• Wrench off: move control to center
26. Rotary Brake Prevent the rotary spindle from turning backwards
• Lock brake: Rotate control to the right
• Unlock brake: Rotate control to the left
27. Rotary Speed • Select a custom value; Rotary Speed Select control must be set
to “vari” for this control to work.
28. Rotary Speed Select • Maximum motor displacement, maximum torque and speed:
select “low” (immediately sets value to zero)
• Select a custom value: select “vari”
• Maximum speed, minimum motor displacement, least amount
of torque: select “high” (immediately sets value to 10)
29. Rotary Joystick • Rotate pipe in makeup (clockwise) direction: push joystick away
from you
• Rotate pipe in breakout (counterclockwise) direction: pull the
joystick toward you
Machine Controls
Engine/Wiggle Steer® Panel
30
31
Power Unit B Power Unit A

Power Unit B
Power Unit A
32
33
34
DD1M9716 EnginePanel
35
37
36
30. Wiggle Steer® Control 34. Engine Stop

31. Rotary RPM Meter 35. Drill Controls - Stop
32. Throttle 36. Drill Controls - Start
33. Engine Start 37. Status Light Panel
Machine Controls
Control Function
30. Wiggle Steer® Control • Use Wiggle Steer in Auto mode: Rotate control right
• Use Wiggle Steer in Manual mode: Rotate control left
• Turn off Wiggle Steer: Rotate control to center
31. Rotary RPM Meter To use the meter to set up Wiggle Steer, see “Appendix B: Wiggle
Steer and Wiggle Steer Codes” section beginning on page 113.
32. Throttle • Increase engine speed: push control away from you
• Decrease engine speed: pull control toward you
33. Engine Start Start the engine of the corresponding Power Supply Unit
• Remotely start the engine: push button
34. Engine Stop Stop the engine of the corresponding Power Supply Unit
• Stop the drill and the engine: push button
35. Drill Controls - Stop • Stop electrical power to the Driller’s Console: push button
• Enable drilling: button must be pulled out
36. Drill Controls - Start • Bring power to the control panel and the drill rig: push button
37. Status Light Panel Status of the item in the corresponding Power Supply Unit
• Filter light on: flow through filter reduced; filter may be clogged
• Hydraulic oil light on: oil level low; check and fill
• Fuel light on: fuel level low; check and fill
• Verify all lights are working: toggle switch to test
Lights are:
• Rotary Filter 1
• Rotary Filter 2
• Carriage Filter 1
• Carriage Filter 2
• Charge Filter
• Return Filter
• Hydraulic Oil Level
• Fuel Level
• Spare (unused light)
Machine Controls
Various Functions Panel
38
39 40
DD1M9716 Various
42
43
41
44
45
38. Drilling Mud Pressure Gauge 43. Auxiliary/Trash Pump - Control

39. Guide Bushing 44. Drilling Mud - Blowdown Signal Lights
40. Top Clamp 45. Drilling Mud Blowdown
41. Caterpillar Messenger for Engine A and B
(if so equipped)
42. Auxiliary/Trash Pump - Speed
Machine Controls
Control Function
38. Drilling Mud Pressure Gauge • Displays mud pressure
39. Guide Bushing • Lower the bushing: move the joystick to the left
• Raise the bushing: move the joystick to the right
40. Top Clamp • Move the top clamp down the thrust frame: push the joystick
away from you
• Move the top clamp up the thrust frame: pull the joystick toward
you
• Ungrip the top clamp: move the joystick to the left
• Grip the top clamp: move the joystick to the right
41. Caterpillar Messenger for Allow the operator to monitor engine information while the engine
Engine A and B is operating (if so equipped)
42. Auxiliary/Trash Pump Speed Set the limit of the maximum current sent to the auxiliary device.
For example, when the value is 30%, the auxiliary device will
receive 30% of the maximum current possible.
43. Auxiliary/Trash Pump Control • Turn Auxiliary Connections On: turn control to ON position
• Turn Auxiliary Connections Off: turn control to OFF position
44. Drilling Mud - Blowdown Signal Mud supply is divided into two hoses for maximum capacity and
Lights flexibility. When light is lit, it confirms that blowdown in both hoses
is closed or open.
45. Drilling Mud - Blowdown • Relieve mud pressure in the drill string: turn and hold control to
Open
• Stop mud pressure relief: turn and hold control to Close
Carriage Position Meter (Optional)

On machines equipped with this option, transducers are installed at various points along the carriage.
The position (in feet) of the carriage is reported on a digital readout located on top of the Driller’s Console.
Driller’s Console
Notes
NOTES:
DD-1100 RST Operators Manual Operations
Preparation
Operations
Site Preparation
Drilling operations may require an exit-side pit. Unsafe pits may collapse
resulting in serious injury or death. Follow national and local laws which
apply to constructing an exit-side pit.
The DD-1100 RST can operate on surfaces with a maximum lateral slope of 3° and a slope in the run-
ning direction up to 5°.
Dig an exit pit if required by the conditions at the site. For more information, see “Exit Pit Construction”
on page 27. Dig the mud return pit where the drill will enter the ground.
Measure and clearly mark the Electrically Charged Safe distance. See “Danger Zones -- Safe Distances”
on page 31. Erect a safety barrier around the dangerous zone to prevent bystanders from approaching the
machine. Prevent anyone who is not wearing proper protective equipment from entering this zone.
Clear all vegetation from the area around the operator’s station when working on electrical jobsites. In
the event of an electrical strike, contact with trees, bushes and weeds could result in electrocution.
Site Layout
Dumpster
Crane
Mud System
Drill Pipe
Drill Rig
Pit
Bore Path
Power Supply Unit
Cabin or Console
Typical Site Layout
Operations DD-1100 RST Operators Manual
Preparation
Cranes
Congested job sites may require the use of a large crane for final placement of the drill and Power Sup-
ply Unit. A crane or excavator may be used to handle drill pipe and downhole tooling.
Mats and Cribbing

When drilling on soft soil, during a long term setup or during periods of freezing and thawing, it may be
necessary to set the drill on mats or cribbing to prevent the machine from settling into the ground. Suitable
mats may be available for rent or lease. Consult a civil engineer for guidance. The weight of the
DD-1100 RST is provided in the “Specifications” section beginning on page 107.
Protection of Wires, Cables and Hoses

The controls are connected to the directional drill by hoses and cables. It is important that these be pro-
tected from damage. Route electrical cables and hydraulic hoses overhead to prevent a tripping hazard to
the crew. Keep cables and hoses out of puddles and away from dripping water. Avoid sharp edges and
places where cables and hoses could be damaged.
Support electrical cables so the weight of the cable does not pull on the connector. This could cause
damage and could result in a loose connection. Disconnect electrical cables by pulling the connector, not the
cable.
Making Power Connections
IMPORTANT:
• Using hydraulic hoses and electrical cables longer than 100 feet (30.5 meters) might result in control
issues.
• Turn off all power to the system when making hydraulic and electrical connections.
• When connecting screw together couplings, the ball valve must be open. Ball valves in the wrong posi-
tion can cause extreme damage to the Power Supply Units.
• If it is necessary to disconnect the wrench, unplug the wrench umbilical (electrical) cable at the cabin.
When connecting hydraulic hoses and electrical cables, follow these best practices:
• Remove protective caps
• Ensure that couplings are clean and free of debris.
• See “Cleaning Hydraulic Connections” on page 90 and “Cleaning Electrical Connections” on page 90
for information on proper cleaning techniques.
Crew
Operation of this machine requires at least two people: the machine operator (or driller) and the drill
tracking equipment operator (or drill locator). The driller operates the DD-1100 RST from the Driller’s Con-
sole which may be located inside a Driller’s Cabin. The drill locator uses the electronic drill tracking system to
mark the location of the drill head along the bore path.
Additional personnel include a crane operator, pipe handlers, steering specialist, excavator operator,
mud plant operator and general labor. Exit side personnel might include a certified welder, pipe handlers and
a crane operator.
Preparation
The Bore Path
Numerous factors must be considered when planning the bore path: machine location, entry angle, bend
limits of the drill pipe, bend and tension limits of the pullback material, pipe length and location of under-
ground utilities. Planning the bore path is outside the scope of this manual. Consult a knowledgeable engi-
neer for assistance. Ensure that the bore path and the location of all utilities are clearly marked on the jobsite
before beginning operations. When drilling, avoid extreme steering corrections. Drill the first and second drill
pipe straight. Consult drill pipe manufacturers for recommended bend radius.
Guidance System
Guidance systems are electronic devices that enable the bore to be directionally steered on a planned
curved path. The guidance devices are installed in the down hole tooling string. They provide drill head loca-
tion information that the operator uses to steer and make directional changes in the bore.
There are 3 types of guidance systems. Wireless walkover, wire line, and wire line magnetic. The wire
line magnetic type is most commonly used for longer deeper bores because they are more capable and
more accurate than the other types.
The guidance system is not provided as standard equipment with the directional drill. The manufacturer
of the guidance system will provide technical instructions on the operation and maintenance of the guidance
system.
Before beginning the bore, ensure that the guidance system has fresh batteries and has been tested and
properly calibrated. Check the location of the drill head frequently to ensure that the bore remains on course.
Take care not to exceed the bend radius of the pipe as this will cause damage or breakage.
Mud Recycling System

Drilling operations might require fluid quantities of 300 to 500 gallons/minute (1135 to1892 liters/minute).
A recycling system enables the driller to reclaim most of the drilling fluid for re-use and minimize the amount
of fresh water required for mixing. The recycling system removes solids from the drilling fluid and usually
includes a high pressure pump (mud pump) to send the fluid through the drill pipe into the bore. The contrac-
tor must provide a trash pump to pump spent drilling fluid from the returns pit to the mud recycling system.
Consult a drilling fluid supplier for assistance in selecting the drilling fluid, preparing an appropriate mix-
ture and establishing the correct mud pump flow rate for drilling and backreaming. Read the mud system
manual or consult the equipment dealer for instructions on operating the mud system and recycling/replen-
ishing the drilling fluid.
ZAPALERT™ Electric Shock Alarm
Electrocution hazard. Machine may become electrically charged if drill string

contacts a power line. Serious injury or death could occur. All crew members
should know the ZAPALERT audible and visible alarm signals and the proper
procedures to follow if the drill becomes electrically charged.
• Do not operate the machine until ZAPALERT testing is complete and all issues
have been satisfactorily resolved.
• The ZAPALERT ground stake must be installed for the unit to work properly,
Preparation
The DD-1100 RST is equipped with the ZAPALERT detection device. ZAPALERT is an electric sensing
device used on equipment which has a high likelihood of striking an underground energized power line.
When drill pipe comes in direct contact with a power line, it becomes charged to the same voltage as the
power line. An audible and visual alarm is triggered. Crew members should follow procedures described in
“Response to Electrical Strike” on page 23when the an alarm is given.
When utility authorities have verified that the drill and associated equipment are no longer energized,
retest the ZAPALERT system and set it up properly before resuming drilling operations.
Read and understand the “ZAPALERT Electric Shock Alarm Instruction Sheet” in Attachment 3 before
using the system. Test the system before beginning the drilling project. After a successful test, install the
ZAPALERT system ground stake into the ground.
es!lok® Exit Side Lockout System
Entanglement hazard. Unexpected movement or rotation of the drill string can

cause death or serious injury. Use the es!lok system to disable the drill while
changing tooling.
• Do not attempt to bypass the es!lok system. Operation of the drill with the es!lok
disabled can result in injury and death.
• Before starting es!lok Exit Side Lockout, be sure you have fully charged batteries
in the devices. If the machine has been in storage, reconnect the es!lok battery
charger to either a 12 volt DC or 24 volt DC supply. Recharge the es!lok batteries
until they are fully charged.
The es!lok Exit Side Lockout system provides a way to disable thrust and rotation from a remote loca-
tion, such as the exit side of a directional bore. Workers in the exit pit can lockout the drill and work directly
on the pipe string or exit side tooling. The es!lok system consists of a receiver which is mounted on the
DD-1100 RST and a transmitter that is carried by a person who must work on or near the drill string.
The exposed person can push the “Lock Drill” button before working on or near the drill rod or tooling.
This sends a signal to the receiver and prevents rotation and thrust. When the designated person and all oth-
ers are clear of potential danger, they push the “Unlock Drill” button. This signals the drill operator to “Reset”
the system and restore thrust and rotation functions.
es!lok Exit Side Lockout System is not intended as a substitute for safety procedures or a replacement
for clear communication between the exit side crew and the machine operator. It is not intended as an emer-
gency shutdown device.
Complete information on setup, testing and operation of the es!lok Exit Side Lockout System is provided
in Attachment 2. Read and understand these instructions before using.
Set Up
Set Up the Machine
Lowering the front foot and rear foot creates a danger of crushing. Keep all
personnel a safe distance away when the machine is being stabilized.
Raising and lowering the drill frame creates a danger of crushing. Keep all
personnel a safe distance away when raising or lowering the drill frame.
• Secure the machine after raising with support struts and locking devices before
operating or performing maintenance tasks.
Pinch point. Moving parts. Keep body and clothing away.
1. Position the front foot and rear foot directly in-line with the planned bore at the proper setback location.
Follow the site plan (see drawing below, not to scale) for the proper spacing between the front and rear
foot. The lifting legs travel on the rear foot plate as the thrust frame is raised. The plate must be posi-
tioned so the lifting legs remain on the plate at all times.
Center Line of Dolly Axle

Center Line of Planned Bore
14.5 feet (4.42 m)
10 feet (3.05 m)
Rear Foot
7 ft (2.1 m)
Front Foot
38.5 ft (11.73 m)
12 ft 4 inches (3.76 m)
5 ft 3.5 inches (1.61 m)
2. Attach the cables provided between the front and rear foot.
3. Back the rig over the rear foot to the front foot. Keep the rig aligned with the planned bore.
4. The center-line of the axle closest to the front foot is exactly 7 feet (2.1m) away from the foot. This will
help guide the thrust frame into the front foot.
Set Up
Lift Cylinder 50dd2100D-setupview
Auxiliary Power Unit

Cross Bracing
Dolly
Dolly Landing Gear

Support Strut
Lifting Legs Dolly Anchor Pin
Front Foot
50dd10002-dxf-RIG
Rear Foot
Cable
Setup Box
5. Disconnect the plug and remove the tail light

bumper.
6. Remove the radio remote transmitter from the
storage box.
7. Start the auxiliary power unit using the Key Igni-
tion Switch on the Setup Box.
8. Remove the lifting leg pins on both sides of the
trailer.
9. Using the radio remote transmitter, lower the lifting
legs onto the rear foot.
Lifting Leg Pin DSCF6553-liftinglegpin
Set Up
10. Remove the anchor pins from the dolly on both

sides of the trailer (see drawing).
11. Set the tractor brakes.
12. Check the Carriage Position Indicator light on the
Setup Box. The light should not be lit. This indi-
cates that the carriage is in position and ready for
setup. (If the light is lit, the carriage is not in posi-
tion to begin the setup process. Do not continue
setting up the machine until you move the carriage
to the proper position and the light goes out.)
13. Slowly move the dolly to the setup position using
the joystick on the Radio Remote Receiver. Keep
Anchor Pins
hoses and cables clear of the moving dolly.
50dd10001-dollyposn1
14. Install the anchor pins to secure the dolly in the

setup position (see drawing showing pin location 50dd10001-dollyposn2
on underside of rig trailer).
15. Lower the dolly landing gear.
16. Dump the air in the dolly air bags.
17. Disconnect the tractor and pull away.
Anchor Pins
18. Lower the walkways.

19. Install the handrails. Secure them to the walk-
ways.
Set Up
20. Raise the rig using the joystick on the radio remote
transmitter.
21. Make small adjustments using the right and left
cylinder controls to guide the thrust frame into the
cradle on the front foot.
22. Swing the securing arms over the tube.
23. Install the pins and secure with clips.
24. Raise the rig to the desired angle for drilling. Maxi-
mum drilling angle is 18°.
25. Pin the struts.

26. Relieve the pressure in the lifting leg cylinders
transferring the weight to the struts.
27. Secure the rig to the rear foot with cross bracing.
28. Remove the hoses from their transport position on top of the thrust frame.
Set Up
29. Unfasten the wrench hose carrier from the car-

riage. Photo on the right shows the hose carrier
fastened to the carriage in transport position.
30. Carefully uncoil the hose carrier. Lay it flat,

extending off the end of the rig past the guide
bushing.
31. Using appropriate lifting equipment, lift the wrench

and lower it into position on the thrust frame.
Set Up
32. When the wrench is in position on the thrust

frame, lower the hook pads.
33. Insert the pins to secure the hookpads.
hose carrier
hookpads
attachment point
34. “Roll” end of the hose carrier back and attach it to

the wrench.
35. Make the hydraulic and electrical connections
from the hose carrier to the fittings on the wrench.
36. Attach the guide bushing if it was removed for
transport.
Photo on right shows the hose carrier in operating

position. Hook pads have been folded down and
secured with pins. Guide bushing is in place.
37. Move the power units and driller’s cabin into position.
38. Position the mud system and connect it to the rig.
39. Connect the two mud hoses between the rear swivel and the carriage mud supply lines.
40. Lower the hose support on the power unit facing the rig (see drawing below).
50dd1430C-hose connections
Hose Connections
Hose Support
Set Up
41. Connect the cables and hydraulic lines to the power units, thrust frame and cabin. Refer to “Protection of
Wires, Cables and Hoses” on page 60 and “Making Power Connections” on page 60.
42. Disconnect the case drain line on the drill rig from the expansion tank and connect it to the power supply
unit.
43. Set the hydraulic valves in the correct position for the power configuration you plan to use (See “Appen-
dix C: Dual Power Units and ROOTS” section beginning on page 115)
44. Connect all components on the drill site with a bonding cable and install a ground stake.
45. Test the ZAPALERT system (Refer to Attachment 3, “ZAPALERT™ Electric Shock Alarm Instruction
Sheet” for complete information).
46. After completing a successful test, install the ZAPALERT ground stake.
47. Verify that all protective guards are in place.
48. Check all fluid levels and replenish if necessary.
49. Perform a final walk-around. Inspect all connections.
50. Start the power units (See “Starting the DD-1100 RST” on page 72).
51. Check the function of all controls.
52. Check all emergency stop and disable buttons.
53. Cycle all equipment several times.
Anchor the Machine

Depending on the soil conditions at the site, one or more of the following anchoring systems should be
used to stabilize the drill so it does not move as it thrusts pipe into the soil or pulls on a backreamer or the
product.
Sheet Piling and Steel Beam
To anchor the machine for thrusting operations, excavate a trench in front of the machine and bury a
steel I-beam. Connect chains from the I-beam to the front foot. Sheet piling may be driven against the back
side of the I-beam to improve anchoring in soft conditions.
During pullback, sheet piling may be driven into the ground and in contact with the front edge of the front
foot as shown in the drawing below.
50dd2100D-setupview-piling
Chain or Cable
Entry Pit
Sheet Piling
Steel I-Beam
Set Up
Concrete Anchor
Create a pit which can be filled with concrete. Place beams or fasteners into the wet concrete and attach
the front foot of the drill using fasteners or welding (see drawing below).
50dd2100D-setupview-concrete
Tie Down Stakes
Drive tie down stakes through the square holes in the front foot and into the soil with the bucket of a
backhoe or excavator.
50dd2100D-setupview-stakes
Set Up
Excavate the Entry Pit and Returns Pit
The directional drill should be securely anchored before excavating the entry and returns pits. The entry
pit is where the drill pipe of the directional drill enters the ground. It is also where the drilling fluid returns from
downhole.
Connect the two pits with a shallow channel as shown in the drawing below. Fluids returning from the
bore enter the smaller pit and overflow into the larger pit. Many of the solids settle to the bottom of the larger
pit and do not have to be handled by the fluid recycling equipment.
The contractor provided trash pump is installed in the larger pit. Suspend the trash pump so that soil
from the pit floor does not enter the recycling system.
Entry Pit Returns Pit
Directional Drill
Pipe and Bit
Trash Pump
Starting the DD-1100 RST

Signal lights and operator displays warn of potential operating problems. If

ignored, damage to the machine could result. In case of unusual noise,
abnormal pressure values, or if signal lights appear, stop the engine
immediately and carry out necessary repairs.
Do not use starting fluid (ether). Immediate engine damage and personal
injury may result.
A manufacturer's manual for the diesel engine is supplied with the DD-1100 RST. The following instruc-
tions cover general engine starting procedures. Consult the manufacturer’s manual for detailed starting and
stopping procedures, engine maintenance and repair instructions.
1. If you have not already done so, test the ZAPALERT system and verify that the ground stake is installed
properly (refer to Attachment 3: ZAPALERT™ Electric Shock Alarm Instruction Sheet).
2. Unplug the block heater, if connected.
3. Disconnect all battery chargers.
4. Pull OUT the emergency stop buttons on the Driller’s Console and in the Power Supply Units. The
engine will not start if any emergency stop button is pushed in.
5. Check the engine oil level, hydraulic fluid level and the diesel fuel level. DO NOT let the diesel engine
fuel tank run dry. If the tank is dry, bleed the fuel system. Refer to Attachment 1: “Diesel Engine Manual”
for instructions.
6. Switch all controls OFF or put them in neutral.
7. Turn the Battery switch to the ON position.
8. Insert the key in the Engine Control Panel.
9. Turn the key and hold it in the START position for about 5 seconds while the warning alarm sounds. This
alerts everyone on the jobsite that the engine is going to start. when the delay period times out, the alarm
will stop and the engine will start.
• You must hold the key in the start position for the full delay period each time you attempt to start the
engine. If you release the key before the end of the delay period, the engine will not start.
10. Alternatively, you may start the engine from the Driller’s Console.
• On the engine panel, turn the ignition key (2) to the right to enable start.
• At the Driller’s Console, push the Engine Start button on the Engine console.

Let the engine run for at least 10 minutes so it is thoroughly warm before operating the machine. Use the
hydraulic tank heater to ensure that the oil is at least 70°F (21°C) before operating the controls. Only a small
fraction of the rotary and carriage circuits circulates through the hydraulic tank. The oil in those circuits must
be warmed very slowly and carefully. Failure to warm the hydraulic oil properly can cause hydraulic system
damage and/or other problems.
• Operate the systems very slowly by using the joysticks for 30 minutes.
• Increase the speed in small increments after the first 10 minutes.
• Before drilling, check the hydraulic filter indicator lights while the rotary and carriage are in motion. Ver-
ify that the lights are not illuminated.
• If the lights are lit, continue to warm the system as described above.
Operating the DD-1100 RST

Test the Indicators, Emergency Stop Buttons and all Controls
If you have not already done so, verify that all gauges on the instrument panel are in working order. Test
all Emergency Stop buttons, disable switches and all controls
Attach the Drilling Fluid Supply Connections

Connect the mud mixing equipment (sold separately) hoses to the directional drill. Mix the drilling fluid
before starting the bore.
Power Wrench Operation
Pipe wrenches can injure or kill. Do not use pipe wrenches. Tighten and
loosen tool joints with the power wrenches on the machine.
The power wrench is made up of two individual wrenches - the wrench clamp and fixed clamp (see the
photo below). The fixed clamp is used to clamp and hold; the wrench clamp is used to clamp and rotate the
tool. The wrench is used to makeup and breakout the drill string.
Adjust the wrench makeup pressure to limit the force applied when making up a tool joint to prevent
damage to the pipe threads. The maximum torque is provided by the drill pipe supplier. Refer to “Appendix
D: Tables Converting Pressure to Torque and Force” section beginning on page 117 for charts that can be
used as a guide to convert the force displayed on the Wrench Clamp Pressure gauge to torque.
Fixed Clamp
Wrench Clamp
Wrenches-a
Direction of Bore

Checks During Operation
It is the operator’s responsibility to stop the machine when the instruments

report a value outside the normal operating range.
Thrust and Pullback Force Controls

The maximum thrust and pullback force can be set with the Carriage Pressure controls on the Operator’s
Display. This can prevent applying too much force and damaging the down hole tooling and the product
being installed. It can also help the drill operator regulate the rate of advance of the cutter head.
Converting Gauge Pressure to Torque and Force

Refer to “Appendix D: Tables Converting Pressure to Torque and Force” section beginning on page 117
for charts that can be used as a guide to convert hydraulic gauge pressure readings to thrust and pullback
force and rotary torque.
Using a Mud Motor

Follow the manufacturer’s instructions with respect to installation and operation of the mud motor. The
mud motor normally requires the use of a non-magnetic pipe section which fits between the mud motor and
the first section of drill pipe. The locating sonde or other instrument is located inside this non-magnetic sec-
tion.
Power Section Transmission Section Cutting Bit
The use of a mud motor normally requires excavation of a pit in front of the drill. The pit should allow the
cutting bit to enter the far vertical wall of the pit. Mud motors vary in design.

Fundamentals: Install Drill Pipe
Entanglement hazard and crushing hazard. A person can get caught in the
rotating drill string or be crushed by the moving carriage causing death or
serious injury. Do not stand on the walkway when the rotary and carriage are
operating.
Fall from height hazard. Unexpected movement when operating the machine
can cause serious injury. Install all handrails before using the walkway.
IMPORTANT:
• High speed threading of drill pipe joints is not recommended. Damage to drill pipe or the drive unit will
result.
• Position the drill drive spindle at the rear of the drill frame before loading drill pipe into the directional
drill.
• Apply thread joint compound to the spindle pin and drill pipe pin each time it is connected to a drill
pipe. This will extend the life of the threads on the spindle.
• Always turn OFF the drilling fluid pump after boring and before adding or removing drill pipes to keep
fluid loss to a minimum.
NOTE: When it is time for a pipe change, drill until the carriage is within a few inches of the wrench
clamp. Do not hit the wrench clamp. Then bring the pipe back until the pipe collar clears the wrench
clamp by about 5 inches (127 mm). This will reduce the risk of clogging the jets and allows fluid passage
when drilling is resumed.
Make Up a New Pipe Joint
1. Clamp the upper shoulder of the joint (made up of the pipe already in the ground and the drill drive spin-
dle) in the top clamp.
2. Clamp the pipe body with the fixed clamp.
3. Break the joint with the rotary.
4. Unclamp the top clamp. Unscrew and slowly back the carriage up until the spindle pin clears the pipe
box.
5. Apply joint compound to the spindle pin.

6. Move the carriage to the rear of the drill frame.
7. Raise the pipe supports.
8. Using a crane and pipe tongs, lift one section of pipe from storage and place it onto the supports.
9. Move the spindle down and slowly screw into the pipe box.
10. Move the carriage and pipe down and apply joint compound.
11. Move the carriage and thread the pin into the existing pipe box.
12. Check the pressure setting on the display and ensure it is appropriate for the desired torque.
13. Makeup until the specified torque is reached, making up both joints.
14. When the new drill pipe is threaded together tight with full clockwise rotation power, open (unclamp) the
fixed clamp.
15. Lower the pipe supports.
16. Resume drilling.
Turn on the Drilling Fluid
Inhalation hazard. Dust from drilling fluid additives such as bentonite may
irritate the respiratory system or lungs. Prolonged exposure may damage the
respiratory system. Use respiratory protection and dust resistant safety
goggles.
Have an adequate supply of drilling fluid (mud) ready. Check that the supply hose from the mud mixing
equipment is securely connected to the directional drill. Follow the manufacturer’s instructions to operate the
transfer pump on the mud mixing equipment to ensure an adequate supply of drilling fluid to the mud pump.
It is normal for drilling fluid to escape from the cutting head even if the mud pump is not operating. Do not
allow the mud pump to run dry as it will damage the pump.
While the DD-1100 RST engine is warming, start the mud system (sold separately) and allow that sys-
tem’s engine to warm up. The procedure below is a general guide. Consult the Mud System Operator’s Man-
ual and information from the drilling mud supplier for specific operating procedures and desired mud flow
rates.
When you are ready to begin drilling:
1. Supercharge the mud pump with an external supply to 30 psi (2.1 bar).
2. Fill the pipe with mud before drilling.
3. Allow the pressure to build up. Approximately 200 to 300 psi (14-21 bar) is required while drilling the pilot
bore.
4. Monitor the mud flow rate by viewing it on the Mud System Console.
5. Set the desired flow of drilling fluid.

Make the Pilot Bore
Electrocution hazard. Machine may become electrically charged if the drill

string contacts a power line. If ZAPALERT beacon is flashing, stay back at
least 25 feet (8m).
• Do not operate the machine until ZAPALERT testing is complete and all issues
have been satisfactorily resolved.
• The ZAPALERT ground stake must be installed for the unit to work properly,
Entanglement hazard. Rotating shaft can crush body parts or kill you. Keep
body parts and clothing away.
IMPORTANT:
• Only rotate the drill CLOCKWISE; NEVER COUNTERCLOCKWISE while drilling or backreaming. You
may unthread the drill pipe in the bore and you will not be able to retrieve them.
• Keep the first drill pipe straight. This will eliminate side pressure on the drill pipes. Use thrust to
advance the pipe. DO NOT make a steering correction until the second pipe is connected.
• Stop work if the machine is vibrating. This is an indication of incorrect operation, for example advanc-
ing the drill pipe too rapidly. Resume work at a slower speed.
• Extreme steering maneuvers of the drill head may cause pipe damage or breakage.
• Since the first pipe length is very important to get the bore path started correctly, proceed very care-
fully. Locate the drill head often, even in the middle of a pipe length, if necessary. Make steering cor-
rections after first pipe has been inserted into the ground.
1. Rotate in the makeup direction momentarily and release the joystick so that the blade is at the 6 o’clock
position.
2. Move the rotary drill carriage forward and push the drill head slowly into the ground, keeping the drill pipe
as straight as possible.
3. When the drill head is completely in the ground, begin rotating the first drill pipe clockwise (makeup).
4. With the first drill pipe rotating clockwise, slowly thrust the first drill pipe partially into the ground.
5. Stop thrusting forward when the carriage is within a few inches of the wrench clamp. Do not hit the
wrench clamp. Then see “Make Up a New Pipe Joint” on page 76.

End of Pilot Bore Drilling

changing tooling or adding pipe.
• Use a swivel when prereaming and backreaming.

• Maintain good communications between drill operator and exit pit crew.
• Do not rotate drill pipe until personnel have been notified and they acknowledge
the notification.
Steer the drill head UP to exit the ground. Maintain verbal contact with personnel at the exit point. Verify
that everyone is clear of the exiting pipe. Plan the exit point so that steer angle is within the minimum pipe
bend radius capacity.
1. When the tooling emerges from the ground, notify the driller and activate the es!lok Exit Side Lockout
System to disable the drilling rig.
2. Turn off the diesel engine and remove the ignition key.
3. Communicate to all personnel that tooling is being removed and attached at the exit side and that the
engine must remain off to ensure crew safety.
4. Using an appropriate tool such as an exit side breakout wrench, remove the drill head assembly. Follow
the manufacturer’s instructions for proper use of the tool.
5. Remove the guidance system.
6. Thoroughly clean the guidance system and store it in a safe location.
Pullback Operations
Backreaming and Pullback

changing tooling or adding pipe.
• Use a swivel when prereaming and backreaming.

• Maintain good communications between drill operator and exit pit crew.
• Do not rotate drill pipe until personnel have been notified and they acknowledge
the notification.
After the completion of the pilot bore, a reamer is used to enlarge the hole so product (cable, tubing, etc)
can be pulled back through the hole. The product pipe must be isolated from rotation by using a swivel.
1. Turn off the engine, remove the key and activate es!lok.
2. Install the selected reamer using appropriate tools.
3. Install a pullback swivel behind the reamer using appropriate tools. The swivel eliminates twisting the
product being pulled back.
4. If you are prereaming, install a pulling eye behind the swivel so that more drill pipe can be pulled in with-
out rotation. This technique prevents the hole from being free of drill pipe throughout the pre-reaming
process. Pulling eyes are also used to pull small diameter product (cable, pipe, etc.) into a pilot hole, if
product is 2 inches (50 mm) or smaller.
5. Install a product coupler and attach the product to the coupler. The drawing below shows one configura-
tion of tools for backreaming.
Pullback Eye Product Coupler
Drill String Blade Reamer Pullback Swivel Utility Product Pipe
6. Ensure that all exit-side personnel are standing a safe distance from the reamer and pipe.
Pullback Operations
7. Turn on the engine.
8. Activate the mud system to ensure that the reamer jets are open.
9. Reset the es!lok Exit Side Lockout System to restore normal functions to the drill.
10. Slowly pull the reamer back to the pilot hole. Rotate the drill pipe and reamer CLOCKWISE.
11. Slowly pull the reamer into the hole.
12. Advance at a slow rate to ensure the drilling fluid and cuttings mix into a slurry that will flow.
13. Remove each section of pipe from the drill string as it is pulled back. Follow the procedures below. Use a
pipe wiper to clean the pipe as it is retracted.
Removing Drill Pipe During Pullback or Backreaming
IMPORTANT:
• Clamp the fixed clamp first. Then clamp the wrench clamp.
• Before breaking out the pipe joint, verify that the upper shoulder of the pipe section still in the ground is
FULLY CLAMPED in the fixed clamp. The wrench clamp applies COUNTERCLOCKWISE rotary
torque, which could loosen the joint threads of the pipe sections still in the ground.
• High speed unthreading of drill pipe joints is not recommended. Damage to drill pipe or drive unit will
result.
• Apply thread joint compound to the drill drive spindle pin and drill pipe pin each time they are con-
nected to another pipe.
1. Pullback with the joystick and backream until the pipe collar to be removed has cleared the wrench by
about 5 inches (127 mm).
2. Stop the pullback and thrust the pipe forward until the joint is between the fixed clamp and wrench
clamp. This will reduce the risk of clogging the reamer jets.
3. Clamp the pipe in the fixed clamp.
4. Clamp the pipe in the wrench clamp.
5. Break the joint. Do not unscrew.
6. Unclamp the wrench clamp. Unclamp the fixed clamp.
7. Pull the drill string back with the carriage until the drill collar of the pipe still in the ground clears the
wrench clamp.
8. Clamp the pipe body in the fixed clamp.
9. Raise the pipe supports.
10. Slowly unscrew the pipe and pullback with the carriage until the pin just clears the box.
11. Move the top clamp to the pipe collar.
12. Clamp the top clamp.
13. Break the joint at the spindle.
14. Unscrew the carriage spindle all the way.
15. Unclamp the top clamp.
16. Pull the carriage all the way back.
17. Remove the drill pipe.
18. Lower the pipe supports.
19. Follow steps in “Engage the Next Pipe to be Removed” on page 82.
Pullback Operations
Engage the Next Pipe to be Removed
1. Thrust the carriage. Stop the carriage spindle pin just before it reaches the pipe box.
2. Apply thread joint compound to the carriage spindle pin.
3. Slowly thrust the carriage until the carriage spindle pin engages the box of the next pipe section to be
removed.
4. Make the joint.
5. Ungrip the pipe from the fixed clamp.
Pullback Operations
Continue Backreaming
Continue backreaming and removing each section of drill pipe as it emerges from the bore. Repeat the
above steps until all the pipe is removed.
End of Pullback Operations
The pullback operation is complete when the pipe or cable has been installed and pulled back to the
bore entry opening.
Equipment Shutdown
Water can damage sensitive electronic components. Do not spray water

against electronic components and control panels.
After every day of operation:
• Set the throttle at idle for a few minutes to allow the engine to cool down.
• Turn OFF the engine and remove key. Store key in a safe location.
• Wash the machine. Clean off all mud and other debris.
Pullback Operations
Rig Down
1. Set the engine RPM to 1500.
2. Move the carriage to the transport position. The Carriage Position Indicator light on the Set Up Box will
be illuminated until the carriage reaches the transport position. Then the light will go out. Do not continue
rig down steps until the light goes out. The auxiliary power unit will not start if the carriage is not in the
transport position.
3. Turn off the engines and release pressure.
4. Remove the two mud hoses between the rear swivel and the carriage mud supply lines.
5. Disconnect the cables and hoses from the wrench.
6. Remove the locking pins from the clamps that secure the wrench to the thrust frame.
7. Swing the clamps open and secure them in this position by installing the locking pins.
8. Disconnect the hose carrier from the bracket on the front of the wrench assembly.
9. Install caps on hoses, fittings, and cables to prevent contamination.
10. Using nylon lifting slings instead of chains, remove the wrench from the thrust frame.
11. Transport the wrench separately.
12. Attach the wrench hose carrier transport support.
13. Attach the wrench hose carrier to the carriage.
14. Disconnect all hoses and cables between the Driller’s Console, Power Supply Units and the rig. Install
caps on hoses, fittings and cables to prevent contamination.
15. Remove the rear foot cross bracing.
16. Disconnect the front foot from the thrust frame.
17. Remove the handrails and store them.
18. Fold the walkway toward the thrust frame and secure it with nylon straps.
19. Coil the mud hoses on the rig deck. Secure them with nylon straps.
20. Wash mud, drilling fluid and soil off the machine.
21. Remove and stow the ZAPALERT ground stake.
22. Remove all tools and loose objects from the area and put them into storage.
23. Start the auxiliary power unit.
24. Raise the thrust frame slightly and remove the pins from the struts.
25. Lower the thrust frame and hookup to the tractor. Note: If the rig is equipped with a wireline stairway,
remove the hitch pins and carefully lower the rig checking that the stairway does not dig in.
26. Air up the trailer brakes and air bags.
27. Raise the dolly landing gear.
28. Unpin the dolly from the setup position.
29. Set the tractor brakes.
30. Slowly move the dolly to the transport position using the radio remove. Keep the hoses and cables clear
of the dolly. The dolly must be in the transport position to properly support the weight of the rig when it is
moved. Pin the dolly in the transport position.
31. Raise the lifting legs and secure with the transport pins.
32. Shutdown the auxiliary power unit and store the radio remove.
33. Move the rig from the site.
34. Remove the tie down stakes from the front foot. Do not attempt to remove the tie down stakes by raising
the front foot with the machine.
35. Load the front foot and rear foot for transport.
Operating in Different Climates

Operating in Hot Weather
To prevent damage to the machine when operating in hot weather, take the following precautions:
• Follow instructions in the diesel engine manual for operating the engine in hot weather.
• Use the appropriate mixture of coolant and water for the temperature range in which you are working.
Test the coolant periodically. Keep the coolant at the correct level in the radiator and the reservoir.
• Use the recommended engine oil viscosity for the operating conditions as specified in your diesel
engine manual.
• Clean dirt and debris from the radiator and engine daily. Check the air cleaner dust valve daily.
• Equipment such as the electrical and electronic components of your machine may have special con-
siderations for operating in very warm temperatures. Consult user’s manuals for these items to deter-
mine if there are special requirements for your operating conditions.
Operating in Cold Weather

Only machines especially configured at the factory can work when the ambient temperature is between
-40°F to +5°F (-40°C and -15°C). Some machines are equipped with an engine preheater to maintain the
minimum temperature needed for starting the diesel engine.
All machines are equipped with preheaters and temperature gauges on the hydraulic oil tanks. Use the
preheaters to raise the hydraulic oil temperature.
• Diesel engines cannot be started until the oil temperature reaches 15°F (-9.5°C).
• Controls cannot be operated until the oil temperature reaches 40°F (4.4°C).
• Hydraulic controls should be operated at 800 rpm (or idle) until the oil reaches 70°F (21.1°C).
Other precautions and special procedures for operating in cold weather are:
• Ensure that the battery is fully charged.

• Use the recommended engine oil viscosity for the operating conditions as specified in your diesel
engine manual.
• Use the proper cold weather fuel. Cold temperatures can cause water to collect in the fuel tank. Check
the collection bowl at the bottom of the fuel-water separator near the fuel system on the engine. Drain
water from the collection bowl using the drain valve at the bottom of the bowl.
• Use the appropriate mixture of coolant and water for the temperature range in which you are working.
Test the coolant periodically. Keep the coolant at the correct level in the radiator and the reservoir.
• Warm the engine thoroughly before beginning operations. Slowly operate each hydraulic control for
about ten minutes. Move the machine very slowly.
• Crack all mud line joints and drain the mud line system after every bore and when the machine is not in
use.
Operating in Different Climates

Engine Block Heater
The DD-1100 RST engine comes with an Engine Block Heater. Plug the power cord of the Engine Block
Heater into an external power source to warm up the engine coolant before starting the engine. The Engine
Block Heater may also remain plugged in for extended periods of time during extremely cold temperatures to
keep the engine coolant warm continually when the engine is not running.
For air temperatures down to but not lower than -30°F (-34°C), use the Engine Block Heater for at least
two hours before starting the engine. This time period may vary depending on ambient weather conditions
(high wind situations, for example). When overnight air temperatures approach -40°F (-40°C), heating may
be required continually when the engine is not running. Do not operate the preheater for more than three (3)
minutes after the engine starts.
Refer to Attachment 1: “Diesel Engine Manual” for additional information about the Engine Block Heater
and for operating requirements during extreme weather conditions.
Engine Preheating Devices
Pre-heating devices operate on high-voltage (110 volts or 220 volts AC).

Connect to a circuit equipped with a ground fault interrupter (GFI). Protect the
electric cables from contact with water or other liquids.
When working in cold temperatures, it is necessary to use a preheating device to keep the temperature
of the oil in the diesel engine warm when the machine is turned off. Plug the preheating device to an electric
supply rated at 1 kW at 110/220V 50/60 Hz single phase.
DD-1100 RST Operators Manual Storage and Transport
Machine Storage and Transport
Storage and Transport

Minimum Storage Space Required
Consult the “Specifications” section beginning on page 107 for the dimensions and weight of the
DD-1100 RST to establish storage space requirements. The surface must be firm enough to support the
weight of the machine and prevent sinking.
Storage Site Conditions

If the machine has been lubricated, it can be stored uncovered for up to 30 days. Protect the machine
from salty or acid environments, solvents, gas, flammable liquids and explosives.
For periods longer than 30 days, the machine should be stored in a covered, dry area.
The temperature ranges recommended for storage are between 32°F and 120°F (0°C to 50°C). Refer to
Attachment 1: “Diesel Engine Manual” for temperatures outside this range.
Preparations for Storage

For short-term storage, i.e. periods less than 30 days:
1. Clean the machine as described in the “Cleaning” section beginning on page 89.
2. Make sure there is no water or drilling fluid in the drilling fluid course. If freezing temperatures are
expected, precharge the drilling fluid system with antifreeze when the machine is not in use.
3. Eliminate sediment and water from the tanks (diesel fuel and oil).
4. Disconnect the es!lok® battery charger. This charger is not affected by the Battery switch. If left con-
nected, it could discharge the power unit batteries.
5. Lubricate the entire machine according to the 10 Hour Inspection and Maintenance schedule. Coat all
exposed hydraulic cylinder rods with oil to protect against corrosion.
For storing longer than 30 days, follow the procedures for short-term storage plus these additional steps:
• Store the machine in a covered, dry location.
• Follow manufacturer’s instructions for long-term storage of a diesel engine.
• Remove and store the batteries where the temperature will remain between 32°F and 105°F (0°C to
45°C).
• Completely fill all gear boxes with lubricant.
Storage and Transport DD-1100 RST Operators Manual
Machine Storage and Transport

Transportation
Improper operation of controls and use of unsafe techniques can result in

serious injury, death and damage to the equipment. Personnel should read
the manual and learn proper procedures to transport and lift the machine.
• Refer to “Rig Down” on page 84 for step-by-step procedures to properly prepare

the rig for transport.
The machine must be transported in accordance with local laws and regulations. All components must
be properly secured on the rig. If the rig exceeds the overall dimensions allowed, they must be flagged
according to the highway laws of the countries or states involved in the transport. The transporter is respon-
sible for using the proper method of transport and following all other applicable regulations.
Lifting the Machine
Crush hazard from above. If the load shifts or falls it could crush you or kill
you. Use appropriate lifting equipment for the size of the load.
• Use chain or cable suitable for the weight of the machine being lifted.
• Ensure load is stable and properly secured before lifting.
• All personnel must remain a safe distance away while the machine is being lifted.
Use spreader bars to ensure that lifting lines do not come in contact with the drill. It may be necessary to
remove the wrench assembly prior to lifting the machine. When lifting the Power Supply Unit, secure the load
lines to the lifting points at the ends of the frame. Use spreader bars to ensure that the lifting lines do not
come in contact with the power unit.
Use Caution: Load may not be

evenly balanced
Maxi Rig Lifting-1
Secure all 4 corners
DD-1100 RST Operators Manual Maintenance
General Maintenance
Maintenance
Failure to turn off the machine and lockout systems before doing maintenance
work may result in personal injury or death. Turn off power, relieve system
pressures, and turn the Battery switch to the OFF position. Remove key from
the Engine Start switch. Install a lock on the Battery switch if the machine is
so equipped. Use proper lockout and tagout procedures before working on
the machine.
Hydraulic oil, gearbox oil, diesel engine oil, pin and bearing greases, diesel engine cooling liquid, battery
liquids and fuel should be handled with care. Consult Material Safety Data Sheets. Dispose of spent fluids
according to laws and regulations. Take appropriate precautions to ensure that these fluids do not leak or
spill on the ground or into sewage systems, streams, rivers, lakes or the sea.
Engines, muffler, gearboxes and the hydraulic system can reach very high temperatures. Do not attempt
maintenance immediately after stopping work. Wait until the parts are cool.
For additional drawings, diagrams and explanations necessary for maintenance and repair, contact the
factory.
Qualification of the Technician

Ensure that all field personnel conducting visual inspections of the rig have adequate training to enable
them to identify problems and that they have read this manual.
The maintenance technician must be trained in directional drill operations. The maintenance technician
is responsible for conducting maintenance with suitable test and repair equipment, personal protective
equipment and attention to safety hazards.
Cleaning
Water can damage sensitive electronic components. Do not spray water

against electronic components and control panels.
General Cleaning
Clean all the marking plates as well as all lighting devices. Do not direct water spray inside the muffler or
the air filter, against electric components and control panels or on caps and open tanks. Do not use acid or
abrasive solutions. Keep caps and covers for hydraulic connections clean. Contamination of hydraulic oil will
negatively impact performance of your DD-1100 RST.
Maintenance DD-1100 RST Operators Manual
General Maintenance
Cleaning Plastic and Resin Parts
Avoid using gasoline, kerosene, paint thinner and similar materials when cleaning the instrument cluster,
gauges, console, plastic windows, etc. These materials will cause discoloration, cracking or deformation of
the part being cleaned. Use ONLY water, mild soap and a soft cloth when you clean these parts.
Cleaning Hydraulic Connections
Hydraulic couplings and protective caps must be kept clean and free of all debris. Use an evaporative,
petroleum-based aerosol cleaner. When hydraulic couplings are not connected, replace protective caps on
the connectors and hose ends. Failure to keep the hydraulic couplings clean could impact equipment perfor-
mance, cause serious damage and may void the product warranty.
Cleaning Electrical Connections
Electrical connectors and dust caps must be kept clean and dry. Use a high quality electrical contact
cleaner. When electrical cables are disconnected, replace dust caps on the connections and cable ends.
Failure to keep the electrical connectors clean could impact equipment performance, cause serious damage
and may void the product warranty.
Welding
IMPORTANT:
• Turn off engine.
• Disconnect all electrical connections before welding. It is particularly important to disconnect the nega-
tive battery cable from the battery.
• Clamp the ground cable for the welder to the component that will be welded as close as possible to the
weld.
• Do not use electrical components to ground the welder.
• Do not weld near the tanks and flammable liquids.
• Failure to follow welding procedure can cause damage to electric and mechanical components. Dam-
age to components due to improper procedures is not covered under warranty.
Consult the factory for additional information about preheating or post weld heat treating requirements if
welding is necessary in cooler temperatures. Welding should not be done when the ambient temperature is
below 0°F.
General Maintenance
Diesel Engine Maintenance
Engine maintenance items are outside the scope of this manual. Consult Attachment 1: Diesel Engine
Manual for recommended engine fluids (gasoline, engine oil, antifreeze) and inspection and maintenance
schedules. Your engine may have specific requirements related to its emission systems.
Approved Replacement Fluids

When adding or replacing fluids, use the same fluid that is in the system. Avoid mixing different fluids as
they may be incompatible. Use the fluid in the table below or contact the factory for advice on the compatibil-
ity of a new fluid with the one in service.
Approved Replacement Fluids

(Ambient temperature 5°F to 110°F [-15°C to 43°C])
Consult factory for specifications at temperatures outside this temperature range.
Carriage Drive Shell Spirax S6 AXME 80W-140 AA Specification 102
Grease Points Shell Gadus S3 V460D 2 AA Specification 301
Hydraulic Oil Shell TellusS2 V46 AA Specification 202
Mud Swivel Grease Shell Gadus S3 V460D 2 AA Specification 301
Pump Drive Shell Spirax S6 AXME 80W-140 AA Specification 102
Rotary Gearbox Shell Spirax S6 AXME 80W-140 AA Specification 102
Slip Sub Grease Jet Lube Kopr Kote AA Specification 302
Scheduled Maintenance
DD-1100 RST Maintenance Schedule

After 10 100 250 500
Function each job hours hours hours hours
Cycle Emergency Stop Buttons X
Engine: Check Fuel Level X
Engine: Check Coolant Level X
Engine: Check Crankcase Oil Level X
Engine: Check Air Filter Service Indicator X
Check Hydraulic Oil Level X
Check Oil in All Gearboxes X
Leak Check Valves, Hoses, Fitting, Cylinders X X
Lubricate Grease Fittings X
Inspect Power Wrench Jaw Teeth X X
Inspect Rotary Drive Spindle Saver Sub X
Change Hydraulic Pump Drive Oil X* X
Check Battery Water Level X
Check and Clean Breather Devices X
Change Hydraulic and Charge Pressure Filters X**
Change Oil in All Gearboxes X
Test Hydraulic Oil X
Drain and Flush Mud Hoses and Swivel X
NOTES:
Do not exceed the indicated number of hours without performing the required maintenance
* After first 100 hours; then after every 500 hours.
** Unless filter indicator shows change required at a more frequent interval
10 Hour Inspection and Maintenance
Perform the 10 hour inspection and maintenance items in the Maintenance Schedule.
Cycle Emergency Stop (Disable) Buttons
Verify that all emergency stop buttons are working properly. Perform an operating check of all controls.
Make necessary repairs before starting operations.
Engine: Check Fuel Level
Begin each shift with a full tank of fuel. To prevent dirt and water from reaching the injection parts which
will cause damage and decrease performance, use clean fuel and service the fuel filter at regular intervals as
prescribed in Attachment 1: Diesel Engine Manual.
Engine: Check Coolant Level
Hot coolant can spray out and cause serious injury. Do not remove radiator
cap while the engine is hot. Wait for the engine to cool.
• Slowly open the radiator cap and allow pressure to escape slowly.
• Always wear face protection (face shield or goggles) when cleaning radiator fins
with compressed air or pressure washer.
IMPORTANT: Water quality is important to the performance of the cooling system. Use distilled, deion-
ized or demineralized water when mixing with coolant concentrate.
Coolant should be checked while the coolant is cold. Check that the level of the coolant is at maximum
and there is no contamination. Add coolant if the level is low. After filling is complete, install and tighten the
filler cap.
Engine: Check Engine Oil Level
IMPORTANT:
• Before checking or changing engine crankcase lube oil, wait for the engine to cool.
• Refer to Attachment 1: “Diesel Engine Manual” for correct crankcase lube oil to use if more oil is
required.
Check that the engine oil is at the proper level and that there is no contamination. Add oil if the level is
low. Select oil based on specifications in Attachment 1: Diesel Engine Manual.
Engine: Check Air Filter Service Indicator
The air filter service indicator provides a quick check of the condition of the air filter(s). When the red
marker on the air filter service indicator appears, the air filter is clogged with dust. This causes a substantial
decrease in engine efficiency and can cause serious damage to inner mechanical parts. Clean or replace the
filter elements. In extremely dusty conditions, increase the frequency of engine air filter maintenance.
Check Hydraulic Oil Level
NOTE: Very small amounts of contamination of hydraulic oil can damage the system.
It is best to check the fluid level when the ambient temperature is 50°F (10°C). Oil level will vary accord-
ing to the effect of temperature (hot oil increases in volume) and the position of the hydraulic cylinders.
1. The power unit should be on a flat, level surface.

2. Retract all cylinders. Hydraulic Tank
3. Check the level in the tank using the transparent Gauge
gauge mounted in it.
• If the oil level is too low, add oil to level indi-
cated on the gauge.
• DO NOT overfill the reservoir.
4. After refilling, lock the tank cap.
Check Oil in All Gearboxes
IMPORTANT: Check oil level when the gearbox is cold.
• Inspect the hydraulic pump gearbox, the rotary drive gearbox and the carriage planetary gearbox for
leaks. In the case of a small loss, fill the gearbox to the correct level.
• After unscrewing a level plug, a small quantity of oil will escape. As soon as this happens, inspect the
oil in order to verify that there is no contamination. If the oil looks dirty or smells burnt, drain the oil and
replace it with fresh fluid. If no problems are detected, change the oil as prescribed on the mainte-
nance schedule.
• For Carriage Planetary Gearbox, see page 103.
• For Hydraulic Pump Drive Gearbox, see page 103.
• For Rotary Drive Gearbox, see page 104.
General Inspections
Use of equipment with damaged hoses, fittings, loose or missing fasteners

may result in damage to the machine, personal injury or death. Inspect the
machine regularly. Replace or repair damaged or missing components
promptly.
Hydraulic fluid under pressure can cause serious personal injury and death if
it penetrates the skin. Stay away from the jet.
• Use a piece of cardboard or wood to check for pressurized leaks to prevent fluid
penetrating the skin.
• Seek immediate medical attention if hydraulic fluid has penetrated the skin even if
the injury seems minor. Prompt medical treatment by a physician familiar with this
injury is essential.
Hot surfaces can cause burns. Do not touch until cool.
Inspect the machine for leaks of gear oil and hydraulic oil. Leaks should be repaired. Allowing oil or other
fluids to leak into the environment is unlawful in most locations. Visually inspect all hoses, fittings and pipes.
Replace parts that are damaged.
Check that hydraulic cylinder rods and struts are not damaged and that they do not leak. Keep cylinder
rods clean to prevent damage. Dirt can cause contamination of the hydraulic fluid and cause failure of shaft
seals.
Check all major fasteners, such as hose clamps, stakedown, tie downs, etc. Tighten all loose fasteners.
Replace any that are missing or damaged. Check the control cable connections and ensure they are tight.
Lubricate Grease Fittings
NOTE: Grease fittings should be kept clean so that contamination is not forced inside. Replace damaged
fittings.
Grease points must be lubricated daily. Two grease pumps are enough unless otherwise specified. Use
the grease type specified in the Approved Replacement Fluids table. When working in very high or low tem-
peratures, consult the factory. The drawings below show the location of the grease fittings.
Guide to Grease Fitting Location Drawings

50dd10002-dxf-RIG
Carriage
Top Clamp
Pipe Support
Wrench
Lifting Legs
Guide Bushing
Underside of Carriage
Grease Points on Carriage
50dd6105-TopWrenchRails
50dd6104-TopWrenchGrease2
Both Sides of Top Clamp
On All Three Sides of Top Clamp

50dd6104-TopWrenchGrease1
Grease Points on Top Clamp

50dd2115-RodSupportGrease
Apply Grease to Grease Points on Both Pipe Supports
Underside of Cylinder
Grease Points on Both Pipe Supports
Apply Grease to Grease Points

on All Three Sides of Wrench
50dd2115-RodSupportGrease
Grease Points on Wrench

50dd2115-GuideBushing Grease
Grease Point on Both Sides

of Guide Bushing
Grease Points on Guide Bushing
50DD10001-LiftingLeg
Grease Points on Lifting Legs
Carriage: Inspect Spindle Saver Sub
IMPORTANT:
• Using a worn or damaged spindle saver sub will wear or damage each drill pipe as it is connected to
the saver sub while drilling.
• High speed threading of drill pipe joints, drill drive spindle or saver sub threads is not recommended.
Damage to drill drive unit, spindle threads or save sub threads will result.
Inspect the drill drive spindle saver sub threads for wear or damage. If threads are worn or damaged, the
connection between the drill pipe and the spindle adapter will not be properly secured. Replace the spindle
saver sub.
Remove a Damaged Saver Sub
The saver sub is threaded onto the end of the side entry sub. It is removed from the side entry sub using
the wrenches. Thread locking compound is used to keep the saver sub from loosening or unthreading.
1. Advance and position the drill drive carriage so the shoulder of the saver sub is in the jaws of the fixed
wrench.
2. Clamp the shoulder of the saver sub in the fixed wrench.
3. Clamp the drill drive spindle shoulder (ABOVE the saver sub joint) in the rotating wrench.
4. Carefully apply heat (approximately 600° F (315° C)) to melt the thread locking compound in the threads
of the joint between the drill drive spindle (external threads) and the damaged saver sub (internal
threads).
5. Breakout until the threads of the side entry sub are completely unthreaded from the damaged saver sub.
6. Ungrip the damaged saver sub from the fixed wrench.
7. Lift the damaged saver sub from the fixed wrench jaws. Set it aside.
8. Clean the threads on the side entry sub.
9. Lower a new saver sub in its place. Keep the plastic protector on the external threaded portion to protect
the new threads from damage.
Install a New Saver Sub
1. Apply thread locking compound to the threads of the side entry sub. Manually thread the replacement
saver sub onto the threads of the drill drive spindle. Stop when the joint is hand tight.
2. Grip the shoulder of the new saver sub in the fixed wrench.
3. Makeup to fully tighten the new saver sub to the side entry sub.
4. Ungrip the saver sub from the fixed wrench.
5. Ungrip the drill drive spindle shoulder from the rotating wrench.
After First 100 Hours of Operation
Change Hydraulic Pump Drive Oil
• Remove the drain plug in the bottom of the hydraulic pump drive.
• Catch the oil in a suitable container.
• Dispose of the oil according to local regulations.
• Replace the drain plug.
• Fill with suitable oil until oil reaches the proper level on the dipstick.
Perform 10 Hour Inspection and Maintenance items, plus:
Engine: Check Battery and Battery Fluid Levels
BATTERY ACID CAN CAUSE SEVERE BURNS. Batteries contain sulfuric acid.
Avoid contact with skin, eyes or clothing. Wear eye protection and gloves
when working with batteries.
ANTIDOTE:
• EXTERNAL: flush with water.
• INTERNAL: drink large quantities of water or milk. Follow with milk of magnesia,
beaten egg or vegetable oil. Call Poison control and a physician immediately.
• EYES: flush with water for 15 minutes and get prompt medical attention.
All exposed metal parts on a storage battery are “live”. Laying a metal object
across the terminals may cause a spark, short circuit or explosion. Personal
injury or damage to the equipment may result. Never lay a metal object across
the battery terminals.
IMPORTANT:
• When disconnecting battery terminals, remove the Negative (-) GROUND cable first; then remove the
Positive (+). When connecting the cables, connect the Positive (+) first, then connect the Negative (-)
GROUND cable last.
• To prevent damage to the battery, DO NOT over tighten the battery hold down.
Check the level of the electrolyte in the batteries. Add distilled water until level is at the split ring of each
cell opening if the level is too low.
Check the battery cables and verify that there are no abrasions or indentations; if necessary, replace the
battery cables. Check that the battery terminals are not corroded. Clean and replace them if necessary. The
voltage of the battery is 12 volts.
Clean corrosion off battery terminals. A paste made of sodium bicarbonate and water is normally enough
to clean terminals and battery box. After cleaning, rinse thoroughly with clean water. Coat the terminals with
battery terminal grease or dielectric grease in order to prevent future corrosion.
Breather Devices
Check that there are no obstructions or deposits accumulated. Clean the breather pipes in case of
obstructions. We recommend using an oil solvent (diesel fuel is OK). Clean breather pipes more frequently
when operating in dusty conditions.
Flywheel gearbox (1)
Hydraulic tank (1)
Fuel tank (1)
Perform 10 and 250 Hour Inspection and Maintenance items, plus:
Change Hydraulic and Charge Pressure Filter Elements
Support the drill frame with a strong support before draining the hydraulic
filters. DO NOT start the engine until personnel have moved away from the
area.
IMPORTANT: When changing the charge filter, first, unscrew the drain plug on the
bottom of the filter. Then, unscrew the plug on top of filter enough to help bleed out.
Finally, unscrew the container and remove the filter element.
An indicator light on the Control Panel Display screen will show when hydraulic or charge pressure filter
elements must be changed. If the light goes on and stays on, change the filter elements as soon as possible.
Hydraulic and charge pressure filter elements should routinely be changed every 500 hours.
1. Place a container under the filter you are changing to catch any spills.
2. Using a filter wrench, remove the filter element and discard. Clean the area with a clean rag.
3. Apply a thin coat of oil to the o-ring of the new filter element. Install the new oil filter element.
4. HAND TIGHTEN filter until making contact with the base. Continue to tighten 3/4 turn. DO NOT use a fil-
ter wrench to tighten the filter. Damage to the filter may result.
5. Run the engine at low speed and operate the rotary.
6. Check the oil level.
7. Run the engine at high speed for 5 minutes.
8. Turn off the engine and inspect for leaks.
Change Hydraulic Pump Drive Gearbox Oil
IMPORTANT: Check hydraulic pump drive gearbox oil level when the gearbox is cold.
To check the oil level in the pump drive, use the dipstick (rod) accessible from the engine door. The cor-
rect level is between the two lines marked on the rod.
• To drain the oil. remove the plug in the bottom of the gearbox. Catch the oil in a suitable container. Dis-
pose of old oil according to local regulations.
• For filling, use the elbows where breather pipe is positioned.
• Remove the breather pipes.
• Fill with suitable oil until the oil reaches the proper level on the dipstick.
Change Carriage Planetary Gearbox Oil
IMPORTANT: Check carriage planetary gearbox oil level when the gearbox is cold.
To drain the oil, remove the plug in the bottom of the gearbox. Catch the oil in a suitable container. Dis-
pose of old oil according to local regulations.
Fill with suitable oil until the oil reaches the midpoint of the sight glass.
Change Rotary Drive Gearbox Oil
IMPORTANT: Check rotary drive gearbox oil level when the gearbox is cold.
Rotary drive
gearbox fill plug
1. Remove the fill/level plug.

2. Remove the drain plug and drain the oil. Catch the oil in a suitable container. Dispose of old oil according
to local regulations.
3. Insert and tighten the drain plug.
4. Fill drill drive to proper level with gear oil.
5. Insert and tighten the fill plug.
Test Hydraulic Oil
NOTICE: Failure to send in samples for inspection will void the warranty.
After 500 operating hours, obtain a sample of hydraulic oil from the hydraulic tank. Use the inspection
bottles provided by American Augers. Send the samples to American Augers for analysis. You will be noti-
fied if it is necessary to change the hydraulic oil. When changing the oil, the filters must also be changed.
Follow instructions in “Change Hydraulic Reservoir Oil” on page 105.
Change Hydraulic Reservoir Oil
Support the drill frame with a strong support before draining the hydraulic
filters. DO NOT start the engine until personnel have moved away from the
area.
IMPORTANT: Keep hydraulic oil clean, properly filtered and do not allow it to over-
heat by overloading.
Hydraulic filters MUST be replaced each time the oil is changed. When draining oil from the reservoir
and filter, ALWAYS use a container and dispose of properly. Make sure the container has enough capacity to
avoid any spillage. NEVER allow oil to drain onto the ground.
1. Verify that the power is off.

2. Clean the external covers and walls of the hydraulic tank.
3. Drain the hydraulic oil from the tank in a container suitable for transportation or disposal.
4. Remove all access covers and remove any deposit of old gaskets.
5. Keep all bolts together.
6. Remove the suction strainers inside the tank.
7. Clean the breather cap with a lint free cloth.
8. Inspect the tank for metal particles and foreign matter. Clean these materials out of the tank to minimize
oil contamination.
9. Clean and reassemble the suction strainer. Alternatively, you may wish to use a new suction strainer.
10. Put the gasket on the inspection cover and reassemble.
11. Tighten the bolts on the cover. Refill the reservoir with the hydraulic oil recommended on the “Approved
Replacement Fluids” on page 91. Do not mix products from different companies due to the possibility of
reactions among the oil.
12. Fill the tank to the appropriate level using the gauge on the outside. The oil level will vary considerably
according to the effect of temperature (hot oil increases in volume) and the position of the hydraulic cyl-
inders.
13. Run the engine at low speed and operate the rotary.
14. Confirm proper oil level in tank.
15. Run the engine at high speed for 5 minutes.
16. Turn off the engine and inspect for leaks.
Notes
NOTES:
DD-1100 RST Operators Manual Specifications
Specifications
Specifications
Machine Dimensions / Weight
Length (transport): 64 feet 10 inches (19.8 m)
Width (transport): 8 feet 1 inch (2.5 m)
Height (transport): 11 feet 10 inches (3.6 m)
Total Weight (with wrench): 112900 lb (51211 kg)
Transport Weight (without wrench): 105040 lb (47746 kg)
Power Supply Unit

Length (transport): 19 feet 10.5 inches (6.05 m)
Width (transport): 8 feet (2.43 m)
Height (transport): 9.5 feet (2.9 m)
Transport Weight: 34520 lb (15691 kg)
Power Train
Engine: Caterpillar C-18 Diesel (Tier depends on place of purchase)
Rating: 765 HP (570 kW)
Fuel Capacity: 650 gallons (2460 liter)
Hydraulic capacity: 220 gallons (833 liter)
Drilling Unit
Drill Angle: 10° - 18°
Wrench Clamp: Triple Jaw Wrenches with 12 inch (305 mm) separation
Hold Down System: H-Beam Type Front
Rotary Drive
Rotary System: (4) Pinion and gear drive. Infinitely variable torque
Maximum Rotary Torque: 100000 ft-lbs (135600 Nm)
Maximum Rotary Speed: 90 RPM
Fluid Course: 4 inches (102 mm)
Maximum Flow: Up to 1000 gallons (3785 liters)/minute
Carriage Drive
Carriage System: Rack and pinion (6) pinion drive with adjustable force limiter
Maximum Thrust/Pullback: 1100000 pounds (500 tonnes)
Maximum Carriage Speed: 105 feet (32 m)/minute
Wrench Assembly
Weight: 7900 lbs (3583 kg)
Specifications DD-1100 RST Operators Manual
Specifications
Drill Pipe
Length (each section): Range II - 34 feet (10.4 m)
Protective Equipment
ZAPALERT™ system with ground stake
es!lok® Exit Side Lockout System
Controls
Radio Remote Transmitter for setup
DD-1100 RST Operators Manual Appendix
Appendix
Appendix
The appendix contains information that we believe the operator of the DD-1100 RST will find useful
to have available for reference during the operation of the DD-1100 RST. The information is placed
in the appendix because it is of general interest or it supplements the information in the body of the
manual.
Notes
NOTES:
DD-1100 RST Operators Manual Appendix A
Appendix A: List of Attachments
Appendix A
Attachment 1: Diesel Engine Manual
Attachment 2: es!lok® Exit Side Lockout system Operation & Safety Instruction Manual (American
Augers’ Part Number 6ER30000)
Attachment 3: ZAPALERT™ Electric Shock Alarm Instruction Sheet
Attachment 4: Cervis - Wireless SmaRT™ Engineered System Manual
Notes
NOTES:
DD-1100 RST Operators Manual Appendix B
Appendix B: Wiggle Steer and Wiggle Steer Codes
Appendix B
Wiggle Steer®
American Augers’ Wiggle Steer® system is a means to rotate and thrust the drill pipe in a back & forth
motion to better open the bore path during steering operations. It is recommended when using a mud motor
or a jetting head.
The Wiggle Steer system will rotate the drill pipe in the makeup (clockwise) direction while thrusting for-
ward. It will then rotate the drill pipe in the breakout (counter-clockwise) direction but will not thrust in the
breakout direction. This method reduces the breakout torque and should prevent the drill string tool joints
from parting down-hole. The speed of the Wiggle Steer™ rotation and thrust are controlled by the carriage/
rotary joystick(s).
Operating Instructions:
1. Stop rotary and thrust functions.

2. Set Rotary Makeup to a higher pressure than Rotary Breakout. This will prevent loosening the pipe joint
in breakout direction.
3. Rotate the drill pipe to midpoint of the desired direction.
• For steering up, rotate the drill pipe to 12:00 (as seen on a clock face).
• For steering to the right, set the drill pipe to 3:00.
4. Use the Wiggle Reset button to reset the counts to zero. Then set the Makeup Counts and Breakout
Counts as desired. This sets the number of counts in the clockwise and counter-clockwise direction
respectively.
5. Tap the Wiggle Steer button to turn Wiggle Steer On and Off.
6. Move Rotary Joystick to desired Makeup rotary speed.
7. Move Carriage Joystick in the thrust direction.
Appendix B DD-1100 RST Operators Manual
Appendix B: Wiggle Steer and Wiggle Steer Codes
STEP PRESS FUNCTION OR MODE COMMENTS
RATE MODE NOTICE THE “R” ON THE

DISPLAYS ROTARY RPM LEFT SIDE
COUNT MODE
NOTICE THE “A” ON THE
DISPLAYS PULSES FROM LEFT SIDE
ROTARY GEAR SENSORS
THE PIPE WILL WIGGLE
COUNT MODE
EQUALLY CW & CCW
RESETS THE COUNT TO ABOUT THIS “0”
“0” ORIENTATION
SET POINT 1 SETS DEGREE OF
MAKEUP DIRECTION ROTATION IN MAKEUP
PULSES TO COUNT DIRECTION
INCREASES DEGREE OF
INCREASES
SET POINT 1 ROTATION IN MAKEUP
DIRECTION
DECREASES DEGREE OF
DECREASES
SET POINT 1 ROTATION IN MAKEUP
DIRECTION
SET POINT 2 SETS DEGREE OF
BREAKOUT DIRECTION ROTATION IN BREAKOUT
PULSES TO COUNT DIRECTION
INCREASES DEGREE OF
INCREASES
SET POINT 2 ROTATION IN BREAKOUT
DIRECTION
DECREASES DEGREE OF
DECREASES
SET POINT 2 ROTATION IN BREAKOUT
DIRECTION
ASKS FOR CODE TO
REPROGRAM THE METER CONSULT FACTORY
DO NOT ADJUST
INDICATES PROGRAMMING
COMPLETE
READY TO START
WIGGLE STEER
DD-1100 RST Operators Manual Appendix C
Appendix C: Dual Power Units and ROOTS
Appendix C
The DD-1100 RST comes equipped with two power units. They are positioned with hydraulic connec-
tions facing opposite directions so the power unit trailer can be located on either side of the drill rig. Each
power unit is identified with a label located as shown in the drawing below.
POWER
UNIT A
POWER
UNIT B
powerunit -side1-inside-PU LABEL
IMPORTANT:
• If you are using only one power unit, proportional controls like the carriage and rotary will run at half
speed. Instructions in this manual are written assuming that the machine is operating using both power
units.
• Turn off all power to the system when making hydraulic and electrical connections.
The machine can be operated in one of several different power configurations:
• Both power units running with ‘A’ Primary

• Both power units running with ‘B’ Primary
• One unit running, powering through unused unit (either A or B)
• One unit running, one unit shut down and isolated (either A or B)
• One unit running, one unit removed (either A or B)
Changes must be made in hydraulic connections, valve settings, electrical and servo line connections.
Contact the factory for detailed instructions to run on one power unit.
Appendix C DD-1100 RST Operators Manual
Appendix C: Dual Power Units and ROOTS

Ball Valve Rules of Thumb
IMPORTANT:
• Ball valves in the wrong position can cause extreme damage to the power units.
• Secure ball valve handles with a locking device to prevent inadvertent change of position.
Open valve: handle is parallel to the hose

Closed valve: handle is perpendicular to the hose
Valve Closed
1451D-PwrSkid2-OOC Valve Closed
Valve Open
Valve Open
Appendix D: Tables Converting Pressure to Torque and Force
Appendix C
Converting Gauge Pressure to Rotary Torque
Hydraulic Gauge Rotary Torque Rotary Torque Rotary Torque

Pressure (PSI) Low Range 25 RPM Mid Range 40 RPM High Range 95 RPM
(Lbs-Ft) (Lbs-Ft) (Lbs-Ft)
600 2882 2078 1273

700 4804 3463 2121
800 6726 4848 2970
900 8647 6233 3818
1000 10569 7618 4667
1100 12490 9003 5515
1200 14412 10388 6364
1300 16333 11773 7212
1400 18255 13158 8061
1500 20177 14543 8909
1600 22098 15928 9758
1700 24020 17313 10606
1800 25941 18698 11455
1900 27863 20083 12303
2000 29784 21468 13152
2100 31706 22853 14000
2200 33628 24238 14849
2300 35549 25623 15697
2400 37471 27008 16546
2500 39392 28393 17394
2600 41314 29778 18243
2700 43235 31163 19091
2800 45157 32548 19940
2900 47079 33933 20788
3000 49000 35318 21637
3100 50922 36703 22485
3200 52843 38088 23333
3300 54765 39473 24182
3400 56687 40859 25030
Converting Gauge Pressure to Rotary Torque (Continued)
Hydraulic Gauge Rotary Torque Rotary Torque Rotary Torque

Pressure (PSI) Low Range 25 RPM Mid Range 40 RPM High Range 95 RPM
(Lbs-Ft) (Lbs-Ft) (Lbs-Ft)
3500 58608 42244 25879

3600 60530 43629 26727
3700 62451 45014 27576
3800 64373 46399 28424
3900 66294 47784 29273
4000 68216 49169 30121
4100 70138 50554 30970
4200 72059 51939 31818
4300 73981 53324 32667
4400 75902 54709 33515
4500 77824 56094 34364
4600 79745 57479 35212
4700 81667 58864 36061
4800 83589 60249 36909
4900 85510 61634 37758
5000 87432 63019 38606
5100 89353 64404 39455
5200 91275 65789 40303
5300 93197 67174 41152
5400 95118 68559 42000
5500 97040 69944 42849
5600 98961 71329 43697
5700 100883 72714 44546
Converting Gauge Pressure to Thrust/Pullback Force
Hydraulic Gauge 1st Gear 2nd Gear 3rd Gear 4th Gear
Pressure (PSI) 24 Ft/Min-Lbs Force 33 Ft/Min-Lbs Force 50 Ft/Min-Lbs Force 105 Ft/Min-Lbs Force
900 120263 90197 60131 30066

1000 142129 106597 71064 35532
1100 163995 122996 81997 40999
1200 185861 139396 92930 46465
1300 207727 155795 103863 51932
1400 229593 172195 114796 57398
1500 251459 188594 125729 62865
1600 273325 204994 136662 68331
1700 295191 221393 147595 73798
1800 317057 237793 158528 79264
1900 338923 254192 169461 84731
2000 360789 270592 180394 90197
2100 382655 286991 191327 95664
2200 404521 303391 202260 101130
2300 426387 319790 213193 106597
2400 448253 336190 224126 112063
2500 470119 352589 235059 117530
2600 491985 368989 245992 122996
2700 513851 385388 256925 128463
2800 535717 401788 267858 133929
2900 557583 418187 278791 139396
3000 579449 434587 289724 144862
3100 601315 450986 300657 150329
3200 623181 467386 311590 155795
3300 645047 483785 322523 161262
3400 666913 500185 333456 166728
3500 688779 516584 344389 172195
3600 710645 532984 355322 177661
Converting Gauge Pressure to Thrust/Pullback Force (Continued)
Hydraulic Gauge 1st Gear 2nd Gear 3rd Gear 4th Gear
Pressure (PSI) 24 Ft/Min-Lbs Force 33 Ft/Min-Lbs Force 50 Ft/Min-Lbs Force 105 Ft/Min-Lbs Force
3700 732511 549383 366255 183128

3800 754377 565783 377188 188594
3900 776243 582182 388121 194061
4000 798109 598582 399054 199527
4100 819975 614981 409987 204994
4200 841841 631381 420920 210460
4300 863707 647780 431853 215927
4400 885573 664180 442786 221393
4500 907439 680579 453719 226860
4600 929305 696979 464652 232326
4700 951171 713378 475585 237793
4800 973037 729778 486518 243259
4900 994903 746177 497451 248726
5000 1016769 762577 508384 254192
5100 1038635 778976 519317 259659
5200 1060501 795376 530250 265125
5300 1082367 811775 541183 270592
5400 1104233 828175 552116 276058
5500 1126099 844574 563049 281525
5600 1147965 860974 573982 286991
Converting Gauge Pressure to Breakout/Makeup Torque
Hydraulic Gauge Breakout Torque Makeup Torque

Pressure (PSI) Cylinder Completely Retracted (Ft-Lbs) Cylinder Completely Extended (Ft-Lbs)
100 7723 5118

200 15446 10235
300 23169 15353
400 30892 20471
500 38615 25589
600 46338 30706
700 54061 35824
800 61784 40942
900 69507 46060
1000 77230 51177
1100 84953 56295
1200 92676 61413
1300 100399 66531
1400 108122 71648
1500 115845 76766
1600 123568 81884
1700 131291 87002
1800 139014 92119
1900 146737 97237
2000 154460 102355
2100 162183 107473
2200 169906 112590
2300 177629 117708
2400 185352 122826
2500 193075 127944
2600 200798 133061
2700 208521 138179
2800 216244 143297
2900 223967 148415
3000 231690 153532
Notes
NOTES:
DD-1100 RST Operators Manual Declaration of Conformity
Sample Declaration of Conformity
Horizontal Directional Drill

DD-1100 RST
American Augers, Inc.
135 US Route 42
P.O. Box 814
West Salem, Ohio 44287
www.americanaugers.com
TEL: 419-869-7107 • 800-324-4930 (USA)
FAX: 419-869-7425
Always include machine serial number when ordering parts

Due to our continuing product improvement, machine specifications are subject to change without notice.
Original Instructions
Manual Part Number 50DD10100
Released January 2014 Revision 01

DD1100RS Operation and Safety Manual Rev 01

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DD-1100 RST

Operation & Safety

Machine Serial Number Locations

Driller’s Console - side view

Location of Machine Serial Number Plate

Machine Serial Number

Safety Awareness Program

Revision to Manual, Continued

Surface Examination ..................................................................................................26

Driller’s Console .............................................................................. 57

Backreaming and Pullback.........................................................................................80

Wrench Assembly.................................................................................................... 107

1. Auxiliary Power Unit 11. Front Foot

Manufacturer Identification Data

Machine Identification Data

Location of identification plate: See drawing on page 3.

• Only skilled and authorized personnel should be permitted to transport, operate

Use of Personal Protective Equipment

If personal protective equipment is not used, serious injury or death of

Warranty: General Conditions

Request for Service/Support

Response to Electrical Strike

• If you are on the machine, stay on it.

Response to a Gas Strike

Response to a Fiber Optic Strike

Response to a Communications Line Strike

Response to a Sanitary/Storm Sewer and Water Strike

Basic Safety Guidelines

Rig operation Mobile equipment operation

Exit Pit Construction

Before Starting the Machine

Material Handling Precautions; Crane Safety

Reaming and Installation Precautions

These practices can help increase safety when welding:

Electrocution Hazard. Personnel are at risk of serious injury or death if an

Electrocution hazard. Improperly grounded components may become

Bonding Cable Bonding Cable

Typical Bonding Scheme

Safety Features - ZAPALERT™

Safety Features - es!lok® Exit Side Lockout System

Safety Features - Fire Extinguisher

Whole body entanglement in Electrocution hazard. If beacon is

In case of an electric strike, do Keep hand and feet at a safe dis-

Diesel engine exhaust warning Read manual before lifting.

Explosion hazard. Call 811 Electrocution/explosion hazard.

Read operator’s manual. Use proper lockout and tagout

Hot surface. Do not touch. Body crush hazard from side.

Diesel Engine Stop Push Buttons (2) on Driller’s Console

To turn off both diesel engines:

Push emergency stop button located

Diesel Engine Stop Push Buttons on Typical Engine Control Panels

Safety Switches - Auxiliary Power Unit

Auxiliary Engine Stop Push Button on the Setup Box

Auxiliary Engine Stop Push Button on Remote Transmitter

Typical Location of Rotary/Carriage Disable

• Lock the carriage brake

Typical Location of Battery Switch

1. Hydraulic Oil Level Indicator 6. Engine Running Light

3. Throttle • Increase engine speed: turn control to the right

5. Key Ignition Switch • Stop: Turn the key straight up

6. Engine Running Light Light on: Auxiliary Power Unit engine is on

7. Battery Charging Light Light on: Battery not charging

9. Preheat Light Light on: Auxiliary Power Unit engine is preheating

1. Emergency Stop Button 5. Controller Setup Toggle Switch