I. Purpose & Scope

To safely and effectively provide instruction on the inspection and proper use of bore machines.

II. Definitions

Standard PPE – High Viz Garment, Hard Hat, Z-87.1 Safety Glasses, Gloves, Pants, Work Boots

III. Process

NOTE: Work instruction does not supplement the manual. For specific instructions for the exact model please refer to the owner’s manual.

A. Potential Hazards

• Electric Shock Hazard
• Moving Parts Hazard
• Burn Hazard
• Fire or Explosion Hazard
• Crushing Hazard
• Flying Objects Hazard
• Noise Hazard

B. PPE

• Standard PPE
• Hearing Protection
• Dielectric Boots and Gloves – Recommended

C. Inspection

1. Check track tension and condition before startup.
   • To adjust pump MPG into fitting until the length of the compressed spring.
   • Drive straight forward one machine length and check tension against.
2. Check fuel filter water separators before startup. Drain water at plug as needed.
3. Check air filter indicator before startup. Change air filter elements when air filter restriction indicator reaches the red zone.
4. Check engine oil at dipstick before startup. Check with unit on level surface. Add DEO at fill as necessary to keep oil level at highest line on dipstick.
5. Check coolant level, with engine cool, at sight glass of expansion tank before startup. Maintain coolant level at halfway point on sight glass. If low, add approved coolant to fill.
6. Check hydraulic hoses for leaks before startup.
7. Check hydraulic fluid level before startup. Maintain fluid level at halfway point on sight glass, when engine is off and fluid is cool. Add THF at hydraulic fluid fill.
8. Check fluid pump oil level at sight glass before startup. Add NDO at fill as needed to maintain level at halfway point on sight glass.
9. Check piston seals for signs of excessive leakage before startup. Replace if leakage becomes excessive.
10. Check control proximity switches before startup and clean or replace as needed.
    • To test turn on the ignition switch to the on position. Do not start engine.
    • Place metal object above target on each switch.
    • If yellow LED on switch lights, switch sensor is working.
11. Check pipe auto lubricator spray nozzle. Ensure that nozzle is free of obstructions and operates properly. Clean as needed.
    • To clean rotate handle to the upward, or cleanout, position.
    • Operate pump until obstruction is flushed.
    • Rotate handle to the downward, or spray position.
    • Clean nozzle guard. If necessary, pull handle/nozzle insert out of housing to clean with fine wire or solvent.
    • Check pipe auto lubricator TJC level. Change pail as needed.
    • Clean drilling fluid y-strainer. Ensure that strainer is free of debris.

D. Use

Lifting

1. This machine is not configured for lifting. If the machine must be lifting, load machine into a container or onto a platform appropriate for lifting.
2. Pipe Box lifting points are identified by lifting decals. Lifting at other points is unsafe and can damage machinery.
3. The pipe box has 7 lift pin block holes.
4. Use center hole to keep pipe box level for transporting pipe boxes and loading onto level drill frame.
5. Use side holes to angle box for loading onto angled drill frame.
   • Remove Pipe Box
     • Install lift block and adjust to match drill frame angle.
     • Remove pin form top of pipe box.
     • Remove back pin and two front pins.
     • Replace pin into top of pipe box.
     • Move pipe box off of drill frame.
   • Install Pipe Box
     • Move pipe box over pipeloader and lower into position. Ensure pipe box is moved all the way to the front.
     • Install back pin and two front pins.
     • Use pin from top of pipe box to tighten threaded caps.
     • Replace pin into top of pipe box.
     • Remove lift block.
     • Raise pipe with lifter on unit.
     • Remove bottom support pins from both ends of pipe box. Store support in holes on top of pipe box.
6. Tiedown points are identified by tiedown decals. Securing to trailer at other points can damage machinery.
7. Loop a transport chain around each tie down point.

Drilling

1. Start system by inserting the key and turning the key clockwise.
2. Run engine at low throttle for 5 minutes.
3. Turn on drilling fluid.
4. Visually check for drilling fluid flow.
5. Turn drill bit to starting position.
6. Slowly move carriage forward.
7. Drill first pipe as straight as possible.
8. Monitor gauges.
9. Record bore path.
   • Locate the drill head every half-length of pipe.
   • As the job is complete, record the actual data for each drill pipe. List pitch and depth of each joint and a brief description of the procedure.
   • Draw a simple sketch of the site and record the depth and rough location of pullback.
10. Add pipe by pressing the top of the drilling unit throttle switch until engine is at full throttle.
11. Enable automated pipeloader system
    • To Add Pipe
      • Open front wrench and retract shuttles for add pipe function to work.
      • Press top of add pipe/manual/remove pipe switch. Green control cycle light will come on.
      • Grippers will open, pipe will be lowered, and then green control cycle light will flash.
    • Remove Pipe
      • Open front wrench and retract shuttles for remove pipe function to work.
      • Press bottom of add pipe/manual/remove pipe switch. Green control cycle light will come on.
      • Grippers will open, pipe will be lowered and lifted off shuttles, and then green control cycle light will flash.
12. Break joint at SaverLok body.
    • Manual Pipeloader Controls
      • Clamp pipe when joint is between wrenches. Always clamp on the larger diameter areas on either side of the tool joint face.
      • Locate drill head.
      • Engage front wrench until pipe is clamped and pressure develops.
      • Slowly move carriage back until movement stops.
      • Slowly rotate spindle counterclockwise. Carriage will move back as threads separate.
      • After threads are fully separated, stop rotation and move carriage to back of frame.
    • Automated Pipeloader Control
      • Clamp pipe when joint is between wrenches. Always clamp on the larger diameter areas on either side of the tool joint face.
      • Locate drill head.
      • Engage front wrench until pipe is clamped and pressure develops.
      • Slowly move carriage back until movement stops.
      • Slowly rotate spindle counterclockwise. Carriage will move back as threads separate.
      • After threads are fully separated, stop rotation and move carriage to back of frame.
      • While carriage is moving, green control cycle light will come on. Grippers will grip, pipe will be lubed, and then green control cycle light will flash.
13. Load Pipe.
    • Manual Pipeloader Controls
      • Make sure shuttle stop is properly positioned on pipeloader and lift arms are completely lowered.
      • Close grippers.
      • Lube upper pipe threads.
      • Move pipe to spindle and lube lower threads.
      • Raise pipe in box.
    • Automated Pipeloader Control
      • Make sure shuttle stop is properly positioned on pipeloader.
      • When carriage is moved to back of drill frame, press RESUME. Green control cycle light will come on.
      • Pipe will be moved to spindle, front threads will be lubed, pipe in box will be lifted, and then green control cycle light will flash.
14. Connect pipe to SaverLok Body.
    • Manual Pipeloader Controls
      • Always rotate clockwise unless breaking pipe joint. Rotating counterclockwise will separate joints.
      • Move carriage forward until SaverLok body meets pipe.
      • Continue to slowly advance carriage and rotate spindle until pipe threads tighten.
      • Relax grippers.
    • Automated Pipeloader Control
      • Always rotate clockwise unless breaking pipe joint. Rotating counterclockwise will separate joints.
      • Move carriage forward until SaverLok body meets pipe.
      • Continue to slowly advance carriage and rotate spindle until pipe threads tighten.
      • Press RESUME. Green control cycle light will come one.
      • Grippers will relax and then green control cycle light will flash.
15. Connect new pipe.
    • Manual Pipeloader Controls
      • Slowly move carriage forward and rotate spindle until pipe threads tighten.
      • To fully torque joint, slowly rotate pipe until spindle stops turning.
      • Open wrench.
      • Open grippers fully.
      • Retract shuttles against shuttle stop.
      • Lower pipe lifters.
    • Automated Pipeloader Control
      • Slowly move carriage forward and rotate spindle until pipe threads tighten.
      • To fully torque joints, slowly rotate pipe until spindle stops turning.
      • Open wrench.
      • Press RESUME. Green control cycle light will come one.
      • Grippers will open, shuttles will retract, pipe lifters will lower, and then green control cycle light will flash.
16. Press and hold quick fill fluid pump switch until pipe fills and fluid pressure begins to rise.
17. Rotate spindle.
18. Slowly move carriage forward. Adjust rotation speed control according to bit size and soil conditions.
19. Engage and set cruise control as desired.
20. Monitor gauges.
21. Locate drill head with tracker at least every half-length of pipe.
22. Drill remaining pipes in pipe box and correct direction as necessary.
23. Add additional drill pipe to empty box to complete bore.
    • Lower shuttle guard and shuttle cover.
    • Move row select to fifth row.
    • Move shuttles out fully.
    • Press top of shuttle lockout switch to prevent shuttle operation.
    • Remove hold pins on each shuttle and rotate auxiliary pipe loaders into position.
    • Remove pipe stop (stored on outside of drill frame) and attach to front of pipe box.
    • Load a pipe in auxiliary pipe loaders and rest it against pipe stop.
    • Press bottom of shuttle lockout switch to allow shuttle operation. Move at least 10 feet away from drill.
    • Move auxiliary pipe loaders under row 5.
    • Raise pipe into row 5.
    • Move shuttles all the way out.
    • Repeat steps to load more pieces of pipe into row 5.
    • Move pipe to pipeloader grippers.
      • Raise last pipe into row 5.
      • Move shuttles out.
      • Lower pipe into front grippers.
    •  Before operating pipeloader:
      • Close both auxiliary pipe loaders.
      • Remove pipe stop and store it on shuttle guards.
      • Step away from drilling unit.
24.   Surface drill head
    • Guide drill head to target pit or up through surface. Make all bends gradual.
    • Clean area around exit point.
    • Turn fluid flow control to off position as soon as drill head emerges.
    • Allow tracker operator to turn off tracker or use DrillLok to disable drilling unit thrust/pullback and rotation hydraulics. Tracker operator waits at least 16 seconds for green light to enter pit and change tools.
    • Clean drill head especially around threats.
    • Disconnect EZ-Connect joint or use quick wrench to remove drill head. Keep threads clean.
      • Attach quick wrench in either the join or break position.
      • Unbolt vise and place jaws around pipe.
      • Bolt jaws of vise together.
      • Place jaw around pipe, transition sub, or downhole tool.
      • Pin handles to wrench jaws. Be sure handles are both up.
      • Attach pivot nuts to wrench handles so that screw drive handle is over joint.
    • To Join
      • Scribe straight line across joint on both sides of separating line.
      • Scribe second line on moveable side of joint in the opposite direction of tightening action away from the first line in the appropriate distance required.
      • turn handle until second line meets first.
      • Turn handle opposite direction two turns to relieve pressure.
      • Remove quick wrench components.
    • To Break
      • Turn handle until joint is broken.
      • Turn handle opposite direction two turns to relieve pressure.
      • Remove quick wrench components.

Backreaming

1. Assemble backream stream.
   • Select backreaming devices.
   • Determine fluid rate requirements and install appropriate nozzles to provide sufficient flow.
   • Attach backreamer to beacon housing if tracking backream.
   • Install beacon following beacon instructions for battery replacement and beacon positioning.
   • Install beacon housing lid.
   • Follow beacon instructions to check beacon operation.
   • Follow tracker instructions to calibrate beacon.
   • Use quick wrenches to attach transition sub to drill pipe string.
   • Use quick wrenches to attach backreamer/beacon housing assembly to transition sub.
   • Attach additional pullback devices or product to end of backreamer/beacon housing assembly.
2. Start drilling unit and adjust throttle.
3. Set drilling flow. Check that fluid flows through all nozzles.
4. Without rotating, slowly pull back until reamer contacts bore hole opening. Do not lodge reamer in hole.
5. Begin slow rotation and pullback.
6. Increase drilling fluid flow and rotation as the backream string enters the ground.
7. If tracking backream, tracker operator may continue tracking when the backream string is no longer visible.
8. Remove extra drill pipe from pipe box to complete backream.
   • Unload all drill pipe loaded with auxiliary pipe loaders. Pipe in fifth row of pipe box can be unloaded only when all other rows are empty.
   • Lower shuttle guard and shuttle cover.
   • Ensure fifth row is selected.
   • Move shuttles out fully.
   • Press top of shuttle lockout switch to prevent shuttle operation.
   • Pull and hold pins on each shuttle and slide out auxiliary pipe loaders.
   • Remove pipe stop (stored on outside of drill frame) and attach to front of pipe box.
   • Press bottom of shuttle lockout switch to allow shuttle operation. Move at least 10 feet away from drill.
   • Raise pipe in row 5.
     • Move shuttles in.
     • Lower pipe to auxiliary pipe loaders.
   • Move shuttles out.
   • Press top of shuttle lockout switch to prevent shuttle operation.
   • Remove pipe form auxiliary pipe loaders and store properly.
   • Repeat steps to unload remaining added drill pipe.
   • After all added drill pipe is unloaded with auxiliary pipe loaders.
     • Close both auxiliary pipe loaders.
     • Remove pipe stop and store it on shuttle guard.
   • Press bottom of shuttle lockout switch to allow shuttle operation. Move at least 10 feet away form drill.
   • Finish loading remaining drill pipe into row 5 using standard procedure.
9. Remove remaining pipe to complete backream.
10. Remove pullback device.
    • Remove Pipe
      • Enable automated pipeloader system.
      • Stop carriage when alignment pin becomes visible behind rear wrench.
      • Clamp pipes.
      • Break front joint.
        • Turn rear wrench counterclockwise to break joint.
        • Disengage rear wrench and rotate wrench clockwise.
      • Grip pipe.
        • Manual Pipeloader Controls
          • Open grippers
          • Lift pipe of shuttles
          • Extend shuttles to spindle position.
          • Close grippers. Leave grippers loose enough to allow pipe to rotate.
          • Lower filters.
        • Automated Pipeloader Control.
          • Press RESUME. Green control cycle light will come on.
          • Shuttles will extend, grippers will grip fully and relax open, pipe lifters will lower, and then green control cycle light will flash.
      • Separate front joint.
        • Slowly rotate spindle counterclockwise and move carriage back to separate pipe.
        • Continue to move carriage back until pipe is properly positioned in rear wrench.

Shut Down Unit

1. Stop track movement.
2. Lower drill frame and stabilizer to the ground.
3. Run engine at low throttle for 3 minutes to cool.
4. Turn ignition switch to STOP.
5. Remove key.

E. Maintenance

1. Check pipe auto lubricator TJC level and change pail as needed.
   • To change pail remove wingnuts and bolts attaching base ring to pail cover.
   • Rotate base ring slightly to clear hooks on cover and remove pail from cover.
   • Remove follower plate from empty pail and install into new pail. Press firmly on follower plate until TJC comes up in center opening.
   • Remove base ring from empty pail and install onto new pail.
   • Install pail into place over pump dip tube. Use hooks on cover to support base ring.
   • Install bolts and wingnuts.
   • Remove cap from discharge tree on pump. Operate pump until discharged TJC is free of air pockets.
   • Replace cap.
2. Check pipeloader inserts at indicated areas for wear. Flip gripper inserts for longer wear or replace as needed.
3. Check pipe guide inserts for wear. Rotate inserts for longer wear, or replace as needed.
4. Check ball valve for leaks. Tighten stem packing as needed.
5. Check track support slide pads. Replace as needed.
6. Check wrench jaw inserts for wear and replace as needed.
7. Change air filter when air filter service indicator reaches the red zone.

F. Live Line Contact

1. Immediately stop work. 
2. Treat equipment, attachments and ground as energized. 
3. Warn people nearby that an electric strike has occurred. 
4. DO NOT exit equipment and stay inside cab while contact or arcing is occurring.
5. Ensure equipment is barricaded.
6. If there is an immediate hazard (i.e. fire hazard) that requires the exiting of equipment employee shall jump out of equipment with both feet together, landing on the ground. 
7. Employee shall than shuffle away from equipment, not walk or run, taking small steps and feet together to minimize voltage difference in the ground until they reach a safe location. 

IV. Reference Documents

Maintenance Log	JT9
Lockout Tagout	JT9
Maintenance Log	JT25
Lockout Tagout	JT25
Maintenance Log	JT30
Lockout Tagout	JT30
Maintenance Log	JT922
Lockout Tagout	JT922
Maintenance Log	JT3020
Lockout Tagout	JT3020
Operation Manuals	All Types