Grundodrill 4x Manual - TT Technologies, Inc.
Contents
1. Sale Seon don ce are ane ahead oe ane s 11 Transportation A Loading Onto a Trailer ALAC SA ade a 11 B Unloading From a a keene 12 Jobsite Preparation A General 12 B Inspection of Jobsite 2 eR 96 09 dae be 12 C Preparation of the Jobsite 12 D Setting Up the Jobsite accede 22662 13 E Bore Planning sis 14 TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com 7 7 Operation A Safety Instructions as to 16 B Driving to Operation Site 16 C Set up of Safety Alert Package 18 D Auger Staking Drill in Place 20 E Preparing Sonde Housing 21 F Connecting the Bentonite System 22 G Bore ModE ee eed 22 Trouble Shooting Trouble Shooting i ss emm2. ART RI U 10249 175 58 FOLLOWER McGILL CF 175 SB 980994036 BUSHING MCMASTER CARR 980994036 DRI U 20050 U 10578 DRI U 10398 U 10399 DRI U 10401 0405 0404 rollpin25X112 0400 RI U 10142 1030 450 WIVEL 6 RI U 10577 PINION GEAR 5 12 1_75 50 12 mm REATHER RI U 10293 2 2 2 2 20 2 2 2 2 le lela x M v lt cce 9 3a 5 8 8 ww 2 1 m 2 1 LI L2 L 1 m 1 4 m 8 sd L3 4 i TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com R 4X GRUNDODRILL WRENCH ASSEMBLY TEM NO GTY PART DESCRIPTION IDR U 10244 WRENCH FRAME FIXED DRI U 10373 CYLINDER ROTATION IDRI U 10516 08 10386 IDRI U 10246 ____ WRENCH FRAME PIVOT PIN CYLINDER CLEVIS 308 0100 PIN _ PN 24 4 6 6 DRI U 10246 7 C DRLU IHHCS MI2X175X25mm DR U I074 48mm 2 DRLU 10378 BEARING 5 5 GF 4447 32 MODIFIED 2 DR U10277 ___ __ ________________ DRLU 10422_ CONNECTOR ______________ SH 275 RETANING RING ROTOR CLIP SH 275 nmm 9 10 4 12 9112 1 75x25 13 4
3. TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com 46 J 4X GRUNDODRILL SUB ASSEMBLY N gt 3 N NI N N gt TT Technologies Inc PART NO FF1868T0808S FF1852T0608S DRI U 10717 DRI U 10806 DRI U 10737 DRI U 10808 DRI U 10809 DRI U 10810 DRI U 10811 DRI U 21500 FF2098T0606S DESCRIPTION FITTING FITTING HOSE ASSEMBLY HYDRAULIC LINE ASSEMBLY HOSE ASSEMBLY HYDRAULIC LINE ASSEMBLY HYDRAULIC LINE ASSEMBLY HYDRAULIC LINE ASSEMBLY HYDRAULIC LINE ASSEMBLY VALVE HOT OIL SHUTTLE FITTING 1 800 533 2078 1 630 851 8200 www tttechnologies com K 4X GRUNDODRILL SUB ASSEMBLY ITEM NO 7 88 89 90 91 93 94 95 96 97 TT Technologies Inc Q N N NIN N NIN N gt gt PART NO DRI U 20030 DRI U 10537 DRI U 10536 202702 6 4S DRI U 10744 DRI U 10743 DRI U 10742 DRI U 10741 DRI U 10739 DRI U 10740 DRI U 10749 2096 45 FF2032T0404S 2240 08085 DRI U 10750 2018 08085 FF2114T0808S 2244 08085 DRI U 10751 DESCRIPTION JOY STICK CONTROLLER PLATE UPPER INSTRUMENT PLATE LOWER INSTRUMENT FITTING HOSE ASSEMBLY HOSE ASSEMBLY HOSE ASSEMBLY HOSE ASSEMBLY HOSE ASSEMBLY HOSE ASSEMBLY HOSE ASSEMBLY FITTING FITTING FITTING BULKHEAD HOSE ASSEMBLY FITTING FITTING FITTING HOSE ASSEMBLY 1 800 533 2078 1 630 851 8200 www tttechnologies com 47 48 L
4. 4 8 2 16 muc 19 20 0 3_ I 22 24 IDR U 10531 GUIDE 4 m __________________ 26l 28 4190170 50 ___ LINCH PIN MCMASTER CARR 0 wt r 1 p 20666 BARNG i DRHU 10483 PLATE BUSHING KEEPER _ _ _ 1 DREU _ 2 0 2168 N TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com 55 5 4X GRUNDODRILL LOOP FLUSHING MANIFOLD JTEMNO QTY PARTNO DESCRPTON _____ DSCH XGN 56 TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com T 4X GRUNDODRILL CUSHION VALVE BLOCK ITEM QTY PART NO 1020823 BLOCK CUSHION VALVE 2 I PF S3A 00 _ 3 I RPEC LAN _ 5 2 TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com U 4X GRUNDODRILL CONTROL PANEL 11 1138091021 ENGOSURECONOLE 2 1138020930 JOYSTKKCONTROUER DRI U 22050 4 1138010936 PLATE LOWERINSTRUMENT 51 1138991097 PLATE UPPERINSTRUMENT 6 7 1 DRU2260 GAUGE BENTONT _ 1I0 389 of 1 QoDQ0 EMERGENCYSTOPOPERATOR 1236 _ 12301 CONNETORMOK TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com 4X GRUNDODRILL MAIN VALVE M
5. Gradual Right Turn Sharp Right Turn Gradual Left Turn Sharp Left Turn Z Z Z XI 5 Setting Up the Bore Rig for Operation 1 Drive the bore rig to the operating entry position Figure 20 2 Raise rear stabilizer to the height desired for entry angle Using rear stabilizer toggle located on lower panel Figure 21 3 Lower boom until boom plate is lying firmly on the ground Using Boom toggle on lower panel Figure 21 Figure 20 Operating Entry Position Figure 21 Lower Panel C SET UP OF SAFETY ALERT PACKAGE After the boring rig is in place the safety alert package for the boring rig must be set in place before boring or staking down of rig TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com 1 Take the grounding rod connected to the zap alert system and unwrap cord from the rig and extend the cord out Figure 22 2 Push the grounding rod into the ground approximately five to six feet away from the boring rig and perpendicular to the boring path Figure 23 electrical strike has been made the siren will continue to sound as long as current is passing into the machine and soil If you attempt to reset the zap alert the siren will not stop until the current has stopped Grounding Figure 22 Zap Alert amp Grounding Rod Figure 23 Grounding Rod A WARNING Do not stop the siren by resetting the zap alert until you have confirmed that the electri
6. aa a ies 28 Warranty Information A rucu MP 31 Maintenance A Service Intervals 32 B Lubrication Products and Oil Table 33 C Jaw Removal 4 Replacement 34 Appendices A Vise Control Block 35 B Overall Assembly 36 C Sub Assemblies A M 4 38 D Sub Assembly 39 E 1 40 Sub Assembly 1 41 Sub Assembly 1 42 1 Sub Assembly re ed ee ek 43 Sub Assembly 44 J Sub Assembly 46 gt Sub Assembly e hama 6 49 8 86 ua ___ 47 L S b Assembly 48 Sub Assembly 1 50 Sub Assembly 1 51 Sub Assembly L 52 P
7. 4X GRUNDODRILL SUB ASSEMBLY 1 TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com PART DESCRIPTION DRI U 10389_ CYLINDER BOOM TILT DRI U 10390_ CYLINDER REAR STABILIZER DRI U 10703 HOSE ASSEMBLY DRI U 10704 HOSE ASSEMBLY DRI U 10705 HOSE ASSEMBLY DRI U 10706 HOSE ASSEMBLY 2041 4 45 FITTING BULKHEAD DRI U 10707 HOSE ASSEMBLY DRI U 10708 HOSE ASSEMBLY FF1868T0404S FITTING DRI U 10710 HOSE ASSEMBLY DRI U 10709 HOSE ASSEMBLY FF1852T0406S FITTING 202702 4 4s FITTING DRI U 10713 HOSE ASSEMBLY 203102 4 4S FITTING 4 4C4OMXS FITTING DRI U 10714 HOSE ASSEMBLY DRI U 10715 HOSE ASSEMBLY DRI U 10817 HYDRAULIC LINE ASSEMBLY FF1852T0608S FITTING DRI U 10802 HYDRAULIC LINE ASSEMBLY DRI U 10803 HYDRAULIC LINE ASSEMBLY DRI U 10818 HYDRAULIC LINE ASSEMBLY DRI U 10804 HYDRAULIC LINE ASSEMBLY DRI U 10805 HYDRAULIC LINE ASSEMBLY FF1852T0812S FITTING DRI U 10717 HOSE ASSEMBLY DRI U 10718 HOSE ASSEMBLY DRI U 21600 VALVE CUSHION 2062 4 45 FITTING 2071 4 45 FITTING DRI U 10745 HOSE ASSEMBLY 102 DRI U 10746 HOSE ASSEMBLY 104 DRI U 10748 HOSE ASSEMBLY N N 3 N 3 gt 2 2 2 9 2 2 2 2 1 2 8 2 2 2 1 1 3 2 2 1 2 1 2 2 TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com 27 28 29 48 91 50 M 4X GRUNDODRILL SUB ASSEMBLY J PART NO FF1852T0808S FF1868T0808S 2027
8. 4X is 96 2 Launch Area amp Exit Pit Launch area and exit pit should be selected to provide optimum drilling conditions The launch area needs to be located where there is enough space to accommodate all drilling equipment and machinery and remain a safe distance from vehicle and pedestrian traffic The launch area should also accommodate the drilling mud system 3 Minimum Set back SB Because steering is dependent on the bending of the drill pipe the drill needs to be positioned far enough back to accommodate the bending of the drill stem The set back distance is the length from entry to horizontal To determine the necessary minimum set back refer to the chart and drawing found on the next page 4 Minimum Depth D Minimum depth is another consideration when positioning the Grundodrill 4X machine Refer to the chart and drawing found on the next page to determine the minimum depth requirement for the specific bore path 5 Pitch or Angle EP or EA The entry pitch or entry angle at which the drill stem enters the ground directly affects the depth and length of the bore path The entry pitch or entry angle is the Grundodrill 4X machine slope compared to level ground Refer to the chart and drawing found on the next page to determine the entry pitch or entry angle requirement for the job TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com GRUNDODRILL 4X ENTRY PITCH 5 AND DEPTH SPEC
9. Inspection Jobsite Planning Preoperational setup Proper setup and operation B INSPECTION OF JOBSITE Can the jobsite be easily reached At which position is the starting point of the bore best suited Where and how will the working pits be dug Can the entire bore be done without any obstacles foundations pipes steel Where will the bentonite system be located Will the bentonite system hoses and electrical reach the boring unit Will the bentonite system be refillable where and how it is positioned Can the bore head be located in the length of the bore What are the soil conditions C PREPARATION OF THE JOBSITE s there a complete location drawing of all buried cables and pipes Have you called the local One Call for utilities Have all buried cables and pipes been located and exposed if needed by the proper services Have all required permits been obtained TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com What will the bore path be What will be the entry position Has the water source for the Bentonite system been identified s the pipe on site What is the outside diameter of the pipe Do you have the correct size backreamer to pull in the O D of the product pipe What are the individual lengths of product pipe Does the contractor have the proper equipment to connect pipe fusion machine H
10. com TT Technologies Inc 38 D 4X GRUNDODRILL SUB ASSEMBLY ITEM NO 55 72 73 74 75 76 77 79 80 81 TT Technologies Inc NA BRM NIN m NIN N N N m PART FF1852T06010S FF1857T0808S FF1852T1008S DRI U 10731 DRI U 10732 DRI U 10733 DRI U 10734 DRI U 10735 DRI U 10736 FF1852T1010S 8 1 2 F5OF 005 02M02A04B0AM 1 FF2032T0808S DRI U 10749 FF2098T0808S DESCRIPTION FITTING FITTING FITTING HOSE ASSEMBLY HOSE ASSEMBLY HOSE ASSEMBLY HOSE ASSEMBLY HOSE ASSEMBLY HOSE ASSEMBLY FITTING FITTING SWIVEL FITTING HOSE ASSEMBLY FITTING 1 800 533 2078 1 630 851 8200 www tttechnologies com 39 40 4X GRUNDODRILL SUB ASSEMBLY ITEM NO N N rm NIN TT Technologies Inc PART NO FF1852T0404S FF1868T0404S DRI U 10724 DRI U 10723 DRI U 10725 DRI U 10726 DRI U 10727 DRI U 10728 DESCRIPTION FITTING FITTING HOSE ASSEMBLY HOSE ASSEMBLY HOSE ASSEMBLY HOSE ASSEMBLY HOSE ASSEMBLY HOSE ASSEMBLY 1 800 533 2078 1 630 851 8200 www tttechnologies com F GRUNDODRILL SUB ASSEMBLY ITEM NO TT Technologies Inc PART NO FF1852T0404S FF1852T06010S DRI U 10719 DRI U 10720 DRI U 10721 DRI U 10722 DESCRIPTION FITTING HOSE ASSEMBLY HOSE ASSEMBLY HOSE ASSEMBLY HOSE ASSEMBLY HOSE ASSEMBLY 1 800 533 2078 1 630 851 8200 www tttechnologies com 41 G 4X GRUNDODRILL SU
11. emergency stop button isn t pushed Add diesel fuel if needed Replace Fuel filter Replace F3 fuse Replace control relay See engine cranks but smokes section Let the engine cool and make sure it has the correct oil pressure Replace the fuel filter Replace the fuel filters Replace the air filter Replace damaged hoses Replace the fuel pump a Clean radiator air inlet area Let engine cool Check coolant level b Make sure to operate within the pressure specs Thrust 3600 PSI Rotation 4200 PSI 1 800 533 2078 1 630 851 8200 www tttechnologies com 7 Engine cranks but smokes a Check for high quality and grade Use high quality and grade of excessively at cold startup or won t start 8 No Hydraulic and hydrostatic operation 9 Hydraulic light comes on 10 Thrust and rotation fail to work or work slowly 11 Thrust or rotation fail to work or work slowly of fuel Operator not using Glow Plugs One or more glow plugs failed Key switch failed K2 control relay failed Basic engine problem a Check for oil in the tank b Check the suction screen for damage c Check the suction hose for damage Failed pump drive Failed hydraulic pump drive coupler Ambient temperature below 40 F Hydraulic filter is restricted Wrong hydraulic oil was used Probable loss of charge pressure Check for braided lines that are damaged c Does the vice
12. machine while driving DO NOT RIDE ON BORE RIG Do not drive over any hydraulic hoses bentonite hoses or control cables When driving bore rig off or on trailer refer to safety instructions in chapter 5 2 Control Steps Prior to Starting Check the coolant level Figure 14 Check the oil level Figure 15 Check the diesel level Figure 16 TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com Figure 15 Check Oil Level Figure 16 Check Diesel Level 3 Starting the Motor 1 Turn key to right to position 4 to start Figure 17 2 Release key as soon as engine fires key will be in position 3 Position 1 Preheat Glow Plugs Only necessary for cold starting Position 2 Off Position 3 On 4 Position 4 Start Figure 17 Starting the Motor 4 Driving Bore Rig Drive bore rig to operations site using the remote drive control While driving bore rig adhere to all prior safety instructions For remote drive control switch positions refer to chapter 4 D TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com 17 18 Figure 18 Remote Drive Control Figure 19 Remote Drive Control To drive boring move toggles to desired direction and then press Master Button and hold to put boring rig into motion Figure 18 To stop boring rig just release Master Button Toggle Steering Controls Left Track Right Track Action Forward Neutral
13. person in charge SAVE THESE INSTRUCTIONS TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com Only qualified and trained personnel should out operation of the machine Before starting the machine all safety requirements must be fulfilled Designated personnel should thoroughly study the operating manual including all safety instructions and warnings prior to the use of the machine New operators and operators in training should work under constant supervision of a qualified operator only The GRUNDODRILL is manufactured to the current technical safety relevant regulations Nevertheless the use of the machine may represent a danger to the health and life of users or third parties Always ensure that you pay particular attention to warnings safety labels and instructions AWARNING Read Operators Manual Before starting the machine fulfill all safety related requirements All personnel should thoroughly read this operating manual Follow all safety instructions concerning safety and possible danger Do not modify or remove the safety devices or warning labels of this machine Keep all labels regarding safety and possible danger on the machine in good readable condition Special care is required before and during the safety check Every crew member should fully understand the safety measures required for the operation and should be capable of following these regulations individually Call B
14. reaming When the bore head reaches the target location and the sonde housing is exposed change of tooling is required Note Shut off boring rig before making any tooling changes Danger Stay away from any turning stem contact may and can cause injury or death If the pilot bore is larger than the product pipe remove the sonde housing and replace with a swiveled piping eye for back pull When the pilot bore needs to be expanded to a larger diameter than that of the pilot bore a change of tooling is than required The sonde housing is exchanged for a backreamer When all tooling is changed and all personnel are clear of the tooling attachment start engine of bore rig Bentonite system must be running and connected Drill Fluid switch needs to be in auto position Flip auto vice select to the pull back position Cycle Smart Vice button by pressing four times until both vices are open and bentonite fluid is flowing Figure 47 Using the joystick rotate clockwise and thrust in drill stem until spindle hits the head cushion Figure 48 RON Smart Vice Cycle Button Rotate clockwise Rotate clockwise amp thrust forward Joy stick Thrust forward Figure 47 Cycle Smart Vice Button Figure 48 Using Joystick Rotate by Pressing Four Times Clockwise and Thrust in Drill Stem 6 Press the Smart Vice cycle button Figure 49 Causing front vice to lock
15. shuttle valve in failed circuit Failed joystick control d Replace joystick control Failed hydrostatic pump e Replace hydrostatic pump TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com 29 30 12 All hydraulic functions fail to work Except the vice and tracks NOTE Functions will work if you hold a manual operation vice function simultaneously 13 All hydraulic functions work except the vice is slow and the tracks only have low speed 14 Any independent hydraulic function doesn t work Boom stabilizer etc 15 The automatic vice doesn t work Smart Vice 16 The work light doesn t work 17 The strobe light doesn t work 18 The horn doesn t work TT Technologies Inc Failed Hydraulic solenoid one dump valve Failed relief valve no one Failed hydraulic pump no one Failed wire or connection Failed hydraulic solenoid two dump valve Failed relief valve no two Failed hydraulic pump no two Failed wire or connection Failure of the associated switch Failure of the associated hydraulic solenoid valve Failed wire or connector The Mode selector switch is set to manual operation The operator isn t using the cycle button correctly F fuse failed Hydraulic system failure Failed wire or connector The jaws are worn a The light element failed replace b F fuse failed replace d e Failed K relay repla
16. training should be working under the constant supervision of a qualified person Personnel operating the GRUNDODRILL should have sufficiently studied the operating manual SAVE THESE INSTRUCTIONS TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com OWNER AND OPERATOR RESPONSIBILITIES The machine owner is obligated to restrict the operation of the machine to operators that Have been made aware of basic regulations for work safety and accident prevention and have been instructed in the correct operation of the machine Have read and fully understood the operating manual particularly the chapter on safety Have been trained and instructed and whose responsibilities as to operating setting up maintaining and repairing the machine have been clearly defined The operating personnel should carry out regular checks to verify safety conscious use of the machine The operating personnel should Be qualified and trained in the respective field of application and should be familiar with the handling of the machine Be informed at regular intervals about difficulties dangers and special procedures for operation of the machine C TRAINING REQUIREMENTS To attain maximum knowledge about the use of this system the operators should be trained by TT Technologies personnel Only trained and qualified personnel are permitted to work on the machine Responsibilities of the s
17. 02 4 45 DRI U 10718 DRI U 10744 DRI U 10746 DRI U 10747 8 P5ON S DRI U 10753 N NIM m 3 1 TT Technologies Inc CUT AWAY FOR ILLUSTRATION DESCRIPTION FITTING FITTING FITTING HOSE ASSEMBLY HOSE ASSEMBLY HOSE ASSEMBLY HOSE ASSEMBLY FITTING HOSE ASSEMBLY 1 800 533 2078 1 630 851 8200 www tttechnologies com N 4X GRUNDODRILL SUB ASSEMBLY ITEM NO PART NO FF1868T0404S DRI U 10262 2062 4 4S DRI U 10747 DRI U 10748 DESCRIPTION FITTING CYLINDER STOP ASSEMBLY FITTING HOSE ASSEMBLY HOSE ASSEMBLY TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com 51 O 4X GRUNDODRILL SUB ASSEMBLY L ITEM NO PART 1015 0 3 4501 16x16 HOSE_16 52 TT Technologies Inc DESCRIPTION SCREEN ASSEMBLY FITTING HOSE 1 800 533 2078 1 630 851 8200 www tttechnologies com P 4X GRUNDODRILL SUB ASSEMBLY FF1852T0812S FF1861T0808S FF2098T0808S HH7414A12M8RBL 12 8 F50G5 S DRI U 10813 DRI U 10814 DRI U 10815 gt 0 DESCRIPTION FITTING FITTING FITTING HYDRAULIC FILTER ASSEMBLY FITTING HYDRAULIC LINE ASSEMBLY HYDRAULIC LINE ASSEMBLY HYDRAULIC LINE ASSEMBLY TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com 53 54 4X GRUNDODRILL DRILL HEAD ASSEMBLY
18. 10267 DRI U 10534 DRI U 10268 LOUVRE PANEL ROD WIPER BRACKET ROD WIPER MOUNT DRI U 10535 DRI U 10485 DRI U 10486 GROMMET BRACKET LOCATOR PIN PIN LOCATOR nut375 WASHER_375_FLAT DRI U 10270 NUT 3 8 16 UNC WASHER 3 8 FLAT SEAT STOP DRI U 10497 DRI U 10496 DRI U 10498 PIN CYLINDER PIN CYLINDER PIN CYLINDER DRI U 10272 DRI U 10269 DRI U 10273 COOLER WELDMENT BRACKET COOLANT LEVEL BEARING BLOCK ASSEMBLY DRI U 10502 DRI U 10490 9376K122 PLATE RADIATOR BRACE SLIDE PLUG ISOLATOR DRI U 10503 DRI U 10276 DRI U 10274 CLAMP CHANNEL COVER WRENCH VALVE MUFFLER WELDMENT 98404A790 DRI U 10417 DRI U 10279 PIN RING GRIP SELF LOCKING 3 4 X 9 00 PLATE ACCESS PIVOT WELDMENT DRI U 10266 DRI U 10532 DRI U 10493 BRACKET LOOP FLUSH VALVE BELL HOUSING COVER DRI U 10538 DRI U 10501 DRI U 10280 SHIM BRACE ROD BRACKET FUEL PUMP DRI U 10539 DRI U 10298 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 2 2 2 1 1 1 4 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 4 4 1 1 1 1 1 1 2 1 2 1 1 1 1 2 1 1 1 1 1 2 1 1 2 1 TT Technologies Inc PLATE STOP BRACKET ROD WIPER PLATE 1 800 533 2078 1 630 851 8200 www tttechnologies com 37 4X GRUNDODRILL SUB ASSEMBLIES A M gt l m m 1 800 533 2078 1 630 851 8200 www tttechnologies
19. 30 851 8200 www tttechnologies com 5 LUBRICATION PRODUCTS AND OIL TABLE Item Type Quantity Intervals General Purpose Lithium Based Drill Head Rollers Grease NLGI2 Daily Drill Stem Thread Copper Antiseize Lube Daily Dry Lube Containing abu cdd Molybdemum disulfide Moly Fuel 2 Diesel above 32 F 10 Gallons Daily No 1 Diesel below 32 F General Purpose Lithium Based Track Tensioner Grease NLGI2 1 2 Sag Weekly Automatic Transmission Fluid Boring Rig Hydraulic Oil Dextron Ill 18 Gallons Annually Drill Head Assembly 80 90 gear lube 1 Quart Annually Under Carriage Drive 80 90 gear lube 1 2 Quart Annually Engine Oil API Classification CD Grades or Higher 6 0 L 1 59 Gal 200 Hrs or above 25 C 77 F SAE 30 SAE10W 30 SAE10W 40 Annually 0 25 C 32 77 F 20 SAE10W 30 SAE10W 40 below 0 C 32 F 10W SAE10W 30 SAE10W 40 Ethylene Glycol Mixed with Water Free Coolant of Minerals 50 50 4 0 L 1 06 Gal 500 Hrs or Vol Freezing Boiling Annually 50 37 to 180 C 34 to 226 F TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com 33 34 JAW REMOVAL AND REPLACEMENT 1 Start Grundodrill 4X drill and close both of the front and rear jaws 2 Turn machine off 3 Remove rod wiper by turning and pulling outward Figure 56 4 Starting with the vice assembly remove ly
20. 8025A035 DRI U 10446 92383A358 WASHER CARR LANE 98025A035 PIN STAKE DOWN STOP ROLL PIN 3 16 X 1 00 C0850 068 3500 DRI U 10138 DRI U 10141 SPRING ASSOCIATED SPRING 0850 068 350 CHUCK STAKE DOWN AUGER WASHER RETAINER DRI U 10221 DRI U 10310 DRI U 10185 STAKE HOLD DOWN PUMP SUPPORT BONDIOLI BRACKET FUEL FILTER DRI U 10184 DRI U 10237 DRI U 10243 BRACKET ZINGA FILTER SPINDLE POWER WRENCH DRI U 10389 DRI U 10390 hhcsm24x3x70 CYLINDER BOOM LIFT CYLINDER REAR STABILIZER HHCS M24 X 3 X 70mm nutjamM24 PRT DRI U 10250 DRI U 10251 JAM NUT M24x3 COVER CLEANOUT DRILL HEAD ASSEMBLY DRI U 10411 PF2832 16 DRI U 10428 BRACKET POWER TRACK DRILL HEAD BEARING POLYGON PGP 2832 16 SHIM 16 GA DRI U 10427 DRI U 10258 DRI U 10436 SHIM 11 GA FIXED BRACKET POWER TRACK PANEL ACCESS DRI U 10437 nut312 DRI U 10259 CHANNEL POWER TRACK NUT 5 16 18 UNC COVER BRACKET T14BH517BC RESERVOIR DRI U 10458 HOUR METER ENM CHICAGO T14BH517BC RESERVOIR COOLANT LEVEL BRACKET FUEL FILTER FUEL PUMP FILTER ASSEMBLY DRI U 10261 FUEL PUMP FUEL FILTER ASSEMBLY CYLINDER ASSEMBLY STAKE DOWN DRI U 10262 DRI U 22000 DRI U 21000 CYLINDER STOP ASSEMBLY VALVE ASSEMBLY WRENCH VALVE ASSEMBLY PRIMARY RIGHT ENCLOSURE DRI U 10466 DRI U 10275 DRI U 10265 FILTER BRACKET BRACKET HOOD MOUNT W TAB BRACKET HOOD MOUNT DRI U
21. ABILIZER DRI U 10212 DRI U 10139 DRI U 20000 PAD REAR STABILIZER PLATE BEARING REAR STABILIZER TRACK DRIVE MOTOR DRI U 10321 DRI U 10247 DRI U 10208 SPROCKET BEARING BLOCK LINKAGE ARM UPPER DRI U 10207 DRI U 10232 DRI U 10220 LINKAGE ARM LOWER BOOM 4X 5 STEM HYDRAULIC RESERVOIR DRI U 10217 DRI U 10257 DRI U 10137 507 3 V1505 B1 DRI U 10211 COMPARTMENT ASSEMBLY ENCLOSURE BODY ANGLE ENGINE MOUNT ISOLATOR ENGINE 3 ENGINE PUMP ASSEMBLY PLATE STAKE DOWN DRI U 10210 DRI U 10213 DRI U 10224 GUIDE SLIDE FRAME MOTOR THRUST 4X DRI U 10204 DRI U 10203 DRI U 10371 DRI U 10354 DRI U 10238 DRI U 10239 ROD BRACKET LOWER ROD BRACKET UPPER PANEL ROD LUBE PLATE BULKHEAD CONSOLE FRAME SEAT SUPPORT shcs375X100 92390A399 DRI U 10092 SHCS 3 8 16 X 1 00 PIN CARR LANE 92390A399 PLATE SEAT DRI U 10226 DRI U 10231 DRI U 20030 o njn nals SEAT ENCLOSURE CONSOLE JOY STICK CONTROLLER 36 TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com ITEM x PART NO DESCRIPTION 37 38 39 DRI U 10347 DRI U 10180 DRI U 10179 9 PANEL PLATE COVER WIDE PLATE COVER NARROW SWITCH GAUGE 98306A510 SWITCH GAUGE PIN CARR LANE 98306A510 DRI U 10241 DRI U 10361 DRI U 10242 PLATFORM TUBE PLATFORM SUPPORT BARRIER 9
22. ANIFOLD DESCRIPTION ITEMNO BTY PARTNO _______ 1 1 MANIFOLD MAIN VALVE MANIFOLD MAIN VALVE VALVE VALVE OIL ____5 4 5 SPACER 8 2105662000 VALVE CHECK VALVE 8 2 EMA3 716 20UNF 2A __ PORT 9 1 7013380 PILOT PISTON P V 1 _ 12 2 RVCA LAN RESSURE RELIEF VALVE DG S4M 00 HC12 ALVE ASSEMBLY DG S4M 00 1EA amp HC12 2EA 14 1 DG S4P 00 HC12 TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com ALVE ASSEMBLY 06 54 00 1EA amp HC12 2EA 60 W 4X GRUNDODRILL MCMASTER CARR ENCLOSURE H9215K11 PARTNO DESCRIPTION ____1___1 9215 11 ENCLOSURE MCMASTER CARR 9215K11 2 I DR U 10581 PLATE STAKE DOWN CONTROL TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com X 4X GRUNDODRILL MCMASTER CARR ENCLOSURE 9215K12 I 192502 ENCLOSURE MCMASTER CARR 49215512 2 _1 DRI U 10580 CONTROL PLATE TRACK DRIVE 4 hma swe 5 6 ITEM NO PARTNO DESCRIPTION E 2 2NT1 WITCH 6741 11 EMERGENCY STOP OPERATOR MCMASTER CARR 6741 11 TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com 61 Technologies Inc 2020 E New York Street Aurora IL 60504 1 800 533 2078 1 630 851 8200 FAX 1 630 851 8299 www tttechnologies com E mail i
23. B ASSEMBLY 0 ITEM NO PART DESCRIPTION 8 22 23 24 25 56 57 58 59 60 61 62 63 64 65 FF1852T0404S FITTING FF1868T0810S FITTING FF1868T1010S FITTING DRI U 10712 HOSE ASSEMBLY DRI U 10711 HOSE ASSEMBLY DRI U 10719 HOSE ASSEMBLY DRI U 10720 HOSE ASSEMBLY DRI U 10721 HOSE ASSEMBLY DRI U 10722 HOSE ASSEMBLY DRI U 10724 HOSE ASSEMBLY DRI U 10723 HOSE ASSEMBLY DRI U 10725 HOSE ASSEMBLY DRI U 10726 HOSE ASSEMBLY DRI U 10727 HOSE ASSEMBLY DRI U 10728 HOSE ASSEMBLY m m rm rm NIN N N TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com H 4X GRUNDODRILL SUB ASSEMBLY E N N NIM N NIN N NO gt HIM rm NI N TT Technologies Inc PART NO DRI U 21000 FF1852T0404S DRI U 10703 DRI U 10704 DRI U 10705 DRI U 10706 DRI U 10707 DRI U 10708 DRI U 10710 DRI U 10709 FF1861T1010S FF1868T0810S DRI U 10712 DRI U 10711 DRI U 10801 FF1868T0808S DRI U 10729 DRI U 10730 FF1994T0808S DRI U 10737 DRI U 10738 DRI U 10813 DRI U 10814 DRI U 10815 FF2281T0810S DESCRIPTION VALVE ASSEMBLY PRIMARY RIGHT ENCLOSURE FITTING HOSE ASSEMBLY HOSE ASSEMBLY HOSE ASSEMBLY HOSE ASSEMBLY HOSE ASSEMBLY HOSE ASSEMBLY HOSE ASSEMBLY HOSE ASSEMBLY FITTING FITTING HOSE ASSEMBLY HOSE ASSEMBLY HYDRAULIC LINE ASSEMBLY FITTING HOSE ASSEMBLY HOSE ASSEMBLY FITTING BULKHEAD HOSE ASSEMBLY HOSE ASSEMBLY HYDRAULI
24. C LINE ASSEMBLY HYDRAULIC LINE ASSEMBLY HYDRAULIC LINE ASSEMBLY FITTING 1 800 533 2078 1 630 851 8200 www tttechnologies com 43 I 4X GRUNDODRILL SUB ASSEMBLY F cZ 0 F OC P C BO 5 am C 0 sq 5 44 TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com PART DESCRIPTION FF1868T0404S FITTING FF1852T0808S FITTING 202702 4 4s FITTING DRI U 10729 HOSE ASSEMBLY FF1861T0808S FITTING FF1010 1208S FITTING DRI U 10731 HOSE ASSEMBLY DRI U 10732 HOSE ASSEMBLY FF1852T1012S FITTING DRI U 10735 HOSE ASSEMBLY DRI U 10736 HOSE ASSEMBLY FF2098T1010S FITTING FF2114T1010S FITTING DRI U 10738 HOSE ASSEMBLY FF1868T0812S FITTING 4C4OMXS FITTING DRI U 10743 HOSE ASSEMBLY DRI U 10742 HOSE ASSEMBLY DRI U 10741 HOSE ASSEMBLY DRI U 10739 HOSE ASSEMBLY DRI U 10740 HOSE ASSEMBLY DRI U 10745 HOSE ASSEMBLY FF2032T0404S FITTING DRI U 10751 HOSE ASSEMBLY 4 1_4 F505 S FITTING LSVI 2F N MANIFOLD BLOCK DRI U 10752 HOSE ASSEMBLY FF2031T0404S FITTING DRI U 10807 HYDRAULIC LINE ASSEMBLY DRI U 10808 HYDRAULIC LINE ASSEMBLY DRI U 10809 HYDRAULIC LINE ASSEMBLY DRI U 10810 HYDRAULIC LINE ASSEMBLY DRI U 10811 HYDRAULIC LINE ASSEMBLY 4601 16x12 FITTING HOSE_16 HOSE DRI U 10753 HOSE ASSEMBLY 140 DRI U 10816 HYDRAULIC LINE ASSEMBLY 10 3 9 2 3 2 2 2 2 2 2 2 2 2 4 2 2 2 2 2 2 2 3 2 1 1 2 1 2 2 2 2 2 1 2 2
25. GRUNDODRILL 4X STEERABLE BORING SYSTEM KES User s Guide amp Safety Manual Includes Maintenance Guide amp Parts Listings REVISION 1 0 8 31 02 Technologies Inc Copyright 2002 TT Technologies Inc Table of Contents General Information A General Description 006 6666 Seda ded eS See ERE 4 B FOWA 2 rrr CTI 4 General Use of the Operating Manual 4 Safety A General Safety Instructions 4 B Owner and Operator Responsibilities 6 C Training Requirements 6 D Staff Requirements 22 25 25 amr loa EEE 6 E Accident Procedure 6 F Protective Measures 7 Technical Specifications GRUNDODRILL Size Retracted and Extended 8 B Technical 2 ee Ferd Ca S dave nea eR au E 8 e Overview A CHASSIS 9 B Control Panel Overview 9 C Upper Control Panel tte 10 D Remote Drive Control
26. IFICATIONS EP or EA Minimum Depth D ft 14 6 29 057 1 26 4 36 15 6 30 632 1 345 4 88 16 7 32 376 1 437 5 486 17 7 33 95 1 52 6 065 18 8 35 671 1 611 6 733 19 8 37 22 1 694 7 369 20 8 38 764 1 776 8 032 21 8 40 294 1 857 8 722 22 8 41 811 1 938 9 439 Based on 1 96 minimum bend radius 2 Drill head sonde housing and 1 2 of first stem totalling 5 in ground before steering TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com 16 Operation A SAFETY INSTRUCTIONS AS TO OPERATOR Operating personnel should thoroughly study the operating manual specifically the chapter on safety instructions prior to the using the machine During the operation of the boring rig it is too late to study the operating manual This is particularly true for operators that use the machine on an irregular basis for set up maintenance or during operation Daily check all hoses pipe lines and securing bolts for correct position and function before starting the bore Visual Check Use only oils and lubricants recommended by the manufacturer Only qualified and trained personnel should use the machine Each member of the crew should fully understand the safety measures required for the operation and each one should be capable of the following the instructions individually New operators or operators in training should be working under the constant supervision of a qualified and experi
27. Remote Track Drive J Thrust amp Pullback Motor C Diesel Engine K Zap Alert D Drill Stem Carrier L Control Panel E Spindle Drive M Operators Seat F Remote Stake Down N Steel Track w Grounded Rubber G Stake Down Motor O Track Drive Motor H Stem Whippier B CONTROL PANEL OVERVIEW O 3 TH 3 J Figure 4 Upper Panel TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com 10 Figure 5 Control Panel Figure 6 Lower Panel IN OUT THRUST ROTATION Figure 7 Joystick Control Figure 8 Joystick UPPER CONTROL PANEL C _ Figure 9 Upper Control Panel A Rotation Pressure psi or bar H Front Vice Open Closed B Thrust Pressure psi or bar 1 Rear Vice Open Closed C Drill Fluid Pressure psi or bar J Wrench Break Loose Close D Ignition Switch Preheat Off On Start Glow Plug Lamp On Preheating Plugs E Strobe Light On Off L Hyd Filter Lamp On Electrical System F Work Light On Off M Charge Lamp On Electrical System G Head Cushion On Off TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com REMOTE DRIVE CONTROL A Emergency Stop Push Stop Pull Reset B Speed Control Low High C Left Track Forward Neutral Reverse D Master Button Push Engages Drives E Right Track Forward Neutral Reverse Figure 10 Remote Drive Control Transportation AWARNING Ne
28. Sub Assembly 53 Q Drill Head Assembly 1 54 Wrench Assembly sas pa akaqa tees 55 S Loop Flushing Manifold 56 T Cushion Valve 57 U Control Panel 58 V Main Valve 1 4 4 59 W McMaster Carr Enclosure 9215K11 60 X McMaster Carr Enclosure 9215K12 61 TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com General Information A GENERAL DESCRIPTION This operating manual deals with general safety instructions for operation of the machine as well as technical data and explanations as to the set up and functioning of the machine B FORWARD This operating manual is considered to be an integral part of the GRUNDODRILL 4X System It is an essential part of the user documentation Adhering to the information instructions and data in this manual is critical to successful equipment operation Technical data or information is subject to alteration without notice If you have questions or ideas concerning these products or this manual please contact TT Technologies Inc 1 800 533 2078 or 1 630 851 8200 C GENERAL USE OF THE OPERATING MANUAL This operating m
29. able Machine operator should not leave the machine Stay a safe distance from the machine Observe cable protection instructions Contact respective power company DANGER DANGER Electrical strike could result in severe personal injury or death In case of gas pipes Do not operate with open flame Extinguish all flames do not light new flames Shut down all engines Do not operate electric buttons or withdraw cable plugs Inform the respective gas company AWARNING WARNING When smelling gas risk of explosion 4 In case of water pipes Obtain information on the next available valve closing NN Call the local utility service department In case of sewage pipes Never enter into manholes or sewage mains alone Never enter into manholes or sewage mains without the proper safety gear Inform the respective owner of the pipe TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com 3327 39 131000 Figure 1 GRUNDODRILL 4X B TECHNICAL Grundodrill 4X Specifications Bore Length dependent on conditions Specifications subject to change at any time Grundomudd 225 Bentonite System 9 5 HP gas or 7 5 HP diesel Figure 2 Technical Data TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com Overview Figure 3 GRUNDODRILL 4 A Rear Stabilizer 1 Smart Vise B
30. anual details the safe correct and proper usage of the Grundodrill 4x Drill as well as the type of applications in which it is designated for Adhering to the instructions will reduce the risk of danger repair costs and down time while increasing the reliability of the machine Local regulations regarding prevention of accidents and safeguarding the environment should be adhered to in addition to those outlined in the operating manual This manual should be made available at every jobsite at all times The operating manual should be read and the instructions applied by each person who works with the machine During operation including set up troubleshooting during operation jobsite cleanup maintenance disposal of lubricants During maintenance inspection repair Transportation Besides the instructions of the operating manual and the regulations of safety prevention from the respective country or site of use standard industry regulations for safety and operation practices should also be adhered to Safet A GENERAL SAFETY INSTRUCTIONS All safety devices and warning labels should not to be changed or removed from the machine Adhere to all instructions concerning safety and possible danger Keep all labels regarding safety and possible dangers on the machine in good readable condition In case of safety relevant modifications to the machine or its operating mode stop the machine immediately and notify the
31. arranty Information DISCLAIMER FOR STEERABLE BORING MANUAL NO WARRANTY AS TO MANUAL TT Technologies makes no warranty that the information provided in this manual is complete accurate in all respects or up to date This manual should be used as a reference work to provide a starting point for addressing steerable boring situations Each particular situation is different The user is responsible for providing the expertise and skill necessary to properly execute a given steerable boring job TT Technologies specifically disclaims all express or implied warranties concerning this manual including the implied warranties of merchantability and fitness In no event shall TT Technologies be liable for consequential special or incidental damages or contingent liabilities including without limitation lost profits or goodwill whether such claim arises in tort contract negligence strict liability or any other basis arising in any way out of the use of this manual LIMITED WARRANTY AS TO PRODUCTS TT provides a limited warranty to the original purchaser of its new products that new products will be free from defects in materials and workmanship for 90 days or 500 hours of actual use whichever occurs first provided they are properly maintained serviced and used for the intended purpose of the product During the 90 day or 500 hours period buyer s remedies are limited to repair or replacement at TT Technologies discretion TT Technologies
32. c power has been locked out If the power has not been properly shut off an automatic resetting circuit breaker could re energize the power line or contact between the boring rig and power line may recur WARNING Danger The operator is not to leave the machine until all safety and electrical shut offs are confirmed and done according to safety standards 3 Place the safety mat out parallel to the bore rig and plug the cable into one of the Sockets on the bore rig a second safety mat can be laid out on the other side of the bore rig as an option Figure 24 4 Connect the grounding stake to the other socket and insert the stake vertically next to the bore rig away from the safety mat Figure 24 Grounding Rod Safety Mat Zap Alert Optional Safety Mat Figure 24 Overhead of Safety Alert Package TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com 19 20 Safety Warnings Electrical strike could result in severe personal injury or death Never start a bore without prior setting up of the complete safety kit When placing stakes in the ground the operator must be wearing electrical safety boots and gloves e It is important that the stake is placed in conductive soil In extremely dry or asphalted soils prior watering of the ground is necessary D AUGER STAKING DRILL IN PLACE The bore rig comes with four auger stakes to secure rig to ground Figure 25 The staking sy
33. ce c The switch failed replace Failed wire or connector a The strobe element failed b F fuse failed replace c The switch failed replace d Failed wire or connector a The horn failed replace b F fuse failed replace c Failed K relay replace The horn switch failed replace Failed wire or connector Replace Hydraulic solenoid one dump valve Replace relief valve no one Replace hydraulic pump no one Replace wire or connection Replace hydraulic solenoid two dump valve Replace relief valve no two Replace hydraulic pump no two Replace wire or connection Replace the associated switch Replace the associated hydraulic solenoid valve Replace wire or connector Set the Mode selector switch to On for Smart Vice operation Make sure the operator is using the cycle button correctly Replace F fuse Check sections titled All hydraulic functions fail All hydraulic functions work Any independent hydraulic function Replace wire or connector Replace the jaws Replace the light element Replace F fuse Replace the switch Replace K relay Replace wire or connector Replace the strobe element Replace F fuse Replace the switch Replace wire or connector Replace the horn Replace F fuse Replace K relay Replace the horn switch Replace wire or connector 1 800 533 2078 1 630 851 8200 www tttechnologies com W
34. d fully understand all general safety instructions and operating safety instructions Operators strict attention is required during the rotation mode Danger of injury around all moving parts TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com No loose clothing or hair Never have physical contact with stem while stem or spindle is in rotation mode 2 Checks Prior to Boring Check the drill stem for fatigue or wear Visual check of the o ring on the drill stem Check bore rig fluids for start up Has bentonite fluid been mixed and is the mixing system ready for operation Check that all hoses and electrical cables have been connected correctly and are operational Make sure that all communications radio or hand signal have been agreed upon between location operator and bore rig operator Check that all safety precautions have been applied Make sure that the strike alert system has been tested and is in good working condition 3 Assembly of First Drill Stem with Sonde Housing 1 Take first stem in the left hand and place the male end of the stem in the vice Figure 34 2 With auto vice selected in the off position close rear vice using toggle on upper panel Figure 35 Figure 34 Place First Stem in Vice Figure 35 Close Rear Vice 3 Move the spindle head forward until the head leads into the female side of stem Figure 36 4 Release hand fro
35. de into drill head matching sonde slot to pin in drill head Figure 29 Note This will lock sonde to 12 o clock position on drill head 2 Slide sonde and rear of drill head into sonde housing with pin aligned Figure 30 Figure 29 Slide Sonde into Figure 30 Slide Sonde amp Rear of Drill Head Drill Head into Sonde Housing TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com 21 22 3 Rotate boring head 90 degrees in sonde housing until pins lock in place Figure 31 4 Insert cap screws to lock drill head onto sonde housing Figure 32 Figure 31 Rotate 90 Until Pin Figure 32 Insert Cap Screws to Lock Locks in Place Drill Head onto Sonde Housing 2 Calibrate Sonde After preparing the sonde housing assembly calibrate sonde in sonde housing according to the type of locating equipment being used With calibration complete test sonde housing assembly with locating equipment for proper depth roll and pitch reading F CONNECTING THE BENTONITE SYSTEM The standard Bentonite system to be used with the 4X boring rig is the TT Technologies 225 Bentonite system The connection of the Bentonite system consists of two hook ups the Bentonite hose and electrical connection Figure 33 Figure 33 4X GRUNDODRILL Bentonite amp Electrical Connections For operation of bentonite system see bentonite systems manual G BORE MODE 1 Safety Instructions The entire crew should read an
36. eck that ventilation is clear of foreign material and debris for x the radiator and oil cooler Check drill head rollers and lubricate with a general purpose x lithium based grease NLGI2 Check drill head guides for excessive side movement of drill X head Check the drill stem guide for wear X Check thrust gear lube use a dry lube containing Molybdemum X disulfide Moly Check for leaks on drill head drive 80 90 gear lube X Check for leaks on track final drive units 80 90 gear lube X Check hydraulic oil level use automatic transmission fluid X Dextron Ill Check the vice and wrench jaws for wear X Change engine oil after 1st 50 hours of use X 50 hrs Check the wear on the drive track X Check the track tension 1 2 sag Use general purpose lithium X based grease NLGI2 as required Check all indicator lights and gauges of the operation panel X Change engine oil every 200 hours thereafter or anually X 200 hrs Change fuel filter and strainer annually or 400 hours X 400 hrs Change antifreeze solution annually or 500 hours X 500 hrs Change hydraulic oil annually or at 500 hours X 500 hrs Change filter and clean screen annually or at 500 hours X 500 hrs Change filter if service lamp indicates X when lit Change drill head assembly 80 90 gear lube X Change under carriage drive units 80 90 gear lube X Change spindle drive oil X Change under carriage drive oil X TT Technologies Inc 1 800 533 2078 1 6
37. efore You Dig Check the existence and exact position of buried pipe and cables by contacting the respective utilities or owners of networks The exact and definite existence and position of buried cables and pipes should be defined by trial pits or using cable and pipe detection equipment or other means Cable Strike A DANGER Should you accidentally hit an electrical cable immediately leave the site ensure no one enters and contact the electrical company to turn off the supply In case of a cable strike the danger resulting from that damaged electric cable can only be evaluated following detailed information by the respective electrical company Never rely on your own knowledge as to types of cables safety measures and protective measures that may not be correct for the type of cable encountered Always consider cables to be live and a potential DANGER danger to life Do not re enter the site until authorized by the electrical company No Loose Clothes Do not wear loose clothes or long hair Danger of body injury by loose clothes or hair being caught in the moving parts of the machine Safety Equipment The operating crew should always wear the appropriate safety equipment i e safety shoes boots hard hat safety glasses gloves ear protection etc Operation by Qualified Personnel Only Operation of the GRUNDODRILL should be carried out by suitably trained qualified and certified personnel only New operators or operators in
38. enced persons only Adhere to the legal minimum age for operators Use only the machine in sound technical condition after having studied the operating manual particularly the safety related aspects Any safety disturbances should immediately be eliminated Rotating and moving parts can present a dangerous situation pulling or wrapping around Open safety covers doors and other equipment only after shut down of the machine The working area should be secured so the machine system contact with the public is prevented Should a dangerous situation arise toward people or the machine immediately push the emergency ON OFF button Never operate the machine without properly installing the electric strike protection system In case of an electrical strike the operator should NEVER leave the bore rig safety mats until there is a 100 confirmation that electrical source has been shut down In case of cable strike the respective electrical company can only evaluate the danger resulting from that damaged electric cable following detailed information Never rely solely on your own knowledge as to the types of cable encountered The entire bore crew should wear functional protective attire including ear protection B DRIVING TO OPERATION SITE 1 Safety Instructions Do not drive bore rig on steep slopes Lift bore rig boom and rear stabilizer before moving rig Always walk with
39. es Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com 4 Drilling Operation 1 Switch drill fluid toggle to auto Figure 42 2 Switch Head Cushion to ON position Figure 43 Figure 42 Switch Drill Fluid Figure 43 Switch Head Cushion Toggle to Auto to ON Position 3 Switch auto vice selector in the Smart Vice to drill out Figure 44 4 Press the Smart Vice cycle button on joystick to close front vice 5 Unscrew spindle head from stem by counter rotating the spindle by pulling back on the joystick 6 Once spindle is completely unscrewed from the stem pull the joystick to the left and thrust spindle drive into head cushion this action then places spindle drive into the beginning position 7 Place next drill stem into position Figure 45 Figure 44 Switch Auto Vice Selector in the Smart Vice to Drill Out into Position 8 Rotate spindle head and thrust forward Smart Vice until stem is tightened between head Cycle Button and previous stem 9 Hit Smart Vice cycle button Figure 46 This will release front vice and turn bentonite fluid on 10 At this point you can thrust in for steering or rotate for straight boring 11 Run stem in until spindle head hits the forward stop 12 Repeat steps 4 11 until exit location is reached Figure 46 Hit Smart Vice Cycle Button TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com 25 26 5 Pre reaming Back
40. m stem 5 Using the joystick rotate the bore head clockwise until head screws into first stem Figure 37 Rotate clockwise Figure 36 Move Spindle Figure 37 Rotate Bore Head Head Forward Clockwise Joy stick Thrust forward TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com 23 24 6 Open rear vice Figure 38 7 Thrust stem forward until male end of stem protrudes the Smart Vice Make sure both front and rear vices are open before thrusting stem forward Figure 39 Figure 38 Open Rear Vice Figure 39 Thrust Stem Forward until it Protrudes Smart Vice 8 Manually turn on Bentonite fluid to flush away any foreign materials 9 Screw sonde housing assembly onto male end of stem protruding Figure 40 and tighten sonde housing assembly with a wrench 10 Open both vices using toggles on upper panel Figure 41 2944 Figure 40 Screw Sonde Housing Figure 41 Open Both Vices Using Assembly onto Male End Toggles on Upper Panel 11 Rotate drill head to the 6 o clock position 12 With Bentonite system running turn drill fluid on to check whether drill fluid exits bore head 13 Using joystick thrust spindle forward until drill head penetrates about 12 18 inches into the ground while keeping drilling fluid running 14 With joystick rotate clockwise and thrust drill head forward until spindle forward thrust comes to a stop 15 Switch drill fluid to off position TT Technologi
41. makes no other warranty express or implied and makes no warranty of merchantability or fitness for any particular purpose No person representative or agent of TT Technologies has the authority to change this warranty in any manner whatsoever Any oral or written statements inconsistent with this limited warranty shall not apply In no event shall TT Technologies be liable for consequential special or incidental damages or contingent liabilities including without limitation lost profits or goodwill whether such claim arises in tort contract negligence strict liability or any other basis arising in any way out of the use of any product or any parts thereof TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com 31 Maintenance A SERVICE INTERVALS Item Daily Weekly Annually Clean Bore Rig Check hydraulic hoses and electrical cables for tightness X correct seating Check and clean the jet nozzle of the bore head back reamers x accessories and tooling before starting Check strike alert system and make sure safety equipment is x functioning properly Check fuel tank level Use No 2 diesel above 32 F Use No 1 X diesel below 32 F Check the engine oil level X Check the engine coolant level X Grease drill stem thread use copper antiseize lube as required X Grease carriage rollers Ch
42. nch pins to remove jaw pins Figure 57 Figure 56 Remove Rod Wiper Figure 57 Remove Lynch Pins 5 After removing both lynch pins pull front pins out Figure 58 6 After the pins are removed slide jaw assembly to the left or to the right to align jaw for removal Figure 59 Figure 58 Pull Front Pins Out Figure 59 Slide Jaw Assembly to Align for Jaw Removal 7 Pull jaw out Figure 60 and replace with new Figure 61 There are two jaws in each jaw assembly after they have been replaced insert pins and lynch pins Repeat the process for changing the jaws in the rear vice Figure 60 Pull Jaw Out Figure 61 Replace With New Jaw TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com S G i Jg DESCRIPTION l wrench valve manifold _ BLOCK VISE CONTROL 4 VALVE TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com I RPEC LAN PRESSURE RELIEF VALVE 1 EMA3 7 16 20UNF 2A TEST PORT 1 DG 4P 00 HC12 VALVE ASSEMBLY DG S4P 00 1EA amp 12 2EA 1 DG S4M 00 HC12 VALVE ASSEMBLY DG S4M 00 1 8 HC12 2EA 35 B 4X GRUNDODRILL OVERALL ASSEMBLY ITEM NO x PART NO DESCRIPTION DRI U 10233 MU1510 MU1531_38_230 4X UNDERCARRIAGE IDLER ASSEMBLY TRACK N 5297 MU1503 DRI U 10222 VALVE KIT 4X IDLER ROLLER ARM REAR ST
43. nfo tttechnologies com All rights reserved No part of this catalog may be reproduced or transmitted in any form or by any means electronic or mechanical including storage on an information retrieval system without written permission from TT TECHNOLOGIES Inc Printed in USA 08 31 02 REV 1 0 Copyright 2002 TT TECHNOLOGIES Inc
44. ow big should the pits be Will there be any support personnel or lifting equipment How and who will empty the pits of the drilling fluid to recycle the mud Who assumes responsibility for accidents or various contractual shortcomings Who assumes responsibility for environmental hazards D SETTING UP THE JOBSITE Has the jobsite been prepared according to specifications Have all maintenance procedures been properly carried out Have all the safety precautions been taken Has the Grundodrill 4x bore rig been properly positioned according to specifications Are all the necessary boring tools and accessories available on site Has the jobsite been marked off according to safety specifications Secure the bore rig and operating space TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com 14 BORE PLANNING Proper bore planning is critical to project success Several considerations must be made in order to ensure a successful bore These items include Bend Radius e Launch amp Exits Minimum Set back Minimum Depth Pitch 1 Bend Radius Creating the bore path depends on the bending of the drill stems Creating bore paths that exceed the recommended bend radius of the drill stems will cause damage Taking into consideration the minimum drill stem bend radius is essential to planning the bore path Minimum bend radius for the drill stems used with the Grundodrill
45. shut bentonite off rear wrench will lock and break stem joint and then release 7 Counter rotate and thrust back about a 1 2 to disengage stems Figure 50 Thrust back Smart Vice Cycle Button Rotate counterclockwise amp thrust back Rotate counterclockwise Figure 49 Press the Smart Vice Figure 50 Counter Rotate and Thrust Cycle Button Back 1 2 to Disengage Stems TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com 8 Press the Smart Vice cycle button Wrench vice closes Figure 51 9 Using joystick counter rotate and thrust back spindle till stops make contact 10 Press the Smart Vice cycle button Opens wrench vice Figure 52 Smart Vice Smart Vice Cycle Button Cycle Button Figure 51 Press the Smart Vice Figure 52 Press the Smart Vice Cycle Button Wrench Vice Closes Cycle Button Opens Wrench Vice 11 Remove stem and place in stem carrier Figure 53 12 Thrust spindle forward until it makes contact with next stem then rotate and thrust till spindle is set into stem Figure 54 Rotate clockwise Rotate clockwise amp thrust forward Joy stick gt Thrust forward Figure 53 Remove Stem and Place Figure 54 Thrust Spindle Forward in Stem Carrier Rotate and Thrust Till Spindle is Set 13 Press the Smart Vice cycle button Releases front vice Figure 55 14 Repeat steps 5 14
46. stem is operated using a remote which is located on the auger stake down Figure 26 amp Figure 27 Figure 25 Auger Stake Locking Pin Operators Seat Control Panel Zap Alert Auger Stake Auger Stake Alignment Holes Line of Entry Figure 27 Stake Down System The remote has two toggle switches Figure 26 1 Auger rotation toggle up auger in toggle down auger out 2 Auger thrust up and down rotates drive motor TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com 1 Setting Auger Stake Bore rig must be running to operate auger stake down system Lock stake down guide into position using locking pin Figure 27 Place the auger stake into alignment hole Figure 27 Bring auger motor down onto auger stake until pins are fully engaged in auger motor chuck Push the auger rotation toggle forward to lock stake into auger chuck Run both toggles forward this will put downward thrust and clockwise rotations on auger screwing it into the ground 7 Stop rotation and thrust when auger plate reaches top on alignment hole Figure 27 8 Repeat steps 2 7 until all four augers are in place 5 gt PREPARING SONDE HOUSING The drilling tool consists of the drill head sonde housing and the transmitting sonde Figure 28 Drill Head Sonde Housing 2222222228 Figure 28 Drill Head Sonde Sonde Housing 1 Sonde Housing Assembly 1 Slide son
47. taff as to the operation set up maintenance and repair of the system are to be clearly defined New operators or operators in training should work under the constant supervision of qualified and experienced personnel only D STAFF REQUIREMENTS At least 2 workers are required for set up disassembly and operation of the GRUNDODRILL boring system Before starting to bore all personnel charged with the use of the machine are obligated to Follow the basic work safety and accident prevention regulations Thoroughly read the operating manual particularly the safety instructions and confirm that they have been fully understood Use personal or work related protection clothing or other means to guarantee safety during the operation of the machine ACCIDENT PROCEDURE Cease immediately operations Take the necessary protective steps according to the type of cable or pipe Notify the owner of the cable or pipe Estimate the type and extent of the damage Warn pedestrians and house occupants and keep them away from the danger TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com F PROTECTIVE MEASURES In case of a telephone cable Respect the cable protection instructions of the local telephone company Notify the local telephone company A CAUTION CAUTION Do not look closely at glass fiber cable Risk of eye injury case of electrical c
48. until back reaming is complete Smart Vice Cycle Button Figure 55 Press the Smart Vice Cycle Button Releases Front Vice TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com 28 Trouble Shootin A TROUBLE SHOOTING 1 Complete machine shutdown Includes no indicator lights 2 Engine doesn t crank 3 Engine cranks but won t start 4 Engine starts and then stops 5 Engine lacks power 6 Engine overheats TT Technologies Inc F1 fuse failed F2 fuse failed The battery is discharged Check battery cable connections check for failed wire or connector Check corrections above Failed ignition switch Failed K5 control relay Failed wire or connector a Check the emergency stop buttons b Check diesel fuel level Fuel filter plugged F3 fuse failed Failed K3 control relay The engine protection device is active The engine is overheated or the engine has no oil pressure The fuel filter is restricted The fuel filter is restricted The air filter is restricted Check fuel hoses for leaks The fuel pump is faulty a Radiator air inlet restricted b Operating above pressure spec a b Replace the 1 fuse Replace the F2 fuse Charge replace the battery Tighten and replace if damaged See solutions above Replace ignition switch Replace 5 control relay Replace wire or connector Make sure the
49. ver allow riders on the boring unit while moving or loading Always load and unload trailers on level ground Make sure boring rig is loaded correctly onto trailer according to trailer size and type Check that trailer is attached to vehicle before loading and unloading LOADING ONTO TRAILER A 1 Make sure trailer is rated for the boring rigs size and weight 2 Make sure trailer is correctly attached to towing vehicle 3 Move boring rig to rear of trailer Figure 11 4 Align ramps with boring rig tracks Figure 11 5 6 7 8 9 WARNING With idle speed on low and boom and stabilizer raised slowly load boring rig onto trailer Position boring rig correctly on trailer Figure 12 Lower boom and stabilizer until they lay firmly on the trailer Shut engine off Attach boring rig to trailer with tie downs amp use the proper tie down locations Figure 13 Figure 11 Prepare Rig for Trailer Figure 12 Position on Trailer TT Technologies Inc 1 800 533 2078 1 630 851 8200 www tttechnologies com 11 Figure 13 Down Points B UNLOADING TRAILER 1 Make sure you are unloading on level ground 2 Remove tie downs 3 Lower trailer ramps 4 Start engine 5 Raise boom and stabilizer 6 At a slow idle slowly and cautiously back boring unit off trailer Jobsite Preparation A GENERAL Many elements go into having a successful bore Qualified Operators Jobsite
50. work correctly No indicates a hydraulic pump failure Pressure less than 300 PSI Check the two charge relief valves in the Hydrostatic pumps Check the charge regulating valve in the Hot oil shuttle manifold Failed hydrostatic pump assembly Failed hot oil shuttle valve f Pressure at or above 300 PSI Failed joy stick control Failed high pressure relief valve on associated function fuel Use Glow Plugs for cold startup Replace glow plugs Replace Key switch Replace K2 control relay Repair engine problem Put oil in the tank Replace the suction screen if necessary Replace the suction hose if damaged Replace pump drive Replace hydraulic pump drive coupler Run engine at low idle speed to warm hydraulic oil Replace the hydraulic filter Use proper Hydraulic oil Dextron Maintain charge pressure Replace braided lines that are damaged Replace hydraulic pump Install test gauge Run engine at low speed Replace the two charge relief valves in the Hydrostatic pumps Replace the charge regulating valve in the Hot oil shuttle manifold Replace hydrostatic pump assembly Replace hot oil shuttle valve f Replace joy stick control a Replace high pressure relief valve on associated function Failed hydrostatic motor in the failed circuit b Replace hydrostatic motor in the failed circuit Failed hot oil shuttle valve in failed circuit c Replace hot oil
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