XCMG XZ5060 Product Manual

Operation Manual of XZ5060 Horizontal Directional Drilling Rig
XCMG Construction Machinery Co., Ltd.

Foreword
Distinguished horizontal directional drilling rig user: Hello!
Welcome you to purchasing the XZ5060 horizontal directional drilling rig manufactured by our company.
This manual is mainly intended to describe the related information and operation instructions of XZ5060 horizontal
directional drilling rig of XCMG Foundation Industry Co., Ltd. to the user.
This manual mainly describes the information in terms of safety, product information, operation instructions, lubrication
and maintenances, and some precautions.
To ensure your smooth construction, every operator must carefully read this manual before operating this drilling rig.
The detailed operation methods are probably not completely same for the equipment of different specification
manufactured by different manufacturers. Even for a product manufactured by one same manufacturer, the part
structure and control mode will be subject to multiple changes along with the time and the technologic progress.
Therefore, every operator (even with abundant construction and operation experiences) who has never operated this
drilling rig (new or old) shall carefully read this operation manual.
For the operation instructions and the maintenances of components such as engine and machine-mounted crane, please
refer to the relevant attached Manual.
This manual defines the anchorage base side as the “Front”, the driver sprocket side as “Rear”, the footplate side as
“Left”, and the engine side as “Right”.
Our company will not be liable for any equipment damage or safety accident arising from the following conditions:
1. Unauthorized modifications to the equipment.
2. Running under any mode beyond the normal operation scope.
3. Operations beyond the specified scope of machine or under loaded condition.
Our company will not offer warranty services for the equipment damages arising from the following conditions.
1. Incorrect operations.
2. Non-timely or insufficient maintenances or improper maintenances or storage.
3. Use of non-recommended fuel or lubricant.
4. Normal wear of drill pipe and drilling tool.
5. Man-made damage, natural disaster, impact or other accident on the machine or the installation of parts other than
XCMG’s manufactured parts or failing the XCMG’s quality standard.
The following parts are wearing parts and are not covered by warranty scope.
1. Engine filter elements and belts.
2. Filter elements within hydraulic system.
3. The wear of jaws and the wear of jaw holders arising from the non-timely replacement of jaws are also not
covered by warranty scope.
4. Electric system fuses and lamps.

Foreword III
5. Drill pipe and protective short connector (Such as the damage of short connector thread caused by the direct
connection of short connector to the drill pipe) are not covered by warranty scope.
6. Tracks, sprockets, and track rubber blocks.
7. Rotary connector seals.
8. Rollers, conducting rings, and conducting poles.
9. Wire ropes of machine-mounted crane.
10. Vice and power head sliders.
Due to continuous improvement of equipment design and the diversification of user demands and configurations, the
contents, diagrams, and other information in this manual may be subject to alternations at any time and such alterations
will probably influence the repairs and maintenances of the drilling rig. The user, especially those in first contact with
this machine, shall obtain the latest and complete date before operations. For the latest information of machine or the
questions about this manual, please contact the manufacturer or the designated dealer, in order to obtain the latest
information.
IV Foreword
Use of Manual
Look up the required information quickly!
This manual is composed of 7 chapters.
1. Safety
2. Product Information
3. Operation Instructions
4. Lubrication and Maintenances
5. Common Malfunctions and Troubleshooting
6. Transport, Storage and Protection
7. Attachments
8. Every chapter is divided into sections, of which the pages are numbered in serial manner. A page number is
indicated on the bottom corner of every page, which can be read from the Contents to ease the lookup.
Chapter No. Chapter title Section No. Section title Page number of section in the manual
Chapter 2 Product Information
2.1 Product Overview
2.2 Model Composition
2.3 Application Scope
Use of Manual V
Contents
Foreword........................................................................................................................................................................... III
Use of Manual ................................................................................................................................................................... V
Chapter 1 Safety ...................................................................................................................................................... 1-1
1.1 Safety Introduction ..................................................................................................................................... 1-1
1.2 Machine Safety ........................................................................................................................................... 1-4
1.3 Descriptions of Safety Signs ....................................................................................................................... 1-5
1.4 General Danger Information ..................................................................................................................... 1-12
1.5 Main Dangers............................................................................................................................................ 1-13
1.6 Operation Safety Regulations ................................................................................................................... 1-14
1.7 Equipment to be Provided by User ........................................................................................................... 1-17
1.8 Classification of Underground Hazardous Substances ............................................................................. 1-17
1.9 Division of Construction Site and Precautions ......................................................................................... 1-18
1.10 Electric Shock Knowledge........................................................................................................................ 1-18
1.11 Safety Emergency Knowledge .................................................................................................................. 1-19
Chapter 2 Product Information ................................................................................................................................ 2-1
2.1 Product Overview ....................................................................................................................................... 2-1
2.2 Model Composition .................................................................................................................................... 2-1
2.3 Applicable Scope ........................................................................................................................................ 2-1
2.4 Product Features ......................................................................................................................................... 2-1
2.5 Overall Dimensions .................................................................................................................................... 2-2
2.6 Main Technical Specification ..................................................................................................................... 2-3
2.7 Product Nameplate ...................................................................................................................................... 2-4
2.8 ............................................................................................................................................................................ 2-4
2.9 Operations ................................................................................................................................................. 2-10
2.10 Drill pipe ................................................................................................................................................... 2-13
2.11 Drilling tool .............................................................................................................................................. 2-18
2.12 Connection of Drill Pipe and Drilling Tool .............................................................................................. 2-21
2.13 Other Auxiliary Tools ............................................................................................................................... 2-22
Chapter 3 Operation Instructions ............................................................................................................................ 3-1
3.1 Preparations before Entrance into Site ........................................................................................................ 3-1
3.2 Checking of Machine .................................................................................................................................. 3-5
3.3 Positioning of Drilling Rig.......................................................................................................................... 3-6
3.4 Start of Machine.......................................................................................................................................... 3-7
I Contents
3.5 Stop of Machine .......................................................................................................................................... 3-8
3.6 Drilling of First Drill Pipe........................................................................................................................... 3-9
3.7 Addition of Drill Pipe ................................................................................................................................. 3-9
3.8 Orientation and Direction Change of Drill Bit .......................................................................................... 3-11
3.9 Unearthing of Drill Bit .............................................................................................................................. 3-13
3.10 Back-Reaming Operation.......................................................................................................................... 3-13
3.11 Disassembling of Drill Pipes .................................................................................................................... 3-16
3.12 Back-Dragging of Pipeline ....................................................................................................................... 3-18
3.13 Clear-up of Site ......................................................................................................................................... 3-18
3.14 Difficulties during Construction ............................................................................................................... 3-18
Chapter 4 Lubrication and Maintenances ................................................................................................................ 4-1
4.1 Lubrication .................................................................................................................................................. 4-1
4.2 Maintenances .............................................................................................................................................. 4-3
4.3 Fuel ............................................................................................................................................................. 4-6
4.4 Engine oil .................................................................................................................................................... 4-6
4.5 Coolant........................................................................................................................................................ 4-6
4.6 Hydraulic Oil .............................................................................................................................................. 4-6
Chapter 5 Common Malfunctions and Troubleshooting ......................................................................................... 5-1
5.1 Common Malfunctions and Troubleshooting of Vices ............................................................................... 5-1
5.2 Common Malfunctions and Troubleshooting of Power Head..................................................................... 5-1
5.3 Malfunctions and Troubleshooting of Hydraulic System ........................................................................... 5-2
5.4 Common Malfunctions and Troubleshooting of Engine ............................................................................. 5-8
5.5 Common Malfunctions and Troubleshooting of Electric System ............................................................. 5-11
Chapter 6 Transport and Storage ............................................................................................................................ 6-V
6.1 Transfer of Machine................................................................................................................................... 6-V
6.2 Transport of Machine................................................................................................................................6-VI
6.3 Daily Storage and Protection ....................................................................................................................6-VI
Mud and Additives ........................................................................................................................................................ VIII
Nozzle Flow................................................................................................................................................................... VIII
Electric Schematic Diagram .............................................................................................................................................. X
Hydraulic Schematic Diagram ..................................................................................................................................... XXV
II Contents
Chapter 1 Safety
1.1 Safety Introduction
The manual specially describes the safety precautions and the user shall conscientiously abide by the safety
regulations and requirements of this machine. The precautions can effectively prevent the danger!
It’s recommended that all relevant personnel involved in the operations of this machine shall read and understand
the contents of these safety precautions in advance, which can help the safe operations of machine and prevent the
occurrence of accidents.
Precautions:
1. The XZ5060 horizontal directional drilling rig must be operated as per the Operation Manual. All other
operations are prohibited.
2. The safety precautions established for the work staff must be observed during the repairs and maintenances
of drilling rig.
3. All personnel without training or authorization are prohibited to operate this machine.
4. Ensure to wear appropriate clothes. All operation staff near the rotating parts shall not wear unbuckled cloths,
scarf, or cloths, long hair, or ornament that will probably be entangled into the rotating parts, in order to
prevent scratches.
5. Keep cleanliness and sufficient operating space for the worktable, footplates, and joysticks and frequently
check the oil pipelines and check for sufficient lubricating grease and contamination, in order to prevent
cracking and entanglement danger.
6. It’s prohibited to directly jump off from the cab or footplate. While getting on or off the cab, keep at least
two hands + one foot or two feet + one hand into close contact with the footplates and handrails.
7. Do not use any joystick, door panel, or hose as handrails. They are non-fixed supports. Avoid pulling any of
them, in order to prevent causing maloperations or malfunctions.
8. The operator must always operate on the control console. It’s prohibited to control this machine outside of
the control console.
9. During operations, set up the operation area of the drilling rig, partition it by railings, and affix the warning
signs. Keep all other personnel away from the operation area.
10. When two operators work together for operations and maintenances, they shall be trained in advance and one
shall stay in the main operating position to supervise the safety and operations of the other operator.
11. One operator is allowed for independent repairs and maintenances only after the whole machine is powered
off.
12. During the repairs and maintenances, the supervising operator shall be capable of accessing the emergency
stop switch in all cases.
13. The operation site of the machine shall be well illuminated.
Safety 1-1
14. The operator and the supervising operator shall establish good and reliable communication or well
understand the transmission methods and meanings of the signals.
15. Check the power head position, limit switch, and emergency stop switch before the use of the machine.
16. Do not operate the machine when feeling uncomfortable or affected by alcohol or drug.
17. When the machine requires maintenance or is malfunctioned, stop the operations immediately and contact
XCMG’s service personnel.
The safety information contained in this manual is classified as below:
This sign is intended to remind you that the negligence or the failure to operate as per the instructions of
this manual will immediately lead to serious personal injury or even death and probably damage the
machine.
this manual will immediately lead to potential danger of personal injury or even death and probably
damage the machine.
this manual will probably lead to personal injury or even death and damage the machine.
Strictly abide by the following warnings while operating this drilling rig.
The engine exhaust gas is toxic! During operations within a limited space, ensure that the exhaust gas will
not breach into the operation area, in order to prevent danger.
Before starting the machine, ensure that all control mechanisms are in safe position and carefully read and
understand this manual to use and operate this machine as per specified requirements. This manual shall
be preserved at an easily accessible position. If this manual is lost or damaged, supplement or replace
timely.
1-2 Safety
Before welding operation on the machine or welding any steel tube connected to the drilling rig, ensure to
disconnect the positive and negative poles of the battery and unplug all connectors of PLC controller and
GPS.
While starting the second engine, adjust the first engine to idling speed. To guarantee the balanced power
output between two engines, adjust the speeds of two engines to approximately same value.
All personnel are prohibited to stand beneath the boom of the machine-mounted crane.
During the operations with this machine, it’s necessary to understand the operation instructions of the
installed guiding equipment and drill pipe, drill bit, and drilling tool and operate as per the specified safety
requirements. If not quite familiar with the related contents, please refer to GB 50424-2007 Code for
Construction of Oil and Gas Transmission Pipeline Crossing Engineering, GB 20904-2007 Horizontal
Directional Drilling - Safety Operation Rules, and API Recommended Practice 7G Recommended Practice
for Drill Stem Design and Operation Limits (API-RP-7G).
The wear of threads and drill pipe arising from the violation operations of this machine (Such as
unreasonable bending curve of drill pipe, use beyond the operating torque and pulling/pushing force of
drill pipe or drill pipe connecting thread, and over-long stop time (≥2h) during pipe dragging), the use of
mud incompatible with the local geological condition, the non-authorized removal of GPS or safety
protection switch, or the normal use of drilling tool and the damages of equipment or drilling tool or the
seizure of back-dragging pipeline arising from the improper operation method or violation operation of the
drilling rig are not covered by warranty scope.
It’s prohibited to stop the engine when the power head still has reverse torque or back-dragging
counter-force. Ensure to idle the engine for >5min before stop. It’s prohibited to use the emergency stop
switch as the engine stop switch.
While lifting and lowering the cab, ensure to operate with cautions and ensure there is no person around
the cab, in order to prevent causing personal harms during the lowering of the cab.
Safety 1-3
Before the ground touch of the anchorage base, ensure to take out the anti-rotation pin of the anchorage
base. While lifting up the anchorage base, ensure to firstly install the anti-rotation pin of the anchorage
base. Before sliding forward or backward the drill frame in large angular change, firstly install the
anti-rotation pin of anchorage base to prevent the overturning of the machine-mounted crane along with
the anchorage baseplate.
The losses of personnel and equipment arising from the overturning of the anchorage base or the
non-unplugged fixing pin of anchorage base at the ground touch are not covered by warranty scope.
During the traveling of drilling rig or the sliding of the drilling frame, pay close attention to the position of
power head to ensure that the power head is always between the idler and drive sprocket, in order to
prevent the imbalance of the drilling rig.
During the movement of integral vice, the operator shall observe the longitudinal position f of the vice to
ensure that the moving vice will not injure the personnel standing on the walkway.
1.2 Machine Safety
All relevant personnel, including the operation personnel and repair personnel, must carefully fulfill the
requirements of equipment safety specifications, in order to eliminate the dangerous factors, prevent the
occurrence of accidents, and guarantee the correct and efficient construction. Otherwise, it will result in
equipment damage and even serious personal injuries.
1-4 Safety
1.3 Descriptions of Safety Signs
Safety sign Description
Keep away by a safe distance during the operations of

machine, otherwise it will probably impact human body
to cause personal harms.
Keep away from the machine by a safe distance, in

order to prevent crushing your body by the upper force.
The heat dissipated by the engine during running will

result in heating of canopy and touching the canopy
will cause personal harms.
Do not operate this machine before reading and

understanding the instructions and warnings of this
manual. The failure to abide by these instructions or the
negligence of these warnings will cause personal
injuries. If the replacement of manual is required,
please contact our sales department.
Electric shock danger. Please keep away by a safe

distance.
Do not adjust any device by hand during operations of

machine, otherwise your fingers or palm will probably
be crushed to cause personal harms.
Please keep away by a safe distance during the working

of power head, in order to prevent the entanglement of
your sleeves or hair into the power head from causing
personal harms.
Safety 1-5
Crushing danger in articulated areas. Please keep away

from the machine by a safe distance.
Danger of arm entanglement by rotating gears. Please

keep away from the machine by a safe distance.
High pressure spray. Please keep away by a safe

distance.
Stop engine and withdraw key before maintenances and

repairs.
Do not open or remove any safety shield during running

of engine.
Foot toe or sole crushing danger! Please keep away by a

safe distance.
The thrown or flying object can impact your whole

body. Please keep away by a safe distance.
1-6 Safety
Body impact danger. Please keep away by a safe

distance.
The motion parts will probably cause serious harms to

your body. Please keep away.
Lock the hydraulic cylinders by locking devices before

accessing the dangerous areas.
Beware of electric shock
Ignition or detonation danger.
Caution
No trespassing without permission.
Safety 1-7
No Smoking
No smoking
Wear safety helmet.
Ensure to wear protective gloves.
Ensure to wear protective shoes.
Engine coolant sign
Engine oil sign
1-8 Safety
Hydraulic oil sign
Drive oil sign
Lubricating oil filling point sign
Diesel sign
Battery sign
Lubricating grease filling point sign
Toolbox sign
Safety 1-9
Lifting point sign
Fire extinguisher sign
Operation instruction for oil suction cutoff valve of

hydraulic main pump
Drilling rig traveling direction sign
Emergency exit
High and low level signs of hydraulic oil tank
Special signs for horizontal directional drilling rig of XCMG Construction Machinery Co., Ltd.:
1-10 Safety
Warning Notice
The violation operations will probably cause To protect the control system:
personal injuries or serious accidents. Please strictly  Do not operate before the proper connection of
abide by the operation regulations and ensure the battery.
correct working of safety protection devices. Ensure  Ensure to cut off the power switch during the
to wear insulation gloves and insulation shoes during quick charging of battery or welding on the
operations. machine.
Notice
To protect the control system:
 Do not operate before the proper connection of
battery.
 Ensure to cut off the power switch during the
quick charging of battery or welding on the
machine.
Notice
Daily check the lubricating oil.
Warning
It’s prohibited to close the cutoff valve at the start or
during the running of the engine.
Safety 1-11
1.4 General Danger Information
1. Take safety measures before operations.
Before operations, set up warning signs, such as

railings and pennants, around the working site and
when necessary assign special personnel to assist the
traffic dispersion, in order to guarantee the construction
safety.
Figure 1-1 Diagram of Safety Measures before
Operations
2. Wear protective appliances.
Please wear safety helmet, protective shoes, and other

protective appliances correctly as per the construction
requirements. Do not wear loose cloths or jewelry,
otherwise they will probably be entangled into the
Figure 1-2 Diagram for Wearing of Protective
machine to cause personal injuries.
Appliances
3. Properly preserve loose objects.
Do not place any fragment, oil, or tool onto the

machine, otherwise it will probably damage the
machine.
Figure 1-3 Warning Diagram for Proper

Preservation of Loose Objects
4. Gesture signals
The personnel familiar with the specific gesture signals

in the working site and entitled to send the gesture
signals shall only accept the gesture signals issued by
specific personnel.
Figure 1-4 Diagram of Gesture Signals

5. Keep away from all rotating and moving parts.
Ensure to keep away from moving parts during

operations, as the moving parts will easily cause serious
personal injuries.
6. Avoid maloperations.
Do not perform any repair or adjustment after the start

of machine.
1-12 Safety
7. Dispose waste oils properly to prevent

environmental pollution.
The oils are pollutant. Do not pour any waste oil into
sewer or river or onto the ground. Pour the waste oils
into appropriate containers and dispose them as per
relevant laws and regulations.
Figure 1-5 Diagram of Gesture Signals

8. The hot oils and parts can probably cause personal
harms.
Guard your skin against the contact with hot oils and
hot parts.
9. Cut off power supply of machine before welding.
Before welding, ensure to cut off the power master

switch on the machine, otherwise the electric
components will be damaged by the stray current and
voltage generated during the welding.
1.5 Main Dangers
1. In event of any machine abnormality or personal injury, immediately push down the emergency stop button
to stop the running of the machine.
2. The power head performs reciprocating motion on the drilling frame during operations of the machine.
During the motions, the operation personnel shall keep away by an appropriate distance, otherwise it will
probably cause serious personal harms.
3. During the transport of drilling rig, ensure to install the anti-rotation pin of anchorage base and do not use the
machine-mounted crane, otherwise it will probably result in personal harms.
4. The machine is equipped with rotating drilling tool. All personnel shall keep away by a distance to ensure
personal safety.
5. The engine body and coolant are hot during running of engine. Touching the hot coolant, engine body, or
steam will cause serious scalding. Before replacing coolant or cleaning cooling system, cool down the
cooling system parts (By observing the water temperature gauge). Check the coolant level only after the stop
of engine. Before removing the filler cap, ensure that the filler cap is cold. The filler cap must be cold enough
to allow the touch by bare hands. Slowly remove the filler cap to relieve the pressure.
6. The cooling system additives contain alkali. Keep them away from your skin, eyes, and mouth, in order to
prevent harms.
7. Frequently check the hydraulic hoses. Upon detection of partial expansion, leakage, or damage, replace
Safety 1-13
immediately.
8. The battery electrolyte is an acid substance. Keep it away from your skin and eyes, in order to prevent
causing harms.
9. The slewing cab will probably cause serious injuries to the personnel on the sides of cab.
10. Before lifting up the drilling frame, it’s necessary to install the anti-rotation pin of the anchorage base. While
installing the fixed anchorage base, take out the anti-rotation pin of anchorage base when the anchorage base
just touches the ground.
11. The rotating parts of the engine will cause personal injuries. Keep away by a safe distance to ensure personal
safety.
12. The hydraulic oil is at high temperature under normal working status. Guard yourself against scalding.
13. While adjusting the angle of drilling frame, the area beneath the drilling frame will cause personal crushing.
Please keep away by a safe distance to ensure personal safety.
14. The sliding of vice will result in the change of motion space and cause personal crushing. Please keep away
by a safe distance to ensure personal safety.
15. The insecure fixing of anchorage base will result in overturning of drilling frame to damage the machine.
16. Before any welding operation on the drilling rig, ensure to cut off the power master switch on the machine,
disconnect the battery cables, and unplug the GPS and controller connectors, otherwise the stray current and
voltage generated during welding will probably damage the electric components.
17. If the anchorage bases are not anchored reliably, the forward or backward movement of power head or the
forward or backward sliding of drilling frame will result in imbalance and rollover of the drilling rig.
1.6 Operation Safety Regulations
1. Operation checking
a) Check all threaded connections for secure tightening and check pins for firmness.
b) Check all portions for sufficient lubricating grease, lubricating oil, coolant, or engine oil.
c) Check for sufficient hydraulic oil and fuel and check hydraulic pipelines and fuel pipelines for leakage.
d) Check the drilling frame rack for presence of impurities, in order to guarantee the smooth running of
power head.
e) Ensure the normal functioning of emergency stop buttons and joysticks.
2. Operation warning
Before starting up the machine, sound the horn for three times to alert the surrounding personnel to keep away.
3. Stability
When the drilling frame is arranged horizontally and the power head is moving forward, the power head rotary
box shall not protrude beyond the front end of idlers, otherwise the overall gravity center of the machine is too
1-14 Safety
forward to deteriorate the stability and there is a forward inclination danger during traveling.
4. Angular adjustment of machine
When the anchorage base is about to touch the ground, remove the anti-rotation pin of the anchorage base, in
order to prevent causing accident due to unstable gravity center of the anchorage base and machine-mounted
crane.
5. Tracks
If a track is too loose, inject grease into the tension cylinder through the maintenance hole on the side face of track
longitudinal beam to tension the track, as shown in Figure 1-1. To loosen the track, slowly loosen the filler valve
till the grease overflows.
Precautions during operations: Do not look into the maintenance hole, in order to prevent the spray of high
pressure grease from causing personal injuries. Do not loosen the filler valve excessively, in order to prevent the
fly-out of parts under high pressure from causing personal injuries.
Figure 1-6 Tensioning of Tracks

6. Rotary water seal
Upon detection of water drips at the rotary connector during operations, it indicates that the rotary seal is already
worn slightly. This problem can be solved by following procedure, as shown in Figure 1-2.
Figure 1-7 Rotary Water Seal

1) Rotate the seal ring compression screw of rotary water seal to the position opposite to the outer tightening
hole.
2) Tighten the screw within the hole by an Allen wrench. After adjustment, ensure to take out the Allen wrench,
in order to prevent causing possible harms to machine or personnel.
3) Rotate the power head spindle and tighten the compression screws of seal ring in turn.
If the mud leakage still can’t be solved by above-mentioned method, the seal ring is probably damaged or the mud
Safety 1-15
mandrel is probably worn and it’s necessary to break up for checking. The structure of the rotary water seal is
shown in Figure 1-3.
Figure 1-8 Rotary Water Seal

7. Machine-mounted crane
1) Before placing the anchorage base of drilling rig steadily onto the ground, it’s prohibited to use the
machine-mounted crane for lifting of weights.
2) Operate with cautions while lifting a load or lifting the boom. The over-winding of the wire rope is
prohibited.
3) It’s prohibited to operate the lifting and luffing motions simultaneously when a load is lifted or operate
the machine-mounted crane to impact a load.
8. Hydraulic oil leakage
Closely observe the hydraulic system for leakage of hydraulic oil. Upon detection of leakage, ensure to find out
the cause and repair.
While checking or repairing the leakage of any pressure pipe without relieving the pressure, ensure to cover by a
thin board or paper board, as the fluid sprayed under high pressure will penetrate your skin to cause serious harms.
9. Replacement or adding of hydraulic oil
To replace or add hydraulic oil, stop the engine and slowly loosen the air filter on the top of hydraulic oil tank to
relieve the internal pressure of oil tank, in order to prevent the splashing of hot oil from causing scalding.
10. Maintenances
All repairs and maintenances are prohibited when the machine is under started status. When the operations by the
repair/maintenance personnel beneath the drilling frame are required, it’s prohibited to support the machine
independently by cylinders. Ensure to wait for the stable support of the machine and then add steel brackets or
other rigid device to assist the support. Otherwise it will probably cause personal injuries or deaths.
1-16 Safety
11. Operations of engine
For the operation safety instructions of engine, please refer to attached engine operation manual.
12. Stability of drilling rig
The smooth engineering operations depend on the reliable anchorage of the drilling rig. The looseness or slip of
the anchorage base during operations will result in the damages of machine and failure of engineering operations.
13. Reasonable pilot hole
In addition to the limit bending radius of the drill pipe, the bending radius of the back-dragging pipeline shall also
be taken into consideration. The reasonable design of pilot curve is an important item for the safe back-dragging
of pipeline and a precondition for the operation safety of drilling rig. The irregular or excessively bent pilot curve
will double the back-dragging force or even result in failure of engineering operations.
14. Appropriate mud
The engineering operations require the mud adapting to local geological condition. Besides the appropriate
viscosity and proportion of the mud, both flow and pressure of the mud shall meet the operating needs.
15. Drill pipe and drilling tool
The drill pipe and drilling tool are subject to the application of complicated loads. Though drill pipe is subject to
really high torque or pushing/pulling force, it’s the application action of single load. Under the action of the
complicated loads, the force or torque applied onto the drill pipe is reduced remarkably. To guarantee the smooth
and safe operations, the actual operating torque of the drill pipe shall never exceed its permissible torque.
The different geological conditions require the use of different drilling tools and the combinations of various
drilling tools can achieve more application scope. The appropriate drilling tool can remarkably speed up the
operation progress.
1.7 Equipment to be Provided by User
1. Fire extinguisher
Ensure that the fire extinguisher can extinguish the fires caused by oil and electricity.
2. The protective clothes, shoes, and helmets for operation personnel, safety and warning signs, and grounding
mats.
3. Other auxiliary equipment, such as mud treatment and recovery equipment, generator, pipelayer, pipe welder,
and lighting equipment.
1.8 Classification of Underground Hazardous Substances
1. Power cables.
2. Natural gas pipelines.
3. Optical fiber cables.
Safety 1-17
4. Running water pipelines.
5. Sewage pipelines.
6. Delivery pipelines for other chemicals, liquids, and gases.
1.9 Division of Construction Site and Precautions
1. Division of construction site
Based on the presence of underground hazardous substance, the construction site can be divided to electricity type,
natural gas type, and other type.
Table 1-1 Division Table of Underground Hazardous Substances
Construction area Type

Within 3m reach to power cables Electricity type
Within 3m reach to natural gas or petroleum pipelines Natural gas type
Within 3m reach to other hazardous substances Other type
2. Detailed precautions for various types of working sites
1) Precautions for electricity type working sites
① Expose the electric cables by manual digging method.
② Cut off the power supply of the power cables during operations. The electric power company shall
check the circuits before resuming the power supply of power cables.
2) Precautions for natural gas type working sites
① The drilling rig shall be installed at the upwind side of the natural gas pipelines.
② Expose the pipelines by manual digging method and follow up the drilling path by probe.
③ Cut off the natural gas supply during operations. The natural gas company shall check the circuits
before resuming the natural gas supply.
3) Precautions for other operation sites
For other underground hazardous substance type construction sites, depending on the specific condition,
timely communicate with related public utilities administration department or special security authority
and jointly seek for appropriate solutions through consultation.
1.10 Electric Shock Knowledge
The basic electric shock knowledge is as below:
1. The current will transmit to the underground through diversified means.
2. All cables on the drill pipe, hoses, and machine have a possibility of transmitting the current onto the machine.
1-18 Safety
3. The low-voltage current can also probably cause personal casualties.
4. In event of any of the following situations, the electric shock shall be assumed and the machine shall be
immediately stopped for checking:
1) Interruption of power supply
2) Smoking
3) Explosion
4) Bursting noise
5) Electric arc
1.11 Safety Emergency Knowledge
1. Electric shock
Before operations near any power cables, consult the operation details with the electric power company in advance and
ask the assisting staff for commanding nearby. Keep away from the electric wires and cables whenever possible, in
order to prevent the occurrence of accident.
In event of electric shock, stay put on the drilling rig or grounding mat. Keep all personnel away from touching or
accessing the drilling rig. All personnel without wearing the insulation shoes are prohibited to enter into the
working site. Immediately contact the related electric power company. Do not restart the drilling without the
permission of the electric power company.
2. In event of drilling through any natural gas pipeline, ensure to:
1) Immediately stop the engine and eliminate all fire sources.
2) Leave from the working site as soon as possible.
3) Warn and evacuate personnel to leave from the site as soon as possible.
4) Contact the local natural gas company.
5) Do not enter into the working site without the permission of the related public utilities authority.
3. In event of drilling through any optical fiber cable, ensure to:
1) Immediately stop the drilling rig and contact the local electric power company.
2) Do not directly look into the fractured end of the optical fiber cable, in order to prevent harming your
vision.
4. In event of drilling through any running water pipeline, ensure to:
1) Immediately stop the drilling rig and contact the local water utility company.
2) Keep all personnel away from accessing the hazardous area.
Safety 1-19
MEMO
1-20 Safety
Chapter 2 Product Information
2.1 Product Overview
XZ5060 horizontal directional drilling rig is a kind of construction machinery to pave diversified types of
underground public utilities (Such as pipelines and cables) under the non-excavated surface condition and is
extensively used for the pavement of water, coal gas, natural gas, and petroleum pipelines crossing highways,
railways, buildings, and rivers and under the conditions with difficult excavation, such as historic reservations,
crop areas, and vegetation reserves. The drill bits and back-reaming bits of different types can be selected
depending on specific stratum and the back-reaming bits of different sizes and specifications can be selected
depending on the specific diameter of the pipelines to be laid. This drilling rig can achieve better economic and
social benefits and create the so-called green and environmental-friendly projects, featuring high rotating speed,
high torque, high push-pull force and speed, high operation speed, good safety performance, and low
comprehensive cost.
2.2 Model Composition
Push-pull force: 5060KN
Directional drilling
XCMG
2.3 Applicable Scope
It’s applicable for the geological conditions, including sandy soil, clay, and pebble, and is suitable for most non-hard
rock regions in China. Working environment temperature: -10℃~+40℃.
2.4 Product Features
The main technical features of the XZ5060 horizontal direction drilling rig are as below:
The digital display system directly displays the main operation parameters, including rotating torque and push-pull
force, to overcome the disadvantage of conversion needs for the pressure gauges of a traditional drilling rig and realize
easy operations.
The rotating torque and push-pull force overload protection system of the power head adopts electronic sensors to
achieve quick and sensitive response and high reliability. The rotating torque and push-pull force can be accurately
Product Information 2-1

preset. The power head spindle is under floating status to reliably protect the drill pipe thread and prolong the life of
drill pipe.
This machine is powered by double engine system and all motions of the drilling rig can be completed by starting either
engine. In combination with the proprietary multi-condition speed regulation technology and the multi-gear rotating and
push-pull control technology, this drilling rig features extensive application scope. Under the small hole diameter
operation condition, the running of only one engine is needed, featuring low fuel consumption and low operation cost.
The drilling frame is slide by push-pull cylinder and the double luffing angle adjustment mechanism achieves simple,
easy, and safe penetrating angle adjustment.
The whole-course floating vice features high shackle torque and eases the casing installation operation. The patented
rotatable jaw holders realize the automatic centering and reliable clamping of the drill pipe.
The multi-pump flow confluence and division control technology guarantees high engine power utilization rate and high
energy-saving and fuel-saving. The multiple advanced energy-saving control technologies, including
electro-proportional control, are applied and the imported hydraulic and electric components are used to ensure reliable
quality.
The multiple control technologies, including closed-loop hydraulic rotation system and load-sensing push-pull control,
are applied and the critical hydraulic, electric, and drive components use world’s renowned products to ensure reliable
quality.
2.5 Overall Dimensions
The overall dimensions of XZ5060 drilling rig are shown as below:
Glass-reinforced Glass-reinforced
plastic observation plastic observation
window window
2-2 Product Information

Item Unit Parameter

Overall length of machine (A) mm 20000
Overall width of machine (B) mm 3400
Overall height of machine (C) mm 3770
Weight of machine t 59
Weight of operating room t 3
2.6 Main Technical Specification
Item Unit Parameter

Manufacturer Cummins
Engine Model QSZ13-C475
Rated power kW/(rpm) 2×354/1900
Maximum push-pull force kN 5300
Push-pull
Maximum push-pull speed m/min 33
Torque N·m 160000
Rotation
Maximum speed r/min 80
Drill pipe Diameter × length mm Φ140/Φ168×9600
Maximum penetrating angle ° 16
Lifting weight t 5
Machine-mounted crane
Lifting torque t•m 12.5
Type Self-propelled steel tracks
Traveling drive Traveling speed km/h 1.5
Gradeability % 30
Overall dimensions of machine mm 20000×3400×3770
Weight of machine t 59
mm 2991×2438×2591/
Dimensions of operating room (Optional)
5982×2438×2591

2.7 Product Nameplate
2.8
1. Chassis
XZ5060 adopts self-propelled chassis with steel tracks, featuring powerful site adaptability and high reliability.
The reducer features stable and reliable performances.
Track width 4,025 mm

Outer width of tracks 2,750 mm
Track width 600 mm
Track gauge 2,150mm
Number of rollers 2×9

Traveling reducer 2×ZFT60

Drive force 415kN
Gradeability 30%
Traveling speed 1.5km/h
Ground pressure 112kPa
2. Engine system
The Cummins turbocharged engine equipped features strong power and meets the China-III emission regulation.
Engine model QSZ13-C475

Rated power 2×354kW/(1900r/min)
Maximum engine torque 2300 N·m /(1200~1500r/min)
Compliant emission regulation China-III
Fuel tank capacity 1100L
3. Hydraulic system
The advanced control technologies are applied, including closed-loop hydraulic rotation system and load-sensing
push-pull control. The imported components guarantee reliable quality.
1) Power head rotating system
Rotating pump 4×Sauer H1P100

Pressure 330bar
Motor 3×Rexroth A6V M200
2) Power head push-pull system
Push-pull pump 2×Sauer D1P193

Pressure 350bar
Motor 8×Rexroth A6V M160

4. Hydraulic oil tank
Hydraulic oil tank capacity 700L
5. Electric system
The advanced intelligent control technology and CAN bus technology are applied in response to horizontal
directional drilling characteristics and the various instruments in clear display ease the observation.
The large-size high-definition display is applied to directly display the actual push-pull force and rotating torque
during operations.
The PLC control incorporates the parameter monitoring and warning for engine speed, water temperature, engine
oil pressure, hydraulic oil level and temperature, oil return filter, and power head limit, and the malfunction
self-diagnosis function to ease the repairs and maintenances.
The wire-controlled traveling and the stepless speed regulation guarantee easy operations and safe site transfer.
The multi-gear control and stepless speed regulation are applied for both rotation and push-pull to realize
extensive stratum and geology applicability.
System voltage DC24V

Battery VARTA 6-QW-120B
Controller Rexroth
Display MURPHY
Push-pull and rotation joystick P+G
Speed sensor Rexroth
Sensing switch Honeywell
Travel switch Honeywell
Temperature sensor Danfoss
Pressure sensor Danfoss

6. Drilling frame
The front rocker arm and the rear support cylinder are applied for simultaneous luffing, featuring easy operations
and large range of angle adjustment.
The drilling frame welded from Q460D high-strength steel is equipped with standard drill pipe bracket to ease the
operations. The sliding of the drilling frame is driven by cylinder to ensure easy angle adjustment.
Sliding range of drilling frame 2500 mm

Drilling frame length 17000 mm
Drilling frame adjustment angle 9~16°
7. Power head
The drilling rig completes the push-pull motions by pinion and rack. The flowing device of the power head
spindle effectively protects the drill pipe thread. The variable displacement motor realizes the high-speed
push-pull motions. The push-pull force can be steplessly adjusted depending on the construction needs to protect
the drill pipe.
Maximum push-pull force 5,300kN

Maximum push-pull speed 33m/min
Maximum rotating torque 160000N·m
Maximum rotating speed 80r/min
Spindle floating range 120mm
Maximum travel of power head 12000mm
Push-pull reducer 8×Brevini SL4003
Rotating reducer 3×Brevini SL4002

8. Vice
The drilling rig is equipped with self-centering high-strength rotating unshackling vice to securely clamp the drill
pipe. The vice can integrally move on the drilling frame to ease the casing installation process. The front and rear
vices can slide relatively to achieve good operating vision and ease the maintenances and replacement of jaws.
Unshackling torque 320000N·m

Rotating angle of rear vice 20°
Separating range of vice 300mm

9. Independent operating room (Optional)
The independent operating room is in standard container size and is reserved with A/C space to remarkably
improve the operating comfort of the drilling rig. It’s also equipped with internal illuminating lamps. The control
console with various instruments and joysticks is suitable for long-time operations.
Input power supply AC 220V

Length of operating room 2991/5982mm
Width of operating room 2438mm
Height of operating room 2591mm
10. Machine-mounted crane (Optional)
The 5t machine-mounted crane guarantees stable and easy manual operations.
Maximum lifting capacity 5t

11. Drill pipe and drilling tool (Optional)
The standard petroleum drill pipe or special non-excavation double-shouldered drill pipe can be used. The cutting
type, squeezing type, runner type, or other special back-reamers in diameter of 400mm~2,000mm can be used,
with the longest operation range up to 2,000m. The user may select the short connector and transfer case of other
type and specification depending on own needs.
Diameter of drill pipe φ140/φ168mm

Length of drill pipe 9600mm
Size of connector on two ends of drill pipe 5-1/2FH(φ140)/6-5/8FH(φ168)

2.9 Operations
1. Start and stop of engine
1) Start of engine
Firstly check and ensure that the emergency stop switches at the traveling control box, control panel, power head,
and vice are under ON status and then operate as below:
① Turn on the power master switch (2 places).
② Rotate the key switch to (ON) to turn on the power supply and observe the fuel level indicated on the display.
Ensure that the fuel is sufficient and all warning and indicator lamps, except the charging indicator lamp and
engine oil pressure warning lamp, are off.
③ Ensure that all switches and joysticks are in neural position.
④ Press the horn button to sound the horn for warning and ensure that no other person is on or near the
machine.
⑤ Rotate the key to (START) position to start the engine.
• The engine start time shall not exceed 20s.
• It’s prohibited to turn off the power switch during the operations after the start of engine.
• After the normal start of engine, run the engine at low speed for 3~5min. In winter, the running time
shall be slightly longer, but shall not exceed 10min.
• When the drilling rig is used under low temperature and the cold start function is installed, rotate the
key counter-clockwise and hold it for approximately 30s and then return the key and start the
machine.
• If the engine fails to start successfully by one time, wait for at least 2min before retry.
2) Stop of engine
① Idle the engine for 3~5min.
② Rotate the key to (OFF) to stop the engine.
③ Withdraw the key from the switch.
④ Turn off the power master switch.
While stopping the electronic control engine, hold the key at (OFF) for at least 30s before turning off the
power master switch.

In event of any emergency, directly push down the red emergency stop switch (STOP) on the control
console panel.
For the detailed operations of the engine, please refer to the engine operation manual.
2. Traveling
1) After the start of engine (For the traveling of drilling rig, the start by the key within the control box is
required), ensure that the working/traveling switch within the control box is under the traveling status.
Observe the position of power head. If the power head center is outside the line between idler and sprocket,
please move the power head into the stable area.
Ensure that the traveling function switch in the traveling control box is under ON status.
The traveling operations can be made independently or in combined manner to realize the forward traveling,
reversing, left turn, right turn, and pivot steering of the drilling rig.
2) The operating directions of the manual control traveling joysticks and the corresponding motions are shown
in diagram below:
Figure 2-1 Operating Direction Diagram

3. After the angle adjustment of drilling frame and the start of machine, ensure to switch over the
working/traveling switch on the control panel to traveling mode so that the operations of the manual valve
for angle adjustment are enabled.

4. Tensioning and loosening of tracks
1. Track tensioning requirement
If a track is too loose, inject grease into the tension

cylinder through the maintenance hole on the side
face of track longitudinal beam to tension the track.
Figure 2-2 Track Tensioning and Loosening Model

Diagram
2. Track loosening requirement
To loosen a track, slowly loosen the relief valve,

till the grease overflows. If the grease overflows
slowly, elevate the track by outriggers, idle the
track for several turns, and then tighten the relief
valve.
Figure 2-3 Operation Sequence Diagram for Tensioning

and Loosening of Tracks
• Never look into the maintenance hole, in order to prevent the spray of high pressure grease from
causing personal injuries.
• Do not loosen the relief valve excessively, in order to prevent the fly-out of parts from causing personal
injuries.
6. Push-pull and rotation
Always keep the drill pipe in forward rotation during the working of power head. The reversing of power
head is allowed only during unshackling operation.
7. Power head high-speed push-pull
Press the power head high-speed push-pull button and meanwhile push the power head push-pull joystick to

realize the high-speed pushing or back-dragging function of the power head.
Precautions for high-speed push-pull operations:
During the high-speed push-pull operation, the push-pull speed is increased, but the push-pull force is reduced
accordingly.
8. Power head high-speed rotation
Press the power head high-speed rotation button and meanwhile push the power head rotation joystick to realize
the high-speed rotation of power head.
Precautions for high-speed rotation operations:
During high-speed rotation operation, the rotating speed is increased, but the rotating torque is reduced
accordingly.
2.10 Drill pipe
1. Classification and structure of drill pipe
During the horizontal directional drilling, the drill pipe performance directly influences the construction process
and project quality. Especially during the operations, the drill pipe performance directly influences the whole
construction success rate. The drill pipe is subject to both axial push-pull force and rotating torque during
operations.
At present, the drill pipes for horizontal direction drilling rig are mainly classified into two structural types:
1) Integral type: Fabricated from the special petroleum drill pipe tube blank that conforms to the API standard,
this drill pipe features reliable performances and adopts the exclusive double upsetting technology for the
drill pipe connector to realize stable and smooth transition zone and reduce the flow-through resistance of the
mud.
2) Welded type: The friction welded type drill pipe realizes the optimal structure combination of drill pipe,
namely the materials of different performances meeting the different needs can be used to fabricate the
different portions of the drill pipe. The friction welded drill pipe incorporates really high mechanical
performance and wear resistance, light weight, and good toughness and can easily realize the welding
combination with the threaded connectors of different types and the steel tubes of different specifications.
Figure 2-4 Three-Dimensional Model Diagram of Drill Pipe

2. Drill pipe specification
The drill pipe specification is listed in table below:
Drill pipe
Dimension
specification
Outside Minimum
Steel Safety torque
Wall diameter Thread curvature
Millimeter Length Weight Thread grade (kNm)
thickness of length radius (m)
(mm)
(m m)
(m) (kg) connector type (mm)
(m m)
5 1/ G105 120 90
￠140 9.19 9.6 300 ￠168 110
2FH S135 130 80
3. Precautions for use of drill pipe
The drill pipe is designed to transmit torque and axial force to the drill bit and is subject to repeated impact during
working, featuring severe and complicated working conditions. To guard the drill pipe against damage and
maloperation, please abide by the following regulations:
1) Select the drill pipe of appropriate specification and model based on the torque, push-pull force, and
minimum permissible curvature radius of the drilling rig.
2) Avoid connecting a drill pipe of larger diameter to a drill pipe of small diameter (Namely the mixed use of
large and small drill pipes) during the operations, in order to prevent the breakage or deformation of small
drill pipe due to insufficient strength.
3) While clamping the drill pipe by vice, take cautions not to clamp the female thread of the female connector,
in order to prevent deforming the female thread.
4) While installing and connecting the drill pipe, take cautions to control the shackling pre-tightening pressure
within 15Mpa, in order to prevent difficult unshackling due to over-high pressure. Avoid baking the
connectors by fire, in order to prevent deteriorating the mechanical performances of the connectors and
shortening the life of connectors (Especially the female connector). The non-pre-tightened thread connection
will swing to cause mutual friction between threads, sharpen the thread top, and form ridges on the side face,
which will lead to thread damage and seized thread connection. The non-pre-tightened connection will lead
to non-compressed female thread shoulder, which can result in fatigue breakage at thread root of the male
thread connector.
5) Before installing and connecting drill pipe, take cautions to thoroughly clean the male and female threads and
apply the thread oil (It’s prohibited to use other waste oil or low quality oil in place of thread oil), in order to
prevent earlier wear or damage of the female and male threads.
6) Before installing and connecting the drill pipe, take cautions to clean the water passage hole, in order to
prevent the blockage of water passage by impurities from causing pressure buildup of the mud system.
7) Take cautions not to forcibly engage the threads. While aligning the threads, ensure the alignment between
male and female connectors and do not aim the male thread at the shoulder and thread of female thread
Ensure the coaxiality between the shackle and power head spindle of the drilling rig.
8) Notice to check the wear status of all drill pipe portions. Upon detection of any abnormal wear, timely find

out the cause:
• Judge whether the drill pipe is scratched by any sharp hard object within the hole.
• If the scratch at the drill pipe body is in depth of approximately 1mm and is in spiral shape for more
than 1 turn, please use with cautions, in order to prevent the breakage of drill pipe during operations
from causing higher losses.
9) Upon detection of damaged thread in drill pipe short connector (Thread disorder or seriously worn thread),
timely replace it to prevent damaging the drill pipe thread.
10) Take cautions to prevent impacting or damaging the male thread during the lifting and handling of drill pipe.
11) Take cautions to prevent using the drill pipes of different thread types or using the drill pipes not
manufactured by same manufacturer (The tolerance and tightness of the fabricated drill pipes are not surly
the same because the different manufacturers have different technical specifications, machining methods, and
cutters and mechanical equipment for the manufacturing of drill pipes). Do not use the drill pipes with
remarkable difference in service life or wear status, in order to prevent causing construction danger.
12) Upon detection of small area partial damage (Approximately 1~2 threads in length of 10mm) in the thread
form of drill pipe, timely repair before use.
13) Take cautions to prevent clamping any portion of the drill pipe body by the vice, in order to prevent crushing
the drill pipe body by the jaws and shortening the life of the drill pipe.
14) Use qualified zinc-base thread grease. It’s inappropriate to use calcium-base grease as the thread grease. The
insufficient thread grease will cause damage and height difference in the shoulder of the connector to easily
result in loose thread connection and thread damage. The failure to use thread grease or the use of
disqualified thread grease will result in bonding of thread surface and seized thread.
4. Possible malfunctions of drill pipe during operations
1) Breakage of drill pipe along male or female threads.
2) Breakage of drill pipe body.
3) Breakage or open weld of friction welded joint.
4) Bending or distortion of drill pipe body.
5) Expansion of drill pipe female thread end face.
6) Deformation of drill pipe female thread end face.
7) Damage of drill pipe thread form.
8) Serious damage at surfaces of drill pipe male and female connectors.
5. Causes and treatment methods of drill pipe malfunctions
1) Breakage of drill pipe along male or female threads
• The torque of the drilling rid exceeds the bearable torque of drill pipe under current inclination.
• The curvature radius of the construction hole exceeds the minimum curvature radius of the drill pipe.

• During the reaming of hole (Especially the reaming of large hole) or the drilling of long-distance pilot
hole, the drill bit encounters against a hard object suddenly to generate a high impact force and result in
sudden increasing of torque and breakage or twist-off of the drill pipe.
• The operator shall reasonably control the rotating speed and pushing force during operations of drilling
rig, in order to prevent the occurrence of such problem.
2) Breakage of drill pipe body
• The torque of the drilling rid exceeds the bearable torque of drill pipe under current inclination.
• The curvature radius of the construction hole exceeds the minimum curvature radius of the drill pipe.
• During the reaming of hole (Especially the reaming of large hole) or the drilling of long-distance pilot
hole, the drill bit encounters against a hard object suddenly to generate a high impact force and result in
sudden increasing of torque and breakage or twist-off of the drill pipe.
• The material or thickness of the drill pipe body fails to meet the technical specification.
• The drill pipe body surfaces are seriously scratched (>1mm in depth and in spiral form).
• The drill pipe approaches or exceeds the fatigue life, with many damages on surfaces, due to long usage
time.
3) Cracking or breakage of drill pipe friction welded joint
Welding quality defects.
4) Bending or distortion of drill pipe body.
• The pushing force is too high or fierce while drilling a pilot hole.
• The curvature radius of the pilot hole is too small during operation.
5) Expansion of drill pipe female thread end face.
• The mixed use of drill pipes with different thread forms or manufacturers or with significant difference
in usage time results in the out-of-tolerance of the standoff and expansion of female thread during the
connection of drill pipe.
• The thread forms are incompatible or seriously worn for the protective short connector of drilling rig
power head and the drill pipe to result in high standoff tolerance.
• The inaccurate fitted length between female and male threads can’t realize the double-shouldered use
(Main and auxiliary shoulders) of the connector.
• The curvature radius of hole exceeds the permissible curvature radius of the drill pipe to result in
expansion of female thread.
6) Deformation of drill pipe female thread end face.
• The female thread portion is clamped by the vice jaws.
• The deformation is caused by the excessive torque or the hammering or fire baking due to difficult
unshackling.

7) Damage of drill pipe thread form
• The qualified thread oil is not used.
• The thread surfaces are not thoroughly cleaned.
8) Serious damage at surfaces of drill pipe male and female connectors.
• The damages are caused by the clamping of vice jaws with over-high hardened and tempered hardness.
• Heat treatment and nitriding hardness defect or material defect of the connectors.
• The connectors are hammered by a large hammer or baked by fire due to difficult unshackling.

2.11 Drilling tool
There are diversified types of drill bits. The operator shall select the drilling tool correctly and reasonably
depending on specific stratum. The correct selection of drilling tool is the key to guarantee the smooth operation
of the horizontal directional drilling rig. Before starting the drilling rig for drilling, the operator or the construction
technician must understand in details the geological exploration data of the construction site, in order to establish
the optimal construction plan.
The directional drilling tools are mainly classified into three types:
a. Pilot drill;
b. Reamer;
c. Transfer case.
1. Pilot drill
1. Classification of pilot drill
The pilot drill includes: Pilot drill bit, guide plate,

starting rod, adapter, octagonal socket, and left-handed
nut.
Figure 2-5 Pilot Drill Model Diagram 1

2. Pilot drill bit
The pilot drill bit is composed of probe box and

beveled bit body so that the high pressure fluid flows
through the nozzles to form high pressure sprays to
assist the cutting and guiding.
The probe box is used for placement of the probe. It’s

provided with magnetic flux groove thereon and is
sealed by non-metallic material to prevent the shielding
of electromagnetic wave and guard against the ingress
of mud. Figure 2-6 Pilot Drill Model Diagram 2
The inclined plate on the beveling drill bit plays an
assisting role during the rotation of the drill bit and
plays a beveling role during the feeding.
The alloy material on the beveling drill bit and its

shape can be selected adaptively based on the
geological condition to effectively improve the

construction efficiency.
3. Octagonal socket
The octagonal socket is functioned to transmit the

torque, protect the threads against damage and seizure,
and make the disassembling of pilot drill bit easier and
more convenient.
2. Reamer
The reaming operation is one really critical process with high workload during the operations of the horizontal
directional drilling rig. The shorter the time of this process is, the safer the drilling is, the higher the pipeline
pavement efficiency is, and the better the economic benefits are. The key for the reaming operation is to select
efficient and suitable reaming bit based on the actual conditions.
The common reaming bits include runner type reamer, squeezing type reamer, and cutting type reamer.
1. Runner type reamer
The runner type reamer is mainly applicable for sand

layer, small pebble layer, and very dense soil layer.
Figure 2-7 Runner Type Reamer Model Diagram

2. Squeezing type reamer
The squeezing type reamer is mainly applicable for

clay layer and soft layer.
Figure 2-8 Squeezing Type Reamer Model

Diagram

3. Cutting type reamer
The cutting type reamer is mainly applicable for hard

soil layer, clay layer, and loose sand layer.
Figure 2-9 Cutting Type Reamer Model Diagram

3. Transfer case
1. Transfer case introduction
The transfer case is designed especially for the

directional drilling and reaming and pipeline pavement
operation. It can guard the laid pipeline against the
influence of rotating torque generated due to the
Transfer case
pipeline dragging of the drilling rig.

Transfer case
During working, the transfer case is connected to the

reamer and drill pipe by male and female pullers.
Transfer case
Transfer case
Composition: Bearings, seals, rolled pin, brake screw,
and oil cup.
Function: It maintains the drill pipe behind the reaming

bit for forward movement without rotation during
reaming operation and maintains the pipeline behind
the reaming bit for forward movement without rotation
during the back-dragging of the pipeline.
Figure 2-10 Three-Dimensional Model of Transfer

Case

2.12 Connection of Drill Pipe and Drilling Tool
The installation varies depending on specific guide method. The common installation methods are as below.
1. Common wireless or wired guide
2. Wireless or wired guide with mud motor
3. Geomagnetic guide with mud motor

2.13 Other Auxiliary Tools
1. Mud mixer
The mud mixer is functioned to make the drilling mud

and can sufficiently mix the additives (Including
bentonite) with water to fabricate the mud required for
the drilling.
Figure 2-11 Mud Mixer Diagram
2. Mud
The mainly functions of mud include removal of

drilling cuttings, protection of hole walls, blockage of
leaks, balance of stratum pressure, cooling of drill bit,
lubrication of drilling tool, prevention of stratum
settlement, reduction of back-dragging resistance, and
spray of guide water.
Figure 2-12 Mud Diagram
3. Detector
The detector is functioned to send high-frequency

electromagnetic wave to the object to be detected.
When the electromagnetic wave reflects upon the
interface between different media, the radar can
measure the two-way travel time of the object detected
by the electromagnetic wave signal and calculate the
transmission rate based on the dielectric constant of the
media to thus obtain the actual depth of the object.
Figure 2-13 Detector Diagram

4. Guide instrument
The guide instrument is a device to detect the depth and

position of underground drill bit, the pitch angle of drill
bit, and the facial angle of the guide drilling tool.
5. Other
Including shackle pliers, electric welder, pipe welder,

and thread oil.
Figure 2-14 Guide Instrument Diagram

Chapter 3 Operation Instructions
3.1 Preparations before Entrance into Site
1. Collection of data
The successful construction starts from the preparations before drilling. The first work step is to look up the
available data of the project and working site.
1) Contact the relevant public pipelines administration departments to position and mark the existing
public underground pipelines.
2) Contact the manufacturing department of the material to be dragged and request for the sample of the
pipeline to be laid. Inspect the density and strength, inquire for related critical factors (Generally, the
bending radius for steel tubes is no less than 1,500 times of the pipeline diameter and the bending radius
for PE pipeline is no less than 300 times of pipeline diameter.), including bending radius of this material,
the friction coefficient with stratum, and thickness of anti-corrosion layer, and check the availability of
appropriate back-reaming bits, cleaning drill bits, and back-dragging facilities for various stages.
3) Based on the diameter and length of the back-dragging pipeline, estimate the torque, the push-pull force,
and the consumptions of mud and various mud additives required for the operations. The torque and
push-pull force shall not exceed the carrying capacity of the drill pipe (Refer to 2.10.2 Carrying
Capacity of Drill Pipe) and back-dragging pipeline. Select the drilling rig, mud pump, mud mixing
system, and mud recovery device of appropriate tonnages based on the torque, push-pull force, and mud
consumption.
4) If the construction site is near a highway, river, or other area, please contact the relevant administration
department and discuss the related safety measures.
5) Prepare the telephone numbers of local emergency agencies and medical departments at hand.
2. Site investigation
Before the placement of machine, investigate mainly the following items of the construction site:
1) Overall planeness and gradient of the site.
2) Height difference of the site, such as hillside and valley.
3) Obstacles, such as buildings, railways, and rivers.
4) Underground pipeline markings (Refer to section Safety Protection).
5) Traffic status and site entrance route.
6) Soil and geological conditions (Geological investigation if necessary).
7) Water supply status and underground water status.
8) Interfering sources on the tracking and positioning system, such as reinforcing steel bars and steel rails.
9) Collection of soil samples from the selected points along the drilling path to determine the reasonable
Operation Instructions 3-1

match of drilling bits and back-reaming bits.
10) Site planning for penetrating point of drilling rig and site arrangement for various supporting facilities.
3. Verification of hazardous substances
Verify the underground hazardous substances and divide the site types (Refer to 1.8 Division of Construction
Site and Precautions).
The underground hazardous substances will probably cause serious injuries or deaths. Ensure to use the
machine correctly, abide by the operation procedures, and properly use and maintain the safety protection
facilities.
4. Selection of hole start and end positions
Selecting the hole start position shall mainly consider the requirements of the pipeline user and meanwhile
the following conditions.
1) Gradient
The mud mixing plant shall be under horizontal position. The consideration shall be given to the extent of the
penetrating angle that will influence the installation of drilling rig and the bending of drill pipe or cause the
outflow of mud from the hole.
2) Traffic status
The motor vehicles and the pedestrians must be kept away by a safe distance from the construction area and a
buffer area of at least 3m distance shall be provided around the machine.
3) Space
Check the hole start and end positions for sufficient space, in order to guarantee the gradual bending of the
drill pipe. Please refer to the section Minimum Deflecting Distance in this chapter.
4) Comfort
In consideration of the shaded area, wind direction, smoke, and other site characteristics, drill hole towards
the downslope direction whenever possible, so that the mud will not flow towards the drilling rig and even
the water permeation from the pipeline will not flood the drilling rig.
5. Design of drilling path, number of back-reaming bit stages, and types of drill bits
Before the official operation, design the drilling path from hole start to hole end and, based on the geological
condition in the working site, the diameter of back-dragging pipeline, the drilling depth, and the site guide
interferences, determine the guide method for the project construction and the number of back-reaming bit stages.
The drilling path can be marked on the ground by spray paint or small flags or by pulling a steel wire from
unearthing point to penetrating point or be drawn with the use of GPS positioning system on paper for the
operator’s reference.
For any complicated drilling, consult with the non-excavation construction expert and ask him to verify geological
condition of the construction stratum and calculate the drilling path. Ensure to inform the engineer of the
3-2 Operation Instructions

minimum penetrating angle, bending limits of the drill pipe and dragged pipeline, the back-dragging material, the
length of drill pipe, and positions of various underground pipelines.
For less complicated drilling, before the drilling operation, take the following four parameters into consideration:
Recommended bending limit radius, penetrating angle, minimum deflecting distance, and minimum depth. The
bending limit radius includes the bending limit radius of drill pipe and the bending limit radius of the pipeline to
be laid (Whichever is larger).
Though the drill pipe can be bended, the bending degree beyond the recommended bending limit will cause
invisible damages, which will result in sudden failure of drill pipe at certain moment after long-term
accumulation.
1) Determination of penetrating angle
The penetrating angle refers to the angle of the drilling rig respect to the ground (In the actual construction of
project, the penetrating angle is commonly expressed by the gradient (%).) and is related to the pipeline to be laid.
This machine can adjust the rocker arm cylinder and the angle cylinder to realize the adjustment of penetrating
angle, with the adjustment range at 100-170.
In response to different projects such as petroleum pipelines, gas pipelines, and sewage pipelines, every
country or region implements specific normative regulation on the construction penetrating angle. Please
ensue to meet the local construction requirement in advance.
The penetrating angle can be obtained by following two methods.
Method I: Place a probe on the ground and on the drilling frame of drilling rig respectively to measure the ground
inclination and drilling frame inclination. The difference between the drilling rig inclination and the ground
inclination is the penetrating angle.
Method II: Measure the ground height A of the carriage front end and the ground height B of the carriage rear end,
obtain the height difference B-A, and then measure the horizontal distance C between the selected front and rear
ends. Then, ((B-A)/C)×100 is the expressed value of the penetrating angle (Namely the inclination indicated by
guide instrument in unit of percentage.

Figure 3-1 Penetrating Angle Model Diagram

For a small penetrating angle, the drilling can enter the horizontal status earlier through less drilling bending. For
a large penetrating angle, the drilling path will be longer and deeper from the ground.
2) Determination of minimum deflecting distance
The minimum deflecting distance refers to the projected horizontal distance from the start of the drilling to the
entry of horizontal status. If the deflecting distance is too small, the drilling inclination will exceed the bending
limit of the drill bit to damage the drill pipe and the steel tube will be blocked due to undersized bending radius
during back-dragging.
Based on the drilling depth requirement to the ground, the minimum deflecting distance can be determined from
the known penetrating angle.
3) Determination of minimum drilling depth
The drill pipe must be bent gently. Therefore, the penetrating angle and bending limit of the drill pipe determine
the ground depth when the drilling reaches horizontal status. The reduction of penetrating angle will reduce the
depth and increasing the penetrating angle and deflecting distance will increase the depth.
For the minimum drilling depth, please refer to the crossing engineering requirements of horizontal directional
drilling specified by GB 50424 Code for Construction of Oil and Gas Transmission Pipeline Crossing
Engineering.
General requirement: The embedded depth of the top the pipeline crossing a river shall be at least 2.5m below the
maximum erosion line of the river and the minimum distance of the crossing segment top to the riverbed bottom
shall be larger than 10~15 times of pipe diameter and no less than 6m. The crossing depth shall be increased for
rivers with high flood control level.
Determine the drilling penetrating angle and the deflecting angle that can meet the working requirements. The
corresponding deflecting distance and penetrating angle can be obtained from the required hole depth.
6. Preparations of guide instrument, mud, and other facilities
Based on the diameter of back-dragging pipeline, construction length and depth, and construction geological
condition, determine the type (Wireless, wired, or geomagnetic) of guide system and pilot drill bit to be used and
timely prepare all accessories (Pilot drill bit, guide power supply, magnetic target, guide cable, wire fixture, mud
refilling short connector, mud motor, thermal shrinkable sleeve, heat gun, wire stripper, crimping pliers,
connecting copper tube, and marking flags).
Based on the mud consumption required for the construction, determine the displacement of mud pump, capacity
of mud mixing system, the mud mixing method, mud recovery system, and sewage pump. Based on the site layout,
procure and place the bentonite reasonably to ensure that the piling of bentonite will not influence the construction
of the project or occupy a large area.
Place the mud at a high place in the site and prepare the waterproof tarpaulin.
Prepare the required drill pipes and drilling tools and thread oil, mainly the quantity of drill pipes, tonnage of
transfer case, and the U-clamp, shackle pliers, and protective short connector for dragging of pipe.
Based on the estimated back-dragging force, predetermine the fixing method of the drilling rig during operations
and prepare the anchorage concrete or caisson of the drilling rig.
Based on the characteristics of the pipeline to be laid, determine the quantity and types of the supporting
construction machinery, including excavator, crane, and pipelayer.
Prepare the fuel, lubricating grease, engine oil, fuel, and hydraulic oil filter elements, log book and pen, generator,
site living and lighting facilities, and fire extinguisher.
7. Verification of hazardous substances in the site
In event of any doubt on the division of site type or on the presence of the unmarked power cable, this site shall be
classified as electricity type. Before the drilling, excavate the area of the power cable to expose the power cable,
in order to facilitate the monitoring.
3.2 Checking of Machine
Before the official operations, the checking of machine is required. The official checking items are as below.
1) Check the levels and capacities of all fluids, including fuel, hydraulic oil, engine coolant, battery power level,
engine oil, and reducer gear oil.
2) Check all machine parts for normal status and function, ensure that the emergency stop button switches,
power master switch, headlamp switch, and hazard warning lamp switch on the control panel and traveling
control box are under OFF status, check for loose bolts, and check all fasteners for reliable connection.
3) Check for leakage of oil and water and check pipelines and connectors for leakage.
4) Check all operating devices and instrument displays for normal functioning and ensure that the vice clamping
switch, rotary switch, and key switch are in neutral position, without any blockage. Check and ensure that the
joysticks, valve stems, and traveling switch on the traveling control box are in neutral position, without any
blockage.
5) Check for complete supporting facilities. Especially, prepare sufficient protective short connectors, jaws, and
thread oil in advance.
6) Check the wear status of jaws and short connectors.
7) Check all bearings and cylinder lubricating hinge points for sufficient lubricating grease.
8) Check rotary connectors for leakage and add lubricating grease.
9) Check the rack of drilling frame for intactness and for adherence or adhesion of impurities.

10) Check the hoses for wear.
11) Check the supporting guide instrument and pay special attention to the battery power level of the guide
instrument.
12) Check the mud pressure measurement hose, check for oil shortage in the mud buffer and mud pressure
measurement hose, and add oil if insufficient. Check the mud electric sensor for blockage and thoroughly
flush away the blockage material (If any).
13) Ensure that the emergency stop buttons are normally operational.
14) Before starting the machine, ensure the sufficient lubrication and oil for all lubricating points.
If the buffer diaphragm is damaged by high pressure mud due to the oil shortage within the mud buffer (or
the oil shortage in the mud pressure measurement hose of the split drilling rid attributed to the
disassembling cause), the replacement of diaphragm or buffer is not covered by warranty scope.
3.3 Positioning of Drilling Rig
1) Fixing of anchorage base
Based on the overall dimensions of drilling rig and the size of anchorage base, arrange the fixing method of
drilling rig in the site in advance, in order to eliminate the movement of anchorage base during operations.
The stability of anchorage base is directly related to the success of the project. The anchorage baseplate on the
front of frame must be supported stably and reliably on the ground. Generally, the operation personnel can take
caisson, cement concrete base, or anchorage baseplate method based on the size of back-dragging force and the
duration of construction during the operations.
2) Starting pit
To guarantee the successful drilling, the first drill pipe must be straight. To prevent bending or distorting the drill
pipe, please dig one starting pit on the ground. Meanwhile, the starting pit can play a role of collecting the
returned mud. If the mud quantity is high during operations, it’s necessary to dig a mud pit and connect it to the
starting pit.

Figure 3-2 Starting Pit Model Diagram

3) Adjust the penetrating angle of drilling rig based on designed drilling path.
Operation procedure for angle adjustment of drilling frame: Based on the required penetrating point, drive the
drilling rig to the required position. Move backward the power head to be above the sprockets, extend forward the
drilling frame, and retract the rocker cylinder. After the ground touch of the anchorage base, it’s necessary to pull
out the anti-rotation pin of the anchorage base. Meanwhile, it’s necessary to fix reliably the anchorage base onto
the caisson, anchorage baseplate, or cement foundation.
To maintain the stability of the drilling rig during operations, please extend the drilling frame as forward as
possible to fully retract the piston of sliding cylinder into the cylinder.
Fix the drilling rig reliably onto properly arranged caisson or anchorage baseplate and when necessary use the
post-caisson for traction (For the use of post-caisson, please consult the service personnel or related technical
experts of our company.).
4) Based on the site layout, arrange the supporting equipment, including mud mixing system, generator set, mud
pump, mud recovery system, and connect the pipelines and electric wires.
5) Plan the safety areas of the site and complete the safety protection measures.
3.4 Start of Machine.
1) Ensure to pay high attention to the requirements specified by 1.3 General Danger Information of the chapter
Safety.
2) Before starting the engine, shift all joysticks and switches to “Neutral” position.
3) Turn on the power switch (Located beneath the hydraulic oil tank), rotate the key switch to turn on the power
supply, and ensure that the power supply is turned on normally, the fuel and hydraulic oil are sufficient, and
all sensors have no warning.

Before start, ensure to select the working mode (working mode or traveling mode. Under traveling mode,
the drilling rig has no rotation or push-pull motion. Under working mode, the drilling rig has no traveling
motion). The key switch within the electric cabinet on the right lower side of the hydraulic oil tank must be
under ON status before operating the drilling rig.
4) Press the horn switch to alert the surrounding personnel to keep away from dangerous area.
5) Observe the display and pressure gauges for normal indications.
6) Continue to rotate clockwise the key switch to the end to start the engine (Refer to the engine operation
manual for the start and use of engine.). After the stop of engine, the key switch must be turned off once so
that the engine can be restarted.
7) Observe the engine for normal pressure, water temperature, and speed.
8) After the start of engine, run the engine at low idling speed for 3~5min to warm up the engine.
While starting the engine 2, the engine 1 must be under idling status.
While stopping the engine, firstly turn off the key switch (On the panel of control console and within the
electric cabinet on the right lower side of the hydraulic oil tank) and then turn off the power switch,
otherwise it will result in the loss of positional information of the power head so that the recalibration of
power head position is required.
While starting the drilling rig under low temperature condition, rotate leftward the key switch and hold for
approximately 30s to warm up the engine and then start the engine as per normal procedure. Please see the
engine operation manual for the detailed use of the engine.
After the start, ensure that the emergency stop buttons are normally operational.
3.5 Stop of Machine
1) Adjust the engine to low idling speed and idle for 3~5min.
2) Ensure that all joysticks, operating valve stems, and button switches are in neutral position.

3) Rotate the key switch leftward to stop the engine.
4) Withdraw the key, turn off the power master switch, and lock the hood side door.
When the machine is not in use, ensure to turn off the power master switch to prevent the depletion of
battery.
3.6 Drilling of First Drill Pipe
1. Adjust the gear of mud pump based on actual need.
2. Adjust the engine accelerator handle to set up the engine speed.
3. Use the vice to connect the drilling tool female thread to drill pipe male thread and pre-tighten.
4. Clamp the drill pipe by rear vice and rotate the power head to connect the short connector male thread to the
drill pipe female thread and pre-tighten.
5. Press the mud pump switch to run the mud pump, till the mud sprays out from the front of the drilling tool.
6. Select the penetrating clock position of the drill bit.
7. Slowly move forward the power head. Drill the first drill pipe as straight as possible.
8. Monitor various measuring instruments.
Do not mix the drill pipes, drilling tools, or short connectors from different manufacturers for use. As the
rotating shaft will lead to death or crushing of limbs, please keep away.
3.7 Addition of Drill Pipe
1. Disconnect the drill pipe connector at spindle thread.

While clamping the vices, firstly clamp the front vice and then the rear vice.
Never clamp the threaded end of the drill pipe, otherwise the thread will be damaged. Place the connector
as close as possible to the rear vice and stop the mud pump.
1. Front vice
2. Rear vice
Figure 3-3 Model Diagram to Disconnect Drill Pipe Connector at Spindle Thread
When the drill pipe is still subject to high push-pull force, do not clamp the drill pipe by the vices, otherwise
the vices will be damaged due to application of high push-pull force. This drilling rig contains built-in
judgment program and the clamping of vices is disabled when the drill pipe is still subject to high push-pull
force.
2. When the drill pipe connector at spindle thread is between the front vice 1 and rear vice 2, stop the push-pull
of the power head. If wired guide method is used, it’s necessary to loosen the seal compression nut of the
guide cable and loosen the guide cable within the drill pipe.
3. Clamp the front vice 1, move backward the power head till the distance of the floating mandrel is half of the
floating travel, and then stop the movement of power head.
4. Rotate the power head counter-clockwise. Continue the rotation. During this process, observe the position of
floating mandrel, till the distance of the floating mandrel is half of the floating travel and the thread is fully
disassembled, and then stop the rotation of power head. If wired guide method is used, cut off the connected
guide cable.
5. Apply thread oil to the spindle thread.
6. Stop the rotation and move the power head to the rear of the drilling frame.
7. Lift one drill pipe by the machine-mounted crane, place the drill pipe to the drilling frame, and align the drill
pipe center with the vice center and the power head spindle center. If the wired or geomagnetic guide is used,
insert one steel wire within the drill pipe in advance.

8. Move forward the power head, till the spindle connector closes to the drill pipe thread, reduce the speed and
slowly move forward the power head, and operate the slow rotation of power head, till the drill pipe thread
comes into contact with the thread of pilot drill bit.
If the wired or geomagnetic guide is used, it’s necessary to connect the guide cable on two ends of the drill
before the next operation.
9. Continue to move forward the power head, slowly rotate the spindle, observe the camera at the power head
floating mandrel, till the distance of the floating mandrel is half of the floating travel (Approximately 40mm),
and then stop the forward movement of the power head and slowly rotate the spindle to screw the spindle
connector into the drill pipe. The rotation of drill pipe thread will result in the movement of floating mandrel
in drill pipe length direction. During this process, observe the position of the floating mandrel to maintain the
distance of floating mandrel half of the floating travel, till the drill pipe thread is tightened.
10. Slowly tighten the drill pipe, withdrawn excessive wire from the inside of the drill pipe, and seal (For wired
guide).
11. Release the vices.
12. Operate the machine-mounted crane to leave from the working position of the working drill pipe.
13. Turn on the mud pump, till the drill pipe is fully filled and the pressure of mud starts to increase.
14 Rotate the spindle and drill in slowly. Adjust to optimal construction speed based on the drill bit size and the
soil condition.
Bear in mind to rotate in clockwise direction, except the disconnection of the drill pipe connector. The
rotation in counter-clockwise direction will loosen the connector.
15. Monitor all instruments. Please stop for checking in event of any abnormal condition.
16. Position and check the drill bit at least once every the drilling of half of the drill pipe length. For every drilled
drill pipe, it's necessary to record the torque, pushing force, angle, depth, and time required for single drill
pipe operation during the construction.
The rotating torque of the drilling rig shall not exceed the permissible value of the installed drill pipe, no
matter for guide or back-dragging operation.
3.8 Orientation and Direction Change of Drill Bit
1. Using the guide instrument (or wired guide operating system) can obtain the positional parameters of the drill
bit, including depth, inclination, bearing angle, and transmitter temperature, and predict the position of next
drill pipe if the current construction angle remains unchanged.
2. Compare the position with the drilling plan to determine the due direction of the drill bit.

3. Rotate the power head, till the guide instrument displays the required clock code position.
4. Direction change procedure
1) Properly adjust the bearing angle of the drill bit.
2) Without rotating the power head, push inward the drill pipe (For common guide method). If the mud
motor guide method is used, start the mud motor but do not simultaneously rotate the power head and
push forward the drill pipe.
3) Via the data display on the guide instrument, judge whether the direction meets the requirement. If yes,
stop the pushing and start the rotating and drilling.
5. The direction calibration is one technique achieved by the guide operator’s experience on the understanding
of equipment and soil condition. These following operations only involve the basic steps.
1) If the wireless guide method is used to drill the pilot hole, one guide operator is required to track and
position the drill bit by guide instrument and, based on the actual path of the drill bit, send the operation
commands of the drilling rig to the drilling rig operator. If the wired or geomagnetic guide system is
used, the guide operator makes judgment based on the displayed data of the system (If the common
wired guide method is used, the guide instrument can be used to track and position the drill bit.) and
sends operation commands of the drilling rig to the drilling rig operator.
2) During the calibration, to track the drill bit, compare the current position with the drilling layout and
change the direction of drill bit as required.
6. Basic rules to be considered during calibration
1) The capability of the direction change depends on the soil condition, the drill bit used, the drill bit
rolling measurement data, and the distance of non-rotating drilling.
2) All calibrations shall be made gradually whenever possible. Please refer to the bending limit of the drill
pipe used. The excessive calibration will lead to the snaking movement, which will probably damage
the drill pipe and make the drilling and back-dragging more difficult. Calibrate the drill pipe as early as
possible.
3) Do not push the whole drill pipe into the ground without rotating the drill pipe (or with the running of
mud motor only), otherwise the bending radius will be exceeded and the drill pipe will be damaged.
It’s prohibited that the bending radius of the construction curve exceeds the permissible bending radius
limit of the drill pipe (or the pipeline to be laid), otherwise the drill pipe will be damaged or the
construction of the project will fail.
The partial bending of the drill pipe is prohibited to exceed the permissible value. Though the whole drill
pipe doesn’t exceed the permissible bending radius limit in such case, it will still result in the damage of
drill pipe or failure of project construction.

3.9 Unearthing of Drill Bit
Guide the drill bit to the target pit or upward to the ground as per the designed drilling curve. It’s necessary to stop
the mud pump once the drill bit is unearthed.
Before replacing the drilling tool, ensure to signal the operator to stop the engine and then replace the
drilling tool by combination pipe wrench. It’s prohibited to start the engine while connecting and replacing
the drilling tool, otherwise it will probably result in personal harms.
3.10 Back-Reaming Operation
At completion of the pilot hole, it can enlarge the hole by means of the back reaming or pull back the laid material
1. Back-reaming procedure
Select the back-reamer based on the performance of drilling rig, the diameter of final back-reamed hole, the
diameter of pilot hole, the number of back-reaming stages, and the soil condition.
The ideal back-reaming hole diameter shall be approximately 1.3~1.5 times of the pipeline diameter. When
the pipeline diameter is >600mm, the recommended reaming hole diameter shall be 200mm larger than the
pipeline diameter. During the applications, it's recommended to select the back-reamer of the size equaling to
1.2~1.5 times of the pipeline outside diameter or the (pipeline outside diameter + 200mm) (Whichever is
smaller). In such case, an annular space can be formed between the hole wall and drill pipe or pipeline to
ease the carry-out of mud or drilling cuttings, reduce the resistance of back-dragging pipeline, and allow the
appropriate bending of the pipeline.
It’s prohibited to rotate the drill bit before entry into the hole.
The connection method of directly bringing back the drill pipe after the drill bit will probably cause serious
personal harms, because the drill pipe at the unearthing end will rotate under non-uniform status under the
drive of the drill bit. If a drill pipe is added on the unearthing end, the operator can’t control whether the drill
pipe on the unearthing end is rotating.
Connect a transfer case to the rear end of the back-reamer to prevent the parts attached on the rear end of
drill bit against rotation.
Before connecting the transfer case, check the transfer case for flexible rotation.
While adding a drill pipe to the unearthing end of drilling rig, it’s prohibited to start the engine.

The basic back-reaming procedure is as below:
1) Determine the number of back-reaming stages, model of back-reamer, and special stratum treatment
scheme based on the factors, including the capacity of drilling rig and the geological condition. If the
geological condition is soft, a float can be added to the rear end of the back-reamer to prevent the sink
of the back-reamer and avoid turning a back-reaming hole to an oblong hole. For the stratums with
collapse danger, such as sandy layer and strongly weathered rock stratum, add a carbon rod to track the
back-reamers and take the emergency measures.
2) Determine the proportion and flow of the mud.
3) Connect the drill pipe and back-reamer and check the mud for normal spray. Many practices have
proved that the pre-tightening of the drill pipe on the unearthing end can effectively prevent the thread
seizure symptom of the drill pipe due to excessive rotating torque during the operations.
4) Maintain appropriate moving speed and rotating speed for the back-dragging of the drill pipe.
The torque during the construction is prohibited to exceed the permissible torque of the drill pipe. Even the
transient over-torque will result in the thread seizure of whole drill pipe assembly to impair the
construction progress and drill pipe life and even result in the failure of the project.
After the replacement of drill pipe each time, start the mud pump, wait for the mud pressure to rise, and
then operate the back-dragging and rotation of the drill pipe, in order to prevent blocking the water holes
of the drill bit.
5) For every back-dragged drill pipe, record the construction parameters including construction time,
torque, and back-dragging force. The refueling, maintenance, malfunction, and jaw replacement for the
drilling rig during construction shall also be recorded, in order to ease the verification of the project
construction.
6) Repeat steps 3.10.1.3~3.10.1.4 in turn based on the models and sizes of the back-reamers, till the
back-reaming operation is finally completed. The above procedure is only for reference. The detailed
procedure is subject to the guidance of the professional construction personnel based on the site
conditions.
Keep all personnel far away from the material being installed and components being moved. Start the
back-reaming or pipeline back-dragging only after it’s confirmed that the back-reamer is already installed
and the relevant personnel are kept far away.
2. Back-reaming instructions
1) Plan the drilling path as straight as possible.
Verify the minimum curvature radius of the back-dragging pipeline to ensure that the curvature radius of the

back-reaming curve is larger than the minimum curvature radius of the pipeline and the back-reaming curve
is under smooth transition. The mud proportion is a critical factor for the successful back-reaming.
Understand the related soil property and underground water information and select appropriate additives.
Compared with the drilling of pilot hole, the back-reaming requires more mud.
2) Determine the mud requirements.
Only the supply of sufficient mud can achieve the successful reaming of the drilling rig. The mud
consumption required for the back-reaming depends on the factors including diameter of back-reaming hole,
drilling tool, and geological conditions. Determine based on the construction experiences or refer to the mud
requirements for the crossing construction of the horizontal directional drilling rig under different geological
and drilling diameter conditions as specified by GB 50424 Code for Construction of Oil and Gas
Transmission Pipeline Crossing Engineering.
This section describes how to find out the minimum mud quantity required under the ideal conditions. In the
actual construction, the mud in use shall be more than the recommended quantity, otherwise it will probably
result in unsuccessful back-reaming.
a. Determine the diameter of back-reaming hole and the outside diameter of the back-dragging material, as
they are related to the consumption of the back-reaming mud and the diameter of the back-reaming bit.
For instance, one back-reaming hole in diameter of 350mm requires at least 96L/m and one 220mm
back-dragging material requires at least 38L/m.
b. Subtract the occupied volume of the back-dragging material from the required mud quantity of the
back-reaming hole to obtain the mud quantity required for the back-reaming per foot or meter. For the
instance a), it can be calculated that at least 58L mud is required for every meter of drilling depth with
the drill bit in diameter of 350mm.
c. Multiply the calculated value by the back-reaming length to estimate the mud quantity required for this
hole. This calculated mud quantity is the result based on the 1:1 proportion between mud and drilling
cuttings. If the proportion between mud and drilling cuttings is 2:1, more mud is required. Generally,
the proportion between total mud quantity and drilling cuttings is taken as (3~5):1. Add up the mud
quantities required for all back-reaming stages to obtain the total mud consumption (The total mud
consumption is also equal to the volume of final hole multiplied by the proportion between mud and
drilling cuttings during drilling.).
d. Estimate the back-dragging speed.
Determine the back-dragging speed based on the pumping flow of the mud pump.
For the instance a), the length of drill pipe in use is 8m, the proportion between mud and drilling
cuttings is 2:1, and the displacement of mud pump is 500L/min so that the drilling cuttings for every
drill pipe is:
58L×6×2=696L
The back-dragging time for every drill pipe is:

696L/ (500L/min)=1.4min
If the mud pump is worn or the mud viscosity and density are high, the working efficiency of the mud
pump will be reduced. Generally, the output flow of the mud pump can only reach approximately 80%

of the rated displacement. The displacement loss also influences the construction time, which shall be
taken into consideration during the calculation of the back-dragging time.
The actual back-dragging time for single drill pipe is:

1.4/0.8=1.7 min
Namely, during the back-reaming with Φ350mm drill bit, the fastest construction time for single drill
pipe is no less than 1.7min. If the proportion between mud and drilling cuttings is 4:1, the construction
time shall be doubled.
e) Estimate the pressure to be used.
3.11 Disassembling of Drill Pipes
Never clamp the threaded end of the drill pipe, otherwise the drill pipe will be damaged. When the
connector is between the vices, place the connection of the connector as close as possible to the rear vice.
1. Unloading of power head back-dragging counterforce
If the back-dragging force is high, due to high resilience force in the drill pipe and pipeline, it's necessary to pull
back the power head by one more distance. This distance shall be determined based on the construction
experience and the resilience distance of previous drill pipe. After the stop of the power head, slowly move
forward the power head to unload the resilience force of drill pipe and pipeline so that the drill pipe connector is
between two vices and is closer to the rear vice under no or really low resilience force.
This machine contains built-in protection program and the clamping of vices is disabled when there is still
high push-pull force.
2. Unloading of power head torque
As the drill pipe is still under the application of the rotating torque, it’s necessary to unload the torque of the
power head before the unshackling. The detailed operation method is to slowly reverse the power head. When the
pressure of the rotating pressure gauge is <5Mpa, it’s considered that the rotating torque is already unloaded.
3. Clamp the drill pipe by front vice.
Unscrew the drill pipe to be disassembled from the previous drill pipe by the vice, clamp the drill pipe by rear vice,
reverse the power head to unscrew the connecting thread of drill pipe from the spindle, and take out the drill pipe
by holding two ends of the drill pipe with two operators (or lifting the middle portion of drill pipe with
machine-mounted crane).
4. Clamp the drill pipe by rear vice.

Operate slowly during the unloading of resilience force and rotating torque. The recommended rotating
angle of the joystick is 1/3 of the maximum angle. It’s prohibited to push the joystick to the limit position.
5. Disconnect the front connector.
Rotate the rear vice clockwise (Observed from the front end of drilling rig) to loosen the drill pipe thread.
Open the rear vice and rotate the rear vice counter-clockwise to reset (Observed from the front end of drilling rig).
6. Separate the front connector.
a) Rotate the spindle counter-clockwise slowly and then move backward the power head and observe the
position status of the floating mandrel by the camera. When the floating mandrel is half of the floating
distance, stop the movement of power head and continue to rotate the power head slowly, till the drill
pipe thread is completely disengaged.
b) Operate the vice separating cylinder to separate the front and rear vices.
c) Continue to move backward the power head, till the drill pipe is correctly seated in the rear vice, and
then stop the backward movement of the power head.
7. Disconnect the rear connector.
a) Lift the drill pipe by machine-mounted crane.
b) Clamp the rear vice.
c) Repeat step 3.11.6.b to unscrew the drill pipe thread.
d) Move backward the power head by a distance (Approximately 500mm, depending on the drilling rig
operator’s habit).
e) Lift down the drill pipe by machine-mounted crane and move the boom of the machine-mounted crane
to a place that will not impair the operations.
f) Retract the vice separating cylinder.
g) Lubricate the power head spindle thread.
8. Connect to next drill pipe.
a) Move forward the power head, till the spindle is about to touch the drill pipe, and then reduce the
movement speed of power head and slowly rotate the power head.
b) Continue to slowly move forward the power head and slowly rotate the power head, till the spindle
comes into contact with the drill pipe. Continue to move and rotate slowly, till the floating mandrel is
half of the floating distance. Stop the movement of power head and continue to rotate the power head,
till the drill pipe thread is tightened.
While tightening the drill pipe to the power head, the rotating torque of the power head is prohibited to
exceed 45,000N.m (For 127 drill pipe. The pressure of hydraulic pressure gauge under different gears
corresponds to different torques. Please observe the indicated torque of the display, which directly
displays the actual output torque).
c) Release the front vice.

Through the pre-tightening of drill pipe can effectively prevent the overload of thread under impact load,
the transient overload of drill pipe tightening torque will result in the seizure of the thread. The shackling
torque of the power head is prohibited to exceed the specified value (The shackling torque is different for
the drill pipes of different diameters and specifications).
9. Start the mud pump to continue back-reaming or back-dragging.
3.12 Back-Dragging of Pipeline
Ensure that all personnel other than the operation personnel are kept away from the materials being installed and
the parts being moved. Start the back-dragging operations only after the back-reamer and transfer case are
connected properly to the back-dragging pipeline and all personnel are kept away from drilling tools and pipeline.
Start the back-dragging without rotation, till the drill bit starts to penetrate into soil, and then slowly operate the
rotation. Except the force majeure, it’s prohibited to interrupt the back-dragging operation (or halt midway for
resting), otherwise it will be highly probable to cause construction failure.
Before the back-dragging of the pipeline, firstly ensure that the reamed hole diameter meets the requirement,
secondly ensure that all residues are already removed thoroughly from the hole, and thirdly ensure that the mud in
use meets the operating requirements.
For a large and long steel pipeline, it’s necessary to test the back-dragging before the official back-dragging.
Based on the test result, determine whether the pipeline can be back-dragged, in order to lower the construction
risk.
3.13 Clear-up of Site
After the back-dragging of the pipeline, the after-treatment of the site is also required.
1) Transfer of the drilling rig and related supporting facilities.
2) Dispose the site wastes, including mud, muck, and man-made wastes, as per the local environmental
protection laws and regulations.
3) Restore the destructed landform and building facilities to original forms.
3.14 Difficulties during Construction
1. Jamming of drill bit
The jamming of drill bit is a difficulty among the common techniques of reaming. In event of the jamming of drill
bit, analyze to judge the cause before treatment.
a) Jamming of drill bit due to collision with other underground pipeline. Re-plan the guide path to detour
the collided pipeline.

b) Jamming of drill bit due to bricks or rocks in miscellaneous fill. Slowly draw back the drilling tool by a
distance, reduce the rotating speed and drilling or back-dragging speed, and continue the construction
slowly. In event of jamming of drill bit due to large rock or concrete block in the miscellaneous fill,
re-plan the guide path to detour the obstacle or dig out the obstacle and then continue the reaming. Do
not operate the reaming brutally, otherwise it will probably result in torsional breakage of the drill pipe
and failure of construction.
c) Frequent jamming of drill bit due to hard clay layer during reaming with large drill bit. Reduce the
reaming speed and rotating speed, increase the mud supply quantity, and ream the hole slowly.
d) Jamming of drill bit due to collision with tree stump. Reduce the rotating speed and drilling or
back-dragging speed and continue the operation slowly. If the back-reaming is required after passing
through the tree stump, smash the tree stump, in order to prevent the blockage of pipeline by the tree
stump during the pavement of pipeline.
2. Hole shrinkage
If the hole water backflows out from the drill pipe after the disassembling of the drill pipe, it indicates the
presence of hole shrinkage in the hole. In event of serious hole shrinkage, the laid pipeline will be crushed to
cause deformation or even blockage.
a) At completion of reaming in soft clay, the mud pressure in the hole is relieved to easily cause hole
shrinkage symptom. In event of serious hole shrinkage in clay layer, guard the walls by mud of high
concentration to balance the pressure in the hole and maintain the drilled hole. Alternatively, ream the
hole with drill bit of enlarged size, clear up the hole, and select the PE or PVC pipeline with high
hardness and wall pressure resistance. If the hole shrinkage is minor, generally the pipeline can be laid
after one more clear-up cycle of the hole.
b) The clay stratum is swollen in contact with water to reduce the diameter of the reamed hole and the
excessive mud crumbs within the hole easily flatten the laid pipeline. In such case, the premium
solid-free wall protection can be selected to mitigate the water loss of mud and reduce the contact
between hole wall and water. The reaming with drill bit of enlarged size and two more hole clear-up
cycles can effectively prevent the swelling of stratum from crushing the laid pipeline.
3. Hole collapse
The reaming in sandy clay layer, sand layer, or loose landfill layer will easily result in hole collapse, which will
probably lead to burial or jamming of drill bit, seizure of pipeline, or cracking or sink of road surface.
Selecting the mud of high viscosity for wall protection can effectively prevent the hole collapse. In event of hole
collapse at a place with accumulated rock blocks, continue the reaming only after the rock blocks are removed.
4. Mud leakage/loss
During the reaming in loose landfill layer, layer with low underground water level, sandy silt layer, silt layer, sand
layer, or riverbed clay or sand layer, the mud leaks/loses in the hole or overflows from the ground surface, instead
of returning from the hole opening.
Increase the mud concentration and viscosity to form mud cake on hole walls to retrain the leakage and effectively
prevent the loss of mud.
5. Mud permeation
The mud probably permeates from hole to the ground surface during the reaming, back-dragging, or pipeline
laying.
1) Causes for mud permeation:
a) The excessive residual mud crumbs in the pipeline pavement hole block the hole so that the mud can’t
return from the hole opening to form high pressure in the hole and permeate from ground surface.
b) The surface cracks are extended to the drilled hole so that the mud permeates through the cracks to the
ground.
Generally, if the mud permeates from the ground surface, it’s only necessary to handle the permeated
mud. Under some specific environments, such as resident housing, fishpond, river, farmland, and
greenbelt, the mud leakage/permeation is disallowed, otherwise it will probably result in claims and
remarkable losses.
2) Measures to prevent the mud permeation are as below:
a) Increase the drilling depth.
b) Improve the drill bit structure, reasonably control the drilling speed and rotating speed, and mix the mud
crumbs in the hole to mud.
c) Increase the viscosity, concentration, and flow of mud to enhance the wall protection, floating, and
crumb discharging capacity of the mud and keep the passage between drill hole and drill pipe and
pipeline non-obstructed.
6. Surface arch
The surface arch is caused by the high pressure of mud due to blockage in the hole. Please refer to mud
permeation preventive measure in 3.14.5.2 for the preventative measures.
7. No stop of mud supply at stop of drilling
During the back-dragging of pipelines, the drilling is frequently stopped due to diversified causes, such as midway
welding of drill pipe, midway repair of protective layer, and contract dispute. In such case, please be noted that
the mud supply can’t be stopped during the stop of drilling. Ensure to continue the circulation of mud within the
hole, in order to prevent the solidification of mud and seizure of pipeline due to over-long stop time of drilling.
Especially in sandy layer, do not stop the supply of mud during the stop of drilling. If it’s necessary to stop the
mud supply, input mud of high viscosity and concentration before the stop of drilling and then stop the mud
supply. After the drilling is resumed, start the pump to pump the mud for 10min till the mud returns well from the
hole opening and then start the back-dragging and pavement of pipeline.
8. Reaming efficiency
The higher the torque and the rotating speed of the drilling rig are, the higher the movement speed of power head
is and the higher the reaming efficiency is. Under the rated torque and rotating speed of the drilling rig, the
reaming efficiency is directly related to the stratum to be reamed, reaming bit, reaming mud quality, and mud
quantity. To promote the reaming efficiency, ensure to understand the geologic conditions of the working site,
select the high-efficiency drill bit suitable for the cutting of this stratum, and select the proportion and flow of
mud suitable for this stratum.
9. Quicksand
The reaming operation in quicksand layer is difficult to form a complete hole. In addition, the quicksand
incorporates high adsorption characteristic to increase the resistance of the laid pipeline. Select heavy colloid solid
mud and reduce the reaming speed to sufficiently emulsify the mud with quicksand, solidify the hole walls, and
eliminate the quicksand adsorption force. During the laying of pipeline, the quicksand is flowed out from the
drilled hole along with the mud.
10. Pipeline deformation
During the reaming in strongly viscous stratum, the clay will easily form blocks and stay within the hole and it’s
really difficult to drain them out by the mud. During the laying of pipeline, the clay blocks will accumulate to
probably cause crushing deformation to the pipeline. Under such stratum, clear up the hole for more times before
the laying of pipeline. The pipeline with minor deformation shall be considered as qualified. For the pipeline with
serious deformation, pull out the pipeline for repair. If non-repairable, scrap the pipeline.
11. Blockage of pipeline
The excessive residual clods in the hole, the obstacles such as rock and steel scrap, the hole collapse, and the hole
shrinkage can easily result in blockage of laid pipeline within the hole. The reading of the back-dragging pressure
gauge rises gradually before the blockage. Upon detection of increased pressure, pause or reduce the
back-dragging speed and increase the mud supply quantity to prevent the blockage of pipeline. If the pipeline is
blocked, depending on the specific site construction status, directly dig up the blocked area, remove the obstacle,
and then continue the back-dragging operation or drag the pipeline out of the hole by machine (Bulldozer or
excavator), re-clear up the hole, and lay the pipeline.

Chapter 4 Lubrication and Maintenances
4.1 Lubrication
Notice:
Before using the lubrication system, check the various joints for tightness and check the pipelines for damage.
Heck the leakage with hardboard or wood card, as it’s difficult to visually detect the leakage of hydraulic oil. It’s
prohibited to check the leakage with any part of the human body.
Wear the protective clothing and goggles.
Seek for medical treatment in event of any injury.
Unless otherwise specified, all maintenances and repairs specified in this chapter shall be fulfilled under the
stopped status of the engine.
1. Refer to table 7-1 for the maintenances of engine.
Table 7-1 Engine Maintenances
Mission Time (Hour) Oil/fuel/fluid

Checking of engine oil 10
Replacement of engine oil and filter
50
(first time)
Replacement of engine oil and filter 250 Please refer to Operation Manual of
Engine.
Replacement of fuel filter (first time) 50
Replacement of fuel filter 250
Replacement of coolant 1000
Ensure to use the approved engine oil, coolant, and various filter elements.
For the optional Volvo engine, the Volvo special Yellow-Label coolant must be used. It’s prohibited to use
any coolant of other model or brand.
Lubrication and Maintenances 4-1

2. Please refer to Table 7-2 for the lubrication of various sliding areas.
Table 7-2 Lubrication and Maintenances for Sliding Connections
Mission Time (Hour) Grease

Lubrication of feeding rack and gear 50
Lubrication of drill frame slideways 50
Automotive all-purpose lithium-base
Lubrication of power head floating lubricating grease L-XCCHA2
50
mandrel
Lubrication of sliding cylinder support 50
3. Refer to Table 7-3 for the lubrication of cylinder pins.
Table 7-3 Lubrication and Maintenance for Cylinder Pins
Mission Time (Hour) Grease

Various cylinder hinged joints 50 Automotive all-purpose lithium-base
Various pins 50 lubricating grease L-XCCHA2
4. Please refer to Table 7-4 for the lubrication of gearbox.
Table 7-4 Lubrication and Maintenance for Gearbox
Lubrication item Time (Hour) Oil/fuel/fluid

Checking of oil in power head 50
Checking of power head reducer oil (12
50
places)
Caltex Meropa 220 (For normal
Checking of traveling reducer oil (2 temperature)
50
places) Caltex Meropa Synthetic EP220 (For
Replacement of lubricating oil in power cold regions)
1000
head Note: It’s prohibited to mix the oils
of different brands or the oils of same
Replacement of power head reducer oil brand but different models for use.
1000
(12 places)
Replacement of traveling reducer oil (2
1000
places)
5. Refer to Table 7-5 for the maintenances of hydraulic system.
Table 7-5 Maintenances of Hydraulic System
Item Time (Hour) Oil/fuel/fluid

Checking of Hydraulic Oil 10 Caltex Rando HD46 (For normal
temperature)
Replacement of filter element (First
250 Caltex Rando HDZ46 (For cold
time)
regions)
Replacement of hydraulic oil and filter Note: It’s prohibited to mix the oils
1000 of different brands or the oils of same
element
brand but different models for use.
6. Drilling tool
Before the first time use and after each drilling, lubricate the drill pipe and drill bit by special thread oil.
4-2 Lubrication and Maintenances

4.2 Maintenances
1. Refer to Table 7-6 for periodical maintenances.
Table 7-6 Periodical Maintenance Schedule
Interval (Hour) Item

Check track tension.
Check fuel level.
Check engine oil level.
Check water tank coolant level.
Check hydraulic oil level.
10 Check various connection pipelines.
Check fasteners.
Check wear status of machine-mounted crane wire rope.
Check wear status of spindle short connector thread.
Check wear status of pinion and rack.
Check gearbox and motor for leakage
Check radiator
Checking of battery
50
Check fan belt
Replacement of fuel filter (first time)
Replacement of fuel filter
Replace engine oil filter.
250
Check and clean air filter element
Replace hydraulic oil filter element (First time).
Replace hydraulic oil.
Replace power head lubricating oil.
1000
Replace reducer lubricating oil.
Replace hydraulic oil filter element.
2000 Replace coolant.
Replace air filter.
Replace spindle short connector
When necessary
Replace machine-mounted crane wire rope.
Check muffler.

2. Maintenances
Before disconnecting any hydraulic pipeline, stop the engine, operate various joysticks to unload, and lower
or lock any lifted device. Cover various connectors by thick cloth, slowly loosen the connector nuts to
relieve the residual pressure, and collect the drained hydraulic oil in a container.
Ensure that the machine is cooled down already before the repairs. The hydraulic units, engine, radiator,
and exhaust system can probably lead to serious personal injuries due to high temperature.
1) Battery
Disconnect the battery before the repairs, welding, and long-time storage.
Check the battery once every 50 hours.
Keep the battery clean and away from corrosion and apply one film of lubricating grease onto the cable
connectors.
2) Checking of pipelines
Check all pipeline system once every 10 hours for leakage or loose connection.
3) Starter motor belt
This drive belt drives the alternator, cooling fan, and water pump. Check the working condition of tensioner and
idler once every 50 hours. Check the belt for wear and for correct position.
4) Radiator
Check once every 25 hours for presence of dirt, weed, and other foreign matters. When necessary, clean by
compressed air or washing gun. Take cautions not to damage the radiator fins with high pressure air or high
pressure water. Check more frequently during the construction under very dirty condition or under weedy
condition. Clean by compressed air or water spray once every 50 hours.
Take cautions to prevent damaging the fins by high pressure air or water. Disassemble screws to remove the
weed and dirt from the inside of the cover. If the engine side of the radiator is very dirty, clean it by
radiator cleaner.
Check the radiator coolant level yearly or once every 600 hours. Please refer to engine operation manual.
5) Spindle short connector
① When necessary, replace the short connector of the spindle.
② Unscrew the threaded connection between drill collar and short connector.
③ Replace with new short connector and apply thread sealant onto the thread.

④ By means of the vice, install the new short connector and tighten.
6) Drilling frame carriage
Check the carriage hook plate for wear and when necessary replace.
7) Refer to Table 7-7 for the maintenances of filter elements.
Item Time (Hour)

Replacement of engine oil filter Refer to chapter Lubrication.
Replacement of fuel filter (first time) 50
Replacement of fuel filter 250
Checking of muffler When necessary
Replacement of air filter When necessary
① Fuel filter
Replace the fuel filter after the first 50 working hours. Afterwards, replace once every 250 working
hours. If the oil added is taken from an oil tank, the filter shall be replaced more frequently.
② Air filter
Replace the air filter once every 1,000 hours or when the yellow strip in the service indicator of the air
filter reaches the red line. Replace the air filter more frequently during the construction in dusty
environments.
③ Muffler
Replace when necessary.
8) Refer to Table 7-8 for the checking of traveling unit.
Item Time (Hour)

Checking of track tension and working condition Daily
Check the track tension when necessary. To adjust the tension, inject calcium-base lubricating grease into the
grease nozzle (Due to high force of the tension cylinder, the user is recommended to prepare the foot-operated
grease gun.).
9) Gearbox and motor
Check all gearboxes and motors for leakage once every 10 hours.
10) Mud connectors
Check the mud connectors for leakage once every 10 hours. When necessary, replace the seals and guide rings.
11) Maintenance of drill pipe
The drill pipe is the critical tool for successful working of drilling rig and shall be maintained periodically.
① Before the long-term storage of drill pipe, please install the protective cap.
② As required, clean the threads by high pressure water and soap. Do not use the gasoline or similar
solvents. After the cleaning, lubricate the threads and shoulders by thread oil. When it’s not to be used
for a long period, ensure to install the special protective cap.
12) Engine
Refer to the engine operation manual for maintenances of engine.
4.3 Fuel
1. Refer to the engine operation manual for the trademark and use of the fuel. The fuel shall meet the
requirements of GB 252 Light Diesel.
2. The filling capacity of fuel is 1,800L.
4.4 Engine oil
Please refer to the engine operation manual for the trademark and use of engine oil.
4.5 Coolant
Please refer to the engine operation manual for the trademark and use of coolant.
For the optional Volvo engine, the Volvo special Yellow-Label coolant must be used. It’s prohibited to use
any coolant of other model or brand. The engine damages arising from the use of incorrect coolant are not
covered by the warranty scope.
4.6 Hydraulic Oil
1. Use Caltex HD46 anti-wear hydraulic (For normal temperature) or HDZ46 anti-wear hydraulic oil (For cold
regions).
2. The filling capacity of hydraulic oil is 1,600L.

Chapter 5 Common Malfunctions and Troubleshooting
5.1 Common Malfunctions and Troubleshooting of Vices
Malfunction symptom Cause analysis Troubleshooting Note

Check the jaws for wear and
Wear of jaws Moderate
when necessary replace.
Adjust the throttle valve on the
Different extending speeds clamping cylinder to ensure same
Moderate
among three cylinders extending speeds among three
cylinders.
Slip of vices No use of thread oil Use thread oil. Moderate

Undersized dimensional
Use special jaw holders. Moderate
specification of drill pipe
Use of all-new drill pipe
Check drill pipe. Moderate
(Without run-in)
Check clamping cylinder for
Internal leakage of cylinder Importance
presence of internal leakage.
Check vice pressure. Moderate
Insufficient vice pressure
Adjust clamping pressure of vice. Moderate
Weak motion of rotating
cylinder Internal leakage of rotating Check rotating cylinder for
Importance
cylinder presence of internal leakage.
Over-high torque Use rotating pressure to limit. Moderate
5.2 Common Malfunctions and Troubleshooting of Power Head

Damage of reducer oil seals Check oil level within box body. Moderate
Outward oil leakage of box
body Damage of rotating motor
Check reducer oil level. Importance
oil seals
Damage of rotating oil seals Check rotating oil seals. Moderate
Oil permeation of spindle oil Damage of spindle Check spindle. Importance
seal
Loose mounting bearings of
Check spindle bearings. Importance
spindle
Dirty oil or insufficient oil
Replace or add oil. Moderate
Noise of reducer of reducer
Damage of reducer Replace parts. Serious
Common Malfunctions and Troubleshooting 5-1

5.3 Malfunctions and Troubleshooting of Hydraulic System
1. Classification of hydraulic system by part function
Malfunctions and Troubleshooting of Hydraulic System for XZ Series Directional Drilling Rig
No. Malfunction symptom Cause analysis Troubleshooting Note
Damage of rotating
Replace pump. Serious
pump
Damage of rotating Adjust relief valve
Insufficient rotating operating valve safety to correct pressure Moderate
pressure valve (≤32t) or replace it.
Damage of reducer Replace reducer. Serious
Damage of motor Replace motor. Serious
Blockage of operating Replace operating
Importance
valve element valve.
Blockage or
Clean or
non-energization of
1 Rotating system No forward or replace/check Importance
rotating pump pilot
reverse rotation of electric circuit.
solenoid valve (≥50t)
power head
Replace valve or
Blockage of rotating repair by
Serious
valve professional
manufacturer.
Blockage of
series/parallel valve Clean or replace. Importance
No high-speed (≤32t)
rotation of power No normal energization Check electric
head or blocked element of circuits/clean or
Moderate
high-speed solenoid replace solenoid
valve (≥50t) valve.
Damage of push-pull
pump
Damage of push-pull Adjust relief valve
operating safety valve to correct pressure Moderate
Insufficient drilling
(≤32t) or replace it.
pressure
Damage or Check electric
non-energization of circuits/clean or
Importance
2 Drilling system push-pull valve power replace power
module module.
Blockage of operating Replace operating
Importance
valve element (≤32t) valve.
No drilling or Damage or Check electric
reversing motion non-energization of circuits/clean or
Importance
push-pull valve power replace power
module module.
5-2 Common Malfunctions and Troubleshooting

Blockage or Clean or replace

non-energization of solenoid
Moderate
push-pull acceleration valve/check electric
No high-speed solenoid valve (≤32t) circuits.
drilling Non-energization or Clean or replace
blocked element of solenoid
Moderate
push-pull motor valve/check electric
high-speed valve (≥50t) circuits.
Damage of pump Replace pump. Serious
Damage of outrigger Adjust relief valve
No pressure or no operating valve safety to correct pressure Moderate
motion of vices valve or replace it.
Damage of vice
Clean or replace. Moderate
unloading valve
Vice system
3 and drill pipe Damage of
Clean or replace
bracket corresponding solenoid
No pressure for solenoid
valve/non-energization
specific motion of valve/check electric Moderate
of solenoid
vice circuits/replace oil
valve/internal leakage of
seal or cylinder.
vice cylinder
Damage of throttle
Replace throttle
Non-aligned jaws valve/internal leakage of Importance
vale/cylinder.
cylinder
Damage of traveling Adjust relief valve
operating valve safety to correct pressure Moderate
valve (≤32t) or replace it.
Serious leakage of
traveling pump
No traveling or
slow traveling Blockage or Check electric
non-energization of circuits/clean or
Importance
traveling valve pilot replace power
Traveling module (≥50t) module.
4
system
Obstructed motor brake Clean brake oil
Importance
oil circuit circuit.
Replace in event of
Malfunction of hydraulic
serious internal Serious
Clearly motor
leakage of motor.
non-synchronized
traveling Replace reducer in
Malfunction of traveling
event of housing Serious
reducer
heating.
No motion or slow Damage of cylinder seals Replace cylinder
Importance
motion of cylinder (Outward oil leakage) seals
Damage of Adjust relief valve
Luffing system corresponding relief to correct pressure Moderate
and drilling valve or replace it.
5 Low pressure
frame sliding
system Damage of
corresponding pump
Automatic Blockage of hydraulic
Clean or replace. Moderate
telescoping lock

Accumulation of dirt on
Clean hydraulic oil
hydraulic oil radiator Moderate
radiator.
surfaces
Noise or leakage of
pump or motor and
Damage of radiator gear clearly insufficient
Fast or excessive temperature rise of Serious
6 pump or gear motor speed of air-cooled
hydraulic oil
radiator. Replace
timely.
Over-high drilling
Frequent opening of or rotation pressure
Moderate
relief valve or load. Change the
drilling speed.
2. Classification by malfunction type
Symptom Cause Measure

1. Hydraulic Pump
Damage of parts Replace parts.

Excessive gap and serious leakage due to Repair or replace parts.
wear of parts Add oil.
Air suction of hydraulic pump due to low
oil level Tighten connectors, check pipelines,
Air suction due to poor airtightness of oil and replace seals.
suction pipeline Tighten connectors, check pipelines,
Leakage due to poor airtightness of and replace seals.
pressure oil pipeline
2. Relief valve
Deformation or breakage of spring Replace spring.
Pressure buildup failure due to blockage of Repair slide valve to ensure flexible
No pressure or really low slide valve at opened position movement.
pressure Non-tight fit between conical valve or steel Replace conical valve or steel ball and
ball and valve seat grind valve seat.
Blocked damping hole Clean damping hole.
3. Connection between high and low
Grind piston and replace seals.
pressure chambers of hydraulic cylinder
Find out unloading cause and take
4. Unloading of specific valves in system
corresponding measure.
5. Serious leakage of system Replace seals to prevent leakage.
6. False symptom of no pressure due to
Replace pressure gauge.
damage or failure of pressure gauge
7. Enhanced system leakage due to low
Increase the viscosity of oil.
viscosity of oil
8. Reduced oil viscosity due to excessive Find out heating cause and take
temperature rise corresponding measure.
1. Unstable flow of throttle valve or speed Select flow control valve of good flow
Creepage
regulator valve stability.

2. Hydraulic cylinder
High friction of hydraulic cylinder parts
due to improper machining or assembling Replace parts of disqualified accuracy
Low stiffness of hydraulic cylinder and re-assemble.
Inconsistent axis between hydraulic Increase stiffness.
cylinder and guide mechanism due to Reinstall.
improper installation
3. Ingress of air
Obstructed oil suction due to low oil level Add oil.
Blockage of oil filter Clean oil filter.
Insufficient spacing between oil suction Set up oil suction and discharge pipes
and discharge pipes to ensure sufficient spacing.
Oil return pipe not immersed into the oil Insert the oil return pipe into the oil.
Ingress of air due to non-tight sealing Replace seals.
4. Dirty oil
Increased friction resistance due to Clean hydraulic motor and replace oil
blockage of hydraulic motor by dirt or enhance oil filtration.
Change of flow due to blockage of Clean hydraulic valve and replace oil
throttling valve by dirt or enhance oil filtration.
Replace with hydraulic oil of
5. Inappropriate viscosity of oil
designated viscosity.
6. External friction force
Over-tight adjustment of wedges or
Re-adjust.
pressure plates
Repair slideways and ensure good
Low accuracy and poor contact of guide
contact.
mechanism such as slideways
Improve lubrication condition.
Poor lubrication condition
7. Hydraulic cylinder
Failure of check valve in damping device Repair check valve of damping
Undersized conicity or gap of damping device.
plunger Repair damping plunger as per
Oversized gap of hydraulic cylinder requirements.
damping plunger due to serious wear Grind the damping plunger or piston.
8. Oversized opening of throttle valve Adjust throttle valve.
9. Reversing valve
Excessive braking conical angle of
Reduce braking conical angle or
Impact test reversing valve or pilot valve
increase braking cone length.
Excessive hydraulic control flow of
Reduce flow of control pressure oil.
hydraulic valve
Adjust the throttling opening in
Improper adjustment of hydraulic valve
damper.
damper
Grind slide valve.
Unsmooth motion of slide valve
10. Pressure valve
Over-high adjustment of working pressure Adjust pressure valve to appropriately
Sudden rise of pressure due to malfunction reduce the working pressure.
of relief valve Solve relief valve malfunction.
Over-low pressure of backpressure valve Increase backpressure appropriately.

Set up backpressure valve or throttle

11. No installed backpressure valve valve to build up return oil
backpressure.
Enhance sealing.
Air suction due to non-tight system sealing Set up check valve or backpressure
valve in oil return pipeline to prevent
Oil loss of hydraulic motor at stop
oil loss of components.
Air suction of hydraulic pump
Enhance sealing of oil suction pipeline
and add oil.
12. Under-low oil viscosity Replace oil.
13. Hydraulic Pump
Air suction due to insufficient oil
Air suction of oil suction pipeline due to Add sufficient oil.
poor airtightness Replace the seals of oil suction
Difficult oil suction due to over-high oil pipeline.
viscosity Replace hydraulic oil.
Low working temperature Heat up the hydraulic oil.
Undersized section of oil suction pipe Increase diameter of oil suction pipe.
Obstructed oil suction due to blocked oil Clean oil filter.
filter Select appropriate speed.
Over-high speed of hydraulic pump Tighten coupling.
Loose coupling Replace low accuracy parts and
Low manufacturing and assembling re-assemble.
accuracy of hydraulic pump Replace worn parts
Wear of hydraulic pump parts
14. Relief valve
Damage of valve seat
Repair valve seat.
Vibration and noise Blocked damping hole
Clean damping hole.
Excessive gap between valve element and
valve body Replace valve element and re-adjust
the gap.
Inflexible movement of valve due to
fatigue or damage of spring Replace spring and remove burrs and
dirt to ensure flexible movement of
Scuffing of valve body or blockage of valve element.
valve element by dirt
15. Reversing valve
Repair electromagnet.
Insecure actuation of electromagnet
Clean or repair valve body and valve
Blockage of valve element
element.
Poor welding of electromagnet
Re-weld.
Damage or excessive hardness of spring
Replace spring.
16. Excessive length or excessive bends of
Change pipeline layout.
pipeline
17. Vibration and noise due to impact Refer to section “Impact”.
18. Vibration of hydraulic system due to
Take vibration-proof measures.
external vibration
19. Over-high pressure Reduce working pressure.
Increased oil temperature
20. Volumetric loss due to serious leakage Replace seals.

Increase machining and assembling

21. Excessive friction between parts of
accuracy of parts to reduce motion
mutual motion
friction.
22. Over-high oil viscosity Select low viscosity hydraulic oil.
23. Temperature rise due to external heat
Isolate heat source.
source
24. Damage of seals Replace seals.
25. Loose pipe connectors Tighten the pipe connectors.
26. Ball out-of-roundness and damaged
Replace steel ball and grind valve seat.
valve seat of check valve
27. Excessive gap between surfaces of Replace some parts and reduce fitting
mutual motion gap.
Leakage 28. Wear of some parts Replace worn parts
29. Defects (Such as pinhole and blister) in
Replace castings or repair defects.
some castings
30. Over-high regulated pressure Reduce working pressure.
31. Under-low oil viscosity Select high viscosity oil.
Reduce working temperature or take
32. Over-high working temperature
cooling measure.
Note:
1. The items listed in the table are only some basic practical experiences. The specific malfunction analysis or
troubleshooting requires professionals for detailed analysis and flexible treatment.
2. The hydraulic system can be checked and repaired only by professionally trained personnel.
3. The troubleshooting of hydraulic malfunctions is mostly a checking process. Start from the simplest and most
basic method and do not operate blindly.

5.4 Common Malfunctions and Troubleshooting of Engine

Looseness or corrosion of
Clean or tighten connectors. Moderate
start circuit
Insufficient charging of Check battery voltage and charge
Moderate
battery when necessary.
No charging voltage of starter
No rotation or slow Check voltage of solenoid coil. Moderate
motor
rotation of diesel engine
Failure of starter motor Replace starter motor. Importance
Rotation of starter motor but Check flywheel ring gear and
Serious
no rotation of engine spring of starter motor for damage.
Blockage of engine stop
No fuel supply of engine Moderate
electromagnet
Check the stop electromagnet
circuit, check whether the speed
Electric or manual stop handle regulator speed is blocked by stop
Moderate
not in stop position connecting rod, and check whether
the handle can be reset by pulling
Stop failure of diesel the connecting rod.
engine
Fuel leakage into intake Fuel injection malfunction (Check
Importance
manifold the fuel injection pump).
Damage of stop circuit or stop Check the stop solenoid valve for
Moderate
solenoid valve presence of action.
Under-low fuel level Refuel. Moderate
Air content in fuel system Check fuel supply pipeline. Moderate
Unstable idling of diesel
engine Obstructed supply of fuel Check the blockage portion. Moderate
Malfunction of fuel injection Check and repair fuel injection
Serious
pump pump.
Incorrect engine oil level Add or drain some oil. Moderate
Failure of engine oil pressure Check and repair pressure regulator
Moderate
regulator valve valve.
Internal permeation of engine
Find out and eliminate the leaks. Moderate
oil
Incorrect engine oil model or
Replace engine oil. Moderate
diluted engine oil by water
Low engine oil pressure
Reduced oil viscosity due to
Check water temperature. Moderate
over-high coolant temperature
Blockage of pressure
Repair or replace pressure regulator
regulator valve at opened Importance
valve.
position or damage of spring
Blockage of engine oil filter Clean or replace engine oil filter. Moderate
Blockage of engine oil cooler Clean or replace engine oil cooler Moderate

Incorrect engine oil level Add or drain some oil. Moderate

Failure of engine oil pressure Check and repair pressure regulator
Moderate
regulator valve valve.
Failure of pressure switch or
Replace corresponding part. Moderate
pressure gauge
Over-high engine oil pressure
Under-low running temperature
Increase engine speed. Moderate
of engine
Over-high engine oil viscosity Replace engine oil. Moderate
Blockage of pressure regulator Repair or replace pressure regulator
Importance
valve at closed position valve.
Excessive engine oil or
Adjust to appropriate engine oil level. Moderate
inappropriate oil
Leakage of turbocharger oil into
Repair turbocharger. Importance
Excessive engine oil intake and exhaust pipes
consumption
Wear of valve stem seal ring Repair seal ring. Importance
Sealing failure of piston rings Repair piston rings. Importance
Oil leakage of engine oil cooler Repair or replace. Importance
Low coolant level Add coolant. Moderate
Malfunction of temperature
Replace sensor. Importance
sensor
Looseness of fan drive belt or
Tension or replace related parts. Moderate
damage of fan
Suction collapse or leakage of
Tighten or replace hose at the leak. Moderate
Over-high coolant radiator hose
temperature (Sudden
overheating) Low pressure of pressure cap Replace pressure cap. Moderate
Opening failure due to blockage

Importance
or damage of thermostat Repair or replace thermostat.
Malfunction of water pump Repair or replace water pump. Serious
Blockage of radiator core internal
Clean internal and external surfaces of
and external surfaces by dirt or Importance
radiator.
poor water or air ventilation
Engine overload Verify the engine for overload. Moderate
Air ingress into fuel system. Check inlet pipe. Moderate
Blocked air filter Clean filter element. Importance
Air leakage between intake and
Check for air leakage. Importance
Black smoke of diesel engine exhaust pipes
under loaded condition
Timing error of fuel injection
pump or malfunction of fuel Calibrate fuel injection pump. Serious
injector
Sealing failure of piston rings Repair piston rings. Serious
Turbocharger malfunction Repair turbocharger. Importance
Contamination of fuel or air
Check fuel and fuel inlet pipe. Moderate
ingress into pipeline system
Leakage of fuel injection high
Flameout of diesel engine Check high pressure fuel pipe. Moderate
pressure fuel pipe
Failure of fuel relief valve Check fuel relief valve. Moderate
Failure of fuel pump Check fuel pump. Importance

Incorrect valve clearance

Check valve clearance. Importance
adjustment
Blockage of fuel injector Check fuel injector. Moderate
Incorrect timing of camshaft or
Repair related supporting parts. Importance
damage of push rod
Loose or damaged engine frame Check engine frame. Moderate
Damage of shock absorbers Check shock absorbers Moderate
Damage or malfunction of fan Check fan. Moderate
Strong vibration of diesel Wear or damage of alternator
engine Check alternator bearings. Importance
bearings
Looseness of motion parts Tighten to specified torque. Moderate
Wear or imbalance of drive
Check related supporting parts. Importance
system
Insufficient tension or over-high Check drive belt and adjust tension and
Moderate
load of drive belt load status.
Intake or exhaust leakage Check intake and exhaust system. Importance
Excessive noise of diesel
Excessive valve clearance Adjust valve clearance Importance
engine
Noise due to friction between
Check turbocharger. Serious
turbocharger and housing
Noise due to drive gears Adjust gear drive system. Importance
Loose or corroded connectors of Adjust connectors to meet
Moderate
battery requirements.
Slip of alternator belt Adjust belt. Moderate
Charging failure or
insufficient charging of Indication failure of instruments Replace instruments. Moderate
alternator
Loose or damaged alternator
Tighten connector. Moderate
wires
Failure of alternator Replace alternator. Importance

5.5 Common Malfunctions and Troubleshooting of Electric System
Malfunction symptom Malfunction cause Troubleshooting

1. Low battery power
1. Charge.
2. Damage of starter switch
2. Repair or replace.
3. Damage of fuse
3. Replace.
Start failure of engine 4. Damage of starter relay
4. Replace.
5. Loose circuit connector
5. Repair circuit.
6. Damage of fuel supply
solenoid valve
1. Insufficient oil 1. Add oil.
Abnormal engine oil 2. Damage of pressure gauge 2. Replace.
pressure 3. Damage of pressure sensor 3. Replace.
Engine 4. Loose circuit connector 4. Repair circuit.
1. Insufficient coolant
1. Add sufficient coolant.
2. Damage of water temperature
Over-high indication of gauge 2. Replace.
water temperature gauge 3. Replace.
3. Damage of sensor
4. Repair circuit.
1. Damage of tachometer
1. Replace.
2. Damage of speed sensor
Inaccurate indication of 2. Replace.
tachometer 3. Insecure installation of speed
3. Reinstall.
sensor
4. Repair circuit.
1. Damage of fuse
1. Damage of traveling/working 1. Replace.
selector switch
Traveling control Traveling failure of 3. Damage of left/right traveling
system machine joystick on traveling control box
4. Damage of traveling solenoid
valve 5. Repair circuit.
1. Damage of fuse 1. Replace.
2. Damage of rocker switch 2. Repair or replace.
No motion of vice valves
3. Damage of solenoid valve 3. Repair or replace.
4. Loose circuit connector 4. Repair circuit.
1. Damage of fuse 1. Replace.
Lighting failure of 2. Damage of rocker switch 2. Repair or replace.
Switching control working lamp or
system instrument lamp 3. Damage of lamp bulb 3. Replace.
4. Loose circuit connector 4. Repair circuit.
1. Replace.
1. Damage of fuse
No push-pull motion of 2. Damage of push-pull joystick
power head 3. Motion in reverse direction
3. Actuated limit switch
only.
4. Repair circuit.

Chapter 6 Transport and Storage
6.1 Transfer of Machine
Please pay attention to the following items during the transfer of the drilling rig:
1) It’s prohibited to carry the operator or other personnel on the drilling rig, otherwise it will probably result in
personal harms.
2) Check fasteners, including anti-rotation pin of anchorage base and limit pin of machine-mounted crane, for
proper installation.
3) During the movement of drilling rig, to guarantee good gradeability and stability, place the drilling frame
horizontal and adjust the power head to the rear of the drilling rig, as shown in diagram below.
4) Run the engine at low speed while driving the drilling rig up or down a slope.
5) Strictly abide by the operation safety requirements. Drive the drilling rig down a slope in drive gear and up a
slope in reverse gear. The operator shall stay in the rear of the drilling rig.
6) During the steering of the drilling rig, operate slowly by multiple steps and avoid the haste or sudden steering,
in order to prevent excessive shaking of the drilling frame.
It’s prohibited to leave the drilling rig operator or other personnel on the drilling rig during the transport.
Otherwise, it will probably lead to personnel falloff or accidents.
To enhance the safety precautions and facilitate the operations, the drilling rig shall travel forward while
moving on horizontal ground or moving downslope and shall travel backward while moving upslope or
climbing onto a trailer.
Run the engine at low speed and drive up or down the transport vehicle at low speed.
During the transport, ensure to fully lower the anchorage base of drilling rig, block the tracks, and secure
the drilling rig by proper cables.
Mud and Additives V

6.2 Transport of Machine
The low-chassis trailer shall be used for long-distance transfer of drilling rig. The drilling rig is equipped with the
traveling chassis. With the use of the ramps (to be welded by the user), it can drive onto the transport vehicle by
self and no crane is required.
Diagram of ramp dimension requirements (Unit: mm):
Figure 6-1 Diagram of Ramp Dimension Requirements (Unit: mm):
In the figure above, the h is the ground clearance of the transport platform of the transport vehicle and the α
should be ≤16° (Namely L≥3500mm×H).
The ramps shall be capable of bearing the overall weight of the drilling rig, with certain safety coefficient.
6.3 Daily Storage and Protection
Pay attention to following precautions during storage of drilling rig:
1) Before the storage of the drilling rig, clean the whole machine, especially the mud pipeline system, to keep
the machine clean and neat.
VI Mud and Additives

2) It’s recommended to place anchorage base levelly onto the ground and, whenever possible, retract the boom
cylinder, angle cylinder, and drilling frame sliding cylinder.
3) Operate as per 3.5 Stop of Machine and check the valve block joysticks, rocker switches, key switch, and
power master switch.
4) The placement site of the drilling rig shall be guarded against wind and rain and be under appropriate
temperature and away from hazardous substances such as inflammables and explosives.
5) Cover the machine by canvas to prevent the dusts and powders from damaging the important portions of the
machine.
6) Charge the battery once every 20 days. Start the drilling rig once every approximately 1 month and test all
motions of the machine for 2~3 times.
7) If the stop time exceeds 2 months, periodically check the cleanliness for the rotating box, diesel tank, and
hydraulic oil tank. If disqualified, clean the box body and then replace the oil/diesel. Fulfill the maintenances
for the machine as per the provisions of Chapter 4 Lubrications and Maintenances.
For the precautions for storage of engine, please refer to the engine operation manual.
For the precautions for storage of machine-mounted crane, please refer to the operation and maintenance
manual of the machine-mounted crane.
Mud and Additives VII

MEMO
VIII Mud and Additives

Mud and Additives

By the application or function of the additives in the mud, the common additives for the directional drilling
operations are classified into alkalinity adjustment, de-filtration, deflocculation, leak stopping, lubrication, surface
activity, viscosity reduction, and thickening additives (For the classification of additives, please refer to the
petroleum and gas industry standard SY/T 5596-2009 Specifications for Naming Drilling Fluid Chemicals.).
For the mud used in directional drilling operations, please refer to GB 50424-2007 Code for Construction of Oil
and Gas Transmission Pipeline Crossing Engineering. The mud viscosity shall meet the requirements of this
standard.
The water for the mixing of mud is ideal in PH value of 8.5-9.5, without calcium, magnesium, or chlorine ion or
solid impurities. As the natural water is in PH value of 7 and is rich with calcium and magnesium ions, during the
actual operations, firstly add the alkaline substances to adjust the PH value and remove the harmful ions,
including calcium (Mainly by adding sodium carbonate) and magnesium (Mainly by adding sodium carbonate. At
PH value of 9.7, the magnesium ions can be converted to Mg (OH)2 to precipitate.). The use and proportion of the
mud are related to the relevant parameters, including local geological conditions and construction speed, and
require rich field construction experiences. Should you have any doubt, please consult with professional mud
experts.
Generally, it’s difficult to remove the chlorine ions. The chlorine ions in concentration of ≤5g/L have insignificant
influence on the performance of bentonite. The chlorine ions in concentration of ≤20g/L (Equivalent to 3.28%
NaCl content) will seriously influence the hydration of the bentonite so that the pre-hydration by fresh water is
required for the bentonite.
The common mud additive types are as below.
1. Bentonite
Also referred to as amargosite, the bentonite is a clay with main content of montmorillonite. If the content of one
positive ion is higher than 50% of the positive ion exchange capacity, the bentonite is named by this positive ion.
The common bentonites include sodium-base and calcium-base bentonites. If no interlayer positive ion content
exceeds 50% of the positive ion exchange capacity, bentonite is named by two positive ions of highest contents,
such as calcium-sodium-base bentonite. The bentonite is an acidic substance and mixing it with alkaline water
helps the dispersion and curing of the bentonite.
The bentonite can absorb the water volume of 8~15 times of its volume to swell by >30 times at most. It can be
dispersed to colloidal in water and incorporates certain degree of glutinousness, thixotropy, and lubricity. Its
mixture with fragmentary materials, such as water, mud, and sand, incorporates plasticity and cohesiveness.
With high water absorption, high swelling upon water absorption, high positive ion exchange capacity, and good
dispersion in water, the sodium-base bentonite is suitable for the mud of most applications.
The application of the calcium-base bentonite is limited due to its low water absorption and formation of large
slim and viscous particles. Generally, it’s used in the shale (killas) application or the fabrication of seawater mud
to prevent the mud loss.
The common additive volume of bentonite is 4%-20% of total water volume. For clay stratum or the addition of
other additives, a low value can be taken.
2. Sodium carbonate
Mud and Additives V
Sodium carbonate is also referred to as soda. The sodium carbonate is mainly used to soften the water, reduce the
water hardness (Remove the harmful calcium and magnesium ions from the water), and adjust the water PH value.
The water treated with sodium carbonate is more suitable for the hydration of bentonite to better play the good
performances of the mud.
The common adding volume of the sodium carbonate is generally 6% of the total added bentonite volume.
Generally, it depends on the actually mixed water.
3. Sodium hydroxide
Sodium hydroxide is also referred to as caustic soda. The sodium hydroxide is a strong alkali that mainly controls
the PH value of water.
The common adding volume of the sodium hydroxide is generally 0.05%-1%% of the total water volume.
Generally, it depends on the local soil properties and water properties.
4. CMC
CMC, carboxymethylcellulose in full name, is a thickening additive that can increase the mud viscosity without
compromising the mud flowability and form a film on the foundation soil surface to increase the strength and
reduce the water loss rate of the mud.
The common CMCs mainly include Na-CMC and ferro-chromo-lignosulfonate-Na-CMC. The adding of
ferro-chromo-lignosulfonate can play a role of preventing the flocculation of mud. The common adding volume of
CMC is generally 0.05-3% of the total water volume.
5. FCI
FCI, ferric chromium lignin sulfonate in full name, is made from lignosulfite and is generally used together with
sodium hydroxide to solve the flocculation and reduce the water loss of the mud while increasing the viscosity. It
can improve the deterioration of stabilizing fluid due to the inclusion of silty soil and concrete and ease the
accumulation of drilling mud particles and speed up the precipitation. The adding volume is 0.3%~0.5% of the
mud.
6. Other materials
In the actual applications, the modified starch (The adding volume is 0.05%-0.6% of total mud quality.),
polypropylene (The adding volume is 0.1%-0.3% of total mud quality.), sulfonated bitumen (The adding volume
is 0.05%-0.6% of total mud quality.), potassium chloride (The adding volume is 0.05%-0.1% of total mud
quality.), ammonium chloride (The adding volume is 0.25%-0.3% of total mud quality.), and PAG-HV (The
adding volume is 0.2%-0.4% of total mud quality.) can also be added.
7. Mud mixing sequence
During the fabrication of mud, firstly add the fixed volume of water into the mixing system and add sodium
carbonate to adjust the PH value of water to control its PH value within 8.5~9.5. Then, slowly add the bentonite as
per the designed mud mixing proportion and mix sufficiently to sufficiently hydrate the bentonite before adding
the thickening additive. As the thickening additive will probably influence the hydration of the bentonite, add the
thickening additive after the bentonite. Finally, add the dispersing additive. It’s better to position the mud for >0.5
hour before use.
8. Mud pressure
VI Mud and Additives

During the use of mud, the control principle is high flow and low pressure, in order to prevent the high mud
pressure, especially the pressure at the mud nozzle outlet, from crushing the stratum and causing mud spillover. In
the guide stage, select the mud pressure as per the table below. However, in the soft stratum (Such as silt layer), a
high mud pressure is adverse to the construction of curved pilot hole. Therefore, start the construction of pilot hole
with low pressure mud or without the mud.
Distance from pilot drill bit to Mud pressure

machine, m MPa PSI
≤300 1.3-1.7 200-250
300-600 2.0-2.4 300-350
600-1000 2.7-3.1 400-450
1000-1500 3.4-3.8 500-550
＞1500 3.8-4.1 550-600
Mud and Additives VII

Nozzle Flow
Use appropriate nozzle size and flow based on the pressure and flow of the mud to be used.
A Flow of every nozzle, unit: L/min

B Nozzle pressure, unit: kg/cm2
C Nozzle diameter, unit: mm
VIII Mud and Additives

Electric Schematic Diagram
X Electric Schematic Diagram

Electric Schematic Diagram XI

XII Electric Schematic Diagram

Electric Schematic Diagram XIII

XIV Electric Schematic Diagram

Electric Schematic Diagram XV

XVI Electric Schematic Diagram

Electric Schematic Diagram XVII

XVIII Electric Schematic Diagram

Electric Schematic Diagram XIX

XX Electric Schematic Diagram

Electric Schematic Diagram XXI

XXII Electric Schematic Diagram

Electric Schematic Diagram XXIII

XXIV Electric Schematic Diagram

Hydraulic Schematic Diagram
Hydraulic Schematic Diagram XXV

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Operation Manual of XZ5060 Horizontal Directional Drilling Rig

XCMG Construction Machinery Co., Ltd.

1. Unauthorized modifications to the equipment.

2. Running under any mode beyond the normal operation scope.

3. Operations beyond the specified scope of machine or under loaded condition.

2. Non-timely or insufficient maintenances or improper maintenances or storage.

3. Use of non-recommended fuel or lubricant.

4. Normal wear of drill pipe and drilling tool.

1. Engine filter elements and belts.

2. Filter elements within hydraulic system.

4. Electric system fuses and lamps.

6. Tracks, sprockets, and track rubber blocks.

7. Rotary connector seals.

8. Rollers, conducting rings, and conducting poles.

9. Wire ropes of machine-mounted crane.

10. Vice and power head sliders.

This manual is composed of 7 chapters.

4. Lubrication and Maintenances

5. Common Malfunctions and Troubleshooting

6. Transport, Storage and Protection

Chapter 2 Product Information

2.1 Product Overview

2.2 Model Composition

2.3 Application Scope

Use of Manual ................................................................................................................................................................... V

Chapter 1 Safety ...................................................................................................................................................... 1-1

1.1 Safety Introduction ..................................................................................................................................... 1-1

1.2 Machine Safety ........................................................................................................................................... 1-4

1.3 Descriptions of Safety Signs ....................................................................................................................... 1-5

1.4 General Danger Information ..................................................................................................................... 1-12

1.5 Main Dangers............................................................................................................................................ 1-13

1.6 Operation Safety Regulations ................................................................................................................... 1-14

1.7 Equipment to be Provided by User ........................................................................................................... 1-17

1.8 Classification of Underground Hazardous Substances ............................................................................. 1-17

1.9 Division of Construction Site and Precautions ......................................................................................... 1-18

1.10 Electric Shock Knowledge........................................................................................................................ 1-18

1.11 Safety Emergency Knowledge .................................................................................................................. 1-19

Chapter 2 Product Information ................................................................................................................................ 2-1

2.1 Product Overview ....................................................................................................................................... 2-1

2.2 Model Composition .................................................................................................................................... 2-1

2.3 Applicable Scope ........................................................................................................................................ 2-1

2.4 Product Features ......................................................................................................................................... 2-1

2.5 Overall Dimensions .................................................................................................................................... 2-2

2.6 Main Technical Specification ..................................................................................................................... 2-3

2.7 Product Nameplate ...................................................................................................................................... 2-4

2.8 ............................................................................................................................................................................ 2-4

2.9 Operations ................................................................................................................................................. 2-10

2.10 Drill pipe ................................................................................................................................................... 2-13

2.11 Drilling tool .............................................................................................................................................. 2-18

2.12 Connection of Drill Pipe and Drilling Tool .............................................................................................. 2-21

2.13 Other Auxiliary Tools ............................................................................................................................... 2-22

Chapter 3 Operation Instructions ............................................................................................................................ 3-1

3.1 Preparations before Entrance into Site ........................................................................................................ 3-1

3.2 Checking of Machine .................................................................................................................................. 3-5

3.3 Positioning of Drilling Rig.......................................................................................................................... 3-6

3.4 Start of Machine.......................................................................................................................................... 3-7

3.5 Stop of Machine .......................................................................................................................................... 3-8

3.6 Drilling of First Drill Pipe........................................................................................................................... 3-9

3.7 Addition of Drill Pipe ................................................................................................................................. 3-9

3.8 Orientation and Direction Change of Drill Bit .......................................................................................... 3-11