An Ounce of Prevention…
The life and performance of any piece of equipment lies in proper maintenance. Compact horizontal directional drills (HDDs) are no exception. These machines operate in dirty, dusty conditions and operators demand peak performance and reliability in even the worst of circumstances.
“Regular maintenance performed at the proper intervals will maintain performance and provide for a more sound operation of the machine,” says Jamie Bouldin, product support manager with Astec Underground in Loudon, Tenn. “A customer who has neglected to perform scheduled maintenance will frequently have more downtime and a machine with decreased performance.
“Do what the manufacturer recommends when the manufacturer recommends and your equipment will last longer and perform better. Work with your local dealer to set up a preventative maintenance plan to ensure you’re getting optimal performance from your drill.”
Owners should consult their operator or service manual for the precise schedule for their particular brand of machine. In general terms, however, there are a number of obvious areas that users should check on a daily basis. John Hoffman, service manager with American Augers in West Salem, Ohio, recommends that the first area of attention be the safety features. If the drill is on a jobsite, make sure the strike alert is properly set up and fully functional before beginning maintenance or drill work.
Cylinder locks on the thrust frame should be checked to ensure they are working properly. This safety feature prevents the thrust frame from falling on someone who is working on the drill. The exit side lockout system, like the proprietary es!lok feature on Astec and American Auger drills, are another important feature when you’re considering a new drill, says Hoffman. The exit side lockout system allows someone on the exit side of the drill to disable the operator controls while changing tooling, checking the pit, etc.
There are seven major areas of a compact HDD that require at least some attention on a daily basis, says Bouldin. The engine, fuel filters, hydraulic system, grease points, gearboxes, tracks and mud pump are all vital to the performance of the HDD.
1. Engine: Check the engine oil daily. Change the engine oil and oil filter as required by the engine manufacturer, usually monthly or every 250 hours. Check the coolant level on a regular basis and change the coolant and flush the cooling system once a year. Be sure to keep the exterior of the radiator clean and free of dirt and debris.
Check the air cleaner daily and also change it according to the manufacturer’s schedule.
2. Fuel filters: Change the fuel filters when you change the engine oil to prevent downtime due to a clogged filter. “These machines are used in dirty, dusty conditions in most cases,” says Bouldin. “It’s cheaper to change a filter a bit prematurely than it is to miss hours of work.”
3. Hydraulic System: Check the hydraulic oil level daily. Be sure to check all the hoses. Many of the hoses may not be in plain view, so look carefully. A low hydraulic fluid level is often your first clue that you have a leak in an obstructed area. Check fittings on the hoses and tighten any that are loose. Loss of hydraulic oil may cause temperatures to rise in the hydraulic system. Change the hydraulic oil and filters at the manufacturer’s rated interval. Keep the oil cooler free of dirt and debris just as you do the radiator. When replacing a hose take care not to get dirt in the system.
“The hydraulic fluid is protecting the single most expensive part of the drill, so be sure to give it proper attention,” says Hoffman. Many larger machines have filter indicators that allow users to easily identify filters that need changing. On these larger drills, operators often take fluid samples and compile histories to monitor the quality of the fluid over time. One test may not tell you much, but over time, you can track the condition and determine when you need to change the fluid. This way you can be sure you’re not changing the expensive fluid prematurely. The filters on some of these machines are so good that the hydraulic fluid is cleaner after it’s been in the machine a while than it is fresh from the drum.
4. Grease Points: There are a variety of different models of drills with a wide range of features available in the marketplace. When you purchase a new drill, read the operator’s manual and learn all the grease points on your machine. Be sure to grease them all and at the proper intervals. This will prevent premature wear of moving components.
5. Gearboxes: Visually inspect the gearboxes for leaks just as you do the rest of your machine. Keep all gearboxes at their recommended fluid levels. And change the fluid as recommended by the drill manufacturer.
6. Tracks: Check the track adjustment regularly and keep them adjusted. Loose tracks may cause wear on the rollers and sprockets. Check the track drive gearboxes at regular intervals. Be sure to use the recommended oil from the manufacturer.
7. Mudpump: Check the oil level in the crankcase every 10 hours of operation and service the oil as recommended by the pump manufacturer.
Another important area to watch for excessive wear is the downhole tooling — the items that are in constant contact with the soil. Watch for broken or excessively worn parts and replace promptly for best performance.
Remember that a proper warm period will help you to keep your drill in top working condition and be careful
to properly winterize your machine when working or storing in cold temperatures. Careful monitoring of these major areas will go a long way toward ensuring your drill performs like the high performance machine it was intended to be. Remember too, that you should have required maintenance items on hand. Things like hydraulic filters, engine filters, pistons, liners, valves and mud swivel packings for mud pumps are among the simple and relatively inexpensive items that you should have in your support trailer.
“You don’t want to spend downtime waiting for replacement parts and paying premium freight charges to rush items to the jobsite,” says Bouldin.
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