MCM-4000 Operation & Safety Instruction Manual

Transcription

1 MCM-4000 Operation & Safety Instruction Manual WARNING Unsafe use of this equipment could result in serious injury or death. This manual contains important instructions for the safe operation and recommended maintenance of your MCM-4000 Drilling Fluid Cleaning System. All operators must carefully read and understand this manual before starting the machine. Keep this manual available both as a reminder for your experienced operator and as a training aid for your new staff. Replacement manuals are available by calling American Augers.

2 Forward Forward Operators Manual Introduction INTRODUCTION Since 1970, American Augers has been a devoted manufacturer of trenchless technology equipment; customers worldwide will recognize the MCM-4000 Drilling Fluid Cleaning System as a premier piece of directional drilling equipment. American Augers always provides its equipment with worldwide technical support, parts and service. American Augers encourages customers to contact the factory with any operational or assistance needs. Every effort has been made to adequately cover the operation of the MCM-4000 Drilling Fluid Cleaning System in this manual. Specifications are subject to change without notice or obligation. American Augers will continue to update its product manuals with current operational information, but some units maybe retrofitted independently by the customer or by the manufacturer per a customer request at the factory, or while in service, and the information herein may not reflect those changes. The materials may not be reproduced in whole or in part without the express written permission of American Augers Inc. Manual Part Number 40MC10000 Released November 3, 2008 Revision 02 Page 2

3 Operators Manual Forward Machine Serial Number Locations Location of Machine Serial Number Plate Machine Serial Number Location of Engine Serial Number Plate Engine Serial Number Page 3

4 Forward Operators Manual Machine Serial Number Locations Location of Genset Serial Number Plate Genset Serial Number Page 4

5 MCM-4000 Operators Manual Forward Revision Record Revision to Manual Revision Number Description of Change Date 01 New Release August /1/ Revised Safety Alerts as a result of Corrective Action /31/2008 Applies to S/N MCM4000T and higher. Page 5

6 Forward MCM-4000 Operators Manual Revision Record Revision to Manual, Continued Revision Number Description of Change Date Page 6

7 MCM-4000 Operators Manual Forward To The Owner To The Owner Thank you for your purchase of the American Augers MCM-4000 Drilling Fluid Cleaning System. This is an authorized accessory for use with our directional drilling equipment. This manual contains important information that will help you and your crew set up and safely operate the Drilling Fluid Cleaning System. DO NOT operate or permit anyone to operate or service this machine until you have read this Manual. Use only trained operators who have demonstrated the ability to operate and service this machine correctly and safely. DO NOT use this machine for any application or purpose other than those described in this Manual. Consult the American Augers factory for changes, additions, or modifications that may be required for this machine to comply with various safety requirements. Unauthorized modifications could cause serious injury or death. Anyone making such unauthorized modifications is responsible for the consequences. Make sure this Manual is complete and in good condition. Contact the American Augers factory to obtain additional manuals and for further information about or assistance with your machine. Your American Augers factory has approved service parts and technicians with special training that know the best methods of repair and maintenance for your machine. Page 7

8 Forward MCM-4000 Operators Manual NOTICE Before using this manual, familiarize yourself with the Description Of Components (page 13). American Augers encourages use of the One-Call system. NOTICE MCM-4000 Drilling Fluid Cleaning Systems have a number of hazards unique to their operation. A series of safety alert decals are provided on American Augers Drilling Fluid Cleaning Systems to alert the operator to hazards of the machines. The Safety Section explains the hazard alert signs. PERFORMANCE Actual machine, accessory, and component performance, capacity, and results can be adversely affected by or vary with such factors, as environmental conditions, weather, failing to exercise proper maintenance, machine functionality not being utilized within suggested operating levels, mechanical or component substitutions that may alter factory standards, operator experience, or other unforeseen limitations not previously listed. Page 8

9 MCM Hz Operators Manual Table of Contents Table of Contents Forward... 2 Introduction... 2 Machine Serial Number Locations... 3 Revision Record... 5 To The Owner... 7 Overview MCM-4000 Machine Components General Information Operation and Maintenance Manual Operator Ownership Of Information Manufacturer Identification Data Machine Identification Data Qualification of Personnel EC-Declaration of Conformity Use of Personal Protective Equipment Legal Disclaimer Purpose of Machine Ground Leveling Ambient Conditions Features of Transport Machine Handling Procedures Warranty Limitations of Warranty Request for Service/Support Warranty and Service for Diesel Engine Instruction Manual Safety Information Safety Standard Basic Safety Guidelines Overhead Hazards Response to Events Page 9

10 Table of Contents MCM Hz Operators Manual Electrical Strike...20 Gas Strike...20 Fiber Optic Strike...21 Communications Line Strike...21 Sanitary/Storm Sewer and Water Strike...21 Operator General Precautions...21 Starting and Stopping Precautions...21 Operating Precautions...21 Maintenance Precautions...22 Dangerous Zones -- Safe Distances...22 Safety Awareness Program...23 Safety Alerts...24 Safety Alerts...24 Site Preparations...31 Site Preparation...31 Swamp Mats...31 Trash Pump...32 Crew...32 Qualification of the Operator...32 Detailed Controls...33 Safety Switches...33 MCM-4000 Motor Control Panel...36 MCM-4000 Remote Control Panel...37 Genset Control Panel...38 Remote Control Pendants...39 Light Switches...39 Valves and Piping...40 Set Up...41 MCM-4000 Set Up...41 Entry Pit and Returns Pit Construction...43 Hose Connections from Trash Pump to Inlet Port...44 High Pressure Discharge Hoses...45 Before Operating the Machine...45 Starting the Genset Engine and Generator...46 Page 10

11 MCM Hz Operators Manual Table of Contents Operating the Drilling Fluid Clean System Preparing Drilling Fluid Adding Bentonite and Agitation Ongoing Drilling Fluid Supply Fluid Pumping Checklist Pumping Fluid to a Directional Drill or Mud Pump Cleaning Drilling Fluid Returns from the Entry Pit Stopping the Genset Engine Machine Storage and Transport Minimum Storage Space Required Storage Drain or Protect the Fluid Course Transport Preliminary Operations for Transportation of the Machine Transportation Responsibility Lifting the Machine General Maintenance Maintenance Qualification of the Technician Welding Cleaning Approved Replacement Fluids Scheduled Maintenance Maintenance Schedule Hour Inspection and Maintenance Hour Inspection and Maintenance Hour Inspection and Maintenance Hour Inspection and Maintenance Hour Inspection and Maintenance Specifications Machine Dimensions / Weight Generator Set Controls Page 11

12 Table of Contents MCM Hz Operators Manual Pump, Mixing/Agitation...71 Pump, Cone Supply...71 Accessories...71 Limited Warranty...73 Page 12

13 MCM-4000 Operators Manual Overview Overview Overview MCM-4000 Machine Components ) Trailer 2) Trailer Jack (4) 3) Front Lifting Eye (2) 4) Clean Tank 5) Remote Control Panel 6) Junction Box 7) First Cuttings Tank 8) Generator Set 9) Rear Lifting Eye (2) 10) Connection to Trash Pump 11) 20 Hp Electric Motor / Pump Assembly 12) 30 Hp Electric Motor / Pump Assembly Page 13

14 Overview MCM-4000 Operators Manual MCM-4000 Machine Components (continued) Overview ) Folding Walkway, some details not shown for clarity 2) Diesel Fuel Fill, Inside Genset enclosure 3) Ground Stake storage 4) Transformer 5) Distribution Panel 6) Shaker #1 7) Chutes 8) Desilting Cones 9) Shaker #2 10) Storage Page 14

15 MCM-4000 Operators Manual Overview Overview MCM-4000 Machine Components (continued) ) Motor Panel 2) Handwheel 3) Bentonite Mixing Hopper 4) Tank Drain (2, one per tank) 5) Tank Cleanouts (2, one per tank, not visible in this view) 6) Freshwater Inlet 7) Connection for heat exchanger, not visible in this view. Page 15

16 Overview MCM-4000 Operators Manual General Information Operation and Maintenance Manual TITLE: MCM-4000 Operation & Safety Instruction Manual EDITION: 2008 Part Number: 40MC10000 Operator The operator must read and follow the manual. Ownership Of Information American Augers, Inc. reserves all rights to the information in this manual. The manual cannot be reproduced or photocopied in part or in whole without previous written authorization from American Augers, Inc. The use of the manual is restricted to the customer who received it and only for purposes of installation, use and maintenance of the relevant machine. American Augers declares that the information contained in this manual fits the technical and safety specifications of the machine. American Augers disclaims responsibility for direct or indirect damages to persons or property caused when the manual or the machine are used in violation of the information contained herein. The information contained in the manual refers only to the machine mentioned in Paragraph, MACHINE IDENTIFICATION DATA. American Augers reserves the right to modify or improve the manual and the machines without notice. Manufacturer Identification Data AMERICAN AUGERS, INC. 135 U.S. Rt. 42, P.O. Box 814 West Salem, Ohio USA Tel Fax Web Site: Machine Identification Data Type: Model: Serial number: Year of manufacture: Drilling Fluid Cleaning System MCM-4000 Found on identification plate Incorporated as part of the serial number. Location of identification plates: See illustrations on pages 3 through 4. Qualification of Personnel Only skilled and authorized personnel should be permitted to transport, use and maintain the machine. These personnel must have studied and must understand the advice and instructions in this manual. Page 16

17 MCM-4000 Operators Manual Overview General Information EC-Declaration of Conformity If required, the declaration of EC conformity is issued at consignment of the machine together with the manual and the CE mark applied. EC conformity is not required in North America. NOTICE American Augers disclaims any responsibility for damages to persons or property caused by the operation of the machine by untrained personnel. Use of Personal Protective Equipment WARNING If personal protective equipment is not used, serious injury or death of personnel can occur. The operator and all other personnel on the worksite should use proper protective equipment according to their duties. Legal Disclaimer NOTICE American Augers disclaims any responsibility for damages to persons or property caused by the operation of the machine in violation of the instructions contained in this manual. Purpose of Machine The machine was designed for the purpose of mixing and recycling drilling fluid. Ground Leveling It is very important to make the pad the unit is to set on as level as possible. Scrape an area 10 feet x 50 feet (3 m x 15 m) to a level grade with a dozer. Ambient Conditions Temperature limits: 5 F and 105 F [-15 C and +40 C] (with oils and coolants recommended). For temperature lower than 32 F [0 C] Refer to: OPERATION UNDER AMBIENT TEMPERATURES BETWEEN - 40 F AND +5 F [-40 C AND -15 C]. For temperatures not included in this range, contact American Augers. Relative humidity: 100% Maximum altitude: 6500 feet [2000 m] above sea level Atmospheric conditions should allow adequate visibility within the operating area. The machine should not be operated when lightning is likely. Features of Transport The machine should be transported by a truck tractor, in accordance with local transportation laws. Page 17

18 Overview Machine Handling Procedures MCM-4000 Operators Manual General Information Use If you are the owner, operator, or the helper using an American Augers Drilling Fluid Cleaning System, it is important that you recognize that these are powerful pieces of construction equipment. THEY SHOULD BE OPERATED WITH RESPECT AND CAUTION. For safety reasons, it is recommended only one person operates the controls. Other trained personnel may work near the Drilling Fluid Cleaning System if they are wearing personal protective equipment. Maintenance During maintenance, with the machine running, be especially cautious to ensure the safety of all personnel. Warranty General Conditions Warranty is subject to the conditions specified in the warranty certificate. The warranty certificate is on the inside of the last page of this manual. If you have questions on the warranty or about any part of the machine operation, please contact American Augers. Limitations of Warranty The warranty for all components purchased by American Augers directly are subject to the original warranties of suppliers/manufacturers and therefore defects in materials or workmanship are considered valid only if they are recognized by those same suppliers/manufacturers. Request for Service/Support For service support in or out of the warranty period, contact American Augers. Provide model number, serial number of the machine and working hours. The number of working hours are shown on the genset engine control panel. Warranty and Service for Diesel Engine The warranty on the engine is valid worldwide and is supplied by the engine dealer in the area where the Drilling Fluid Cleaning System is sold. Only diesel engine dealers are authorized to perform repairs under warranty, provide service and supply spare parts. Instruction Manual This manual is part of the safety system of the equipment. Use it during training of all personnel who will participate in the operation of the equipment. Ensure that a copy is always available on the jobsite and that the operators have read it and have access to it. Carefully follow the instructions, advice, and procedures contained in this manual. Page 18

19 MCM-4000 Operators Manual Safety Information Safety Safety Safety Standard This manual contains important information about the safety practices and safe operation of the MCM Drilling Fluid Cleaning System. All operators must read and understand the Operation and Safety Instruction Manual before starting the MCM Careful adherence to the safety and operating instructions in this manual will help ensure a safe and productive jobsite. This manual does not cover all safety practices related to using your directional drilling equipment or working on a drilling site. Therefore, you must refer to the Operation and Safety Manual you received with your directional drill for additional safety information. Furthermore, it is the responsibility of each person working with this equipment to learn and follow all applicable local, state and federal safety regulations. Basic Safety Guidelines 1) Before using the MCM-4000, all operators should receive thorough training in the use of this equipment. This manual should be used as a training tool. 2) A copy of this manual should remain on the jobsite and be accessible to all personnel at all times. 3) Personnel on the jobsite should receive training on safety practices, procedures, safety signs and hazards. Operators, support personnel, repair technicians, and visitors should be aware of their responsibilities and any restrictions to their activities. 4) Be sure all new, inexperienced employees receive a complete orientation to the jobsite and thorough training in their job duties. Never allow inexperienced personnel to operate or work near the machine unless they are carefully supervised. 5) The meaning of the hazard alert signs on the equipment is explained in the "Safety Alerts" section of this manual. 6) Follow all OSHA, State and Local regulations regarding, but not limited to: Drilling fluid system operation Pilot bore tracking Vehicle operation Trench shoring and sloping Mobile equipment operation Confined space entry Noise Hand tools Traffic control Communications Power tools Verification of utilities Fall protection Security of jobsite and isolation of hazards Material handling Manual lifting Page 19

20 Safety MCM-4000 Operators Manual Safety Information In the United States, workplace safety is regulated by the Occupational Health and Safety Administration (OSHA). OSHA regulations are found in the Code of Federal Regulations, Chapter 29. This is known as 29CFR1910. Information can be obtained from your Regional U.S. Department of Labor Office. 7) Know and use the recommended protective equipment required when operating this machine. Examples are: Hard hats meeting OSHA criteria Safety glasses, goggles, or face shields meeting OSHA criteria Work boots Work gloves Highly visible reflective clothing Hearing protection Boots and gloves made for electrical insulation Any other safety equipment mandated by other rules or required by the Owner or regulatory agency 8) If a hazardous situation is suspected, stop work until an evaluation is made and appropriate corrective action taken. 9) Know and use hand signals required for specific jobs and know who has the responsibility for signaling. 10) Post the location and phone number of the nearest aid station or hospital. Have a fire extinguisher and complete first aid kit on site. Have at least one of your workers trained in first aid. Overhead Hazards Overhead lines must be avoided. Overhead lines are of particular concern during mobilization/demobilization, loading and unloading heavy equipment and while handling drill pipe. If the voltage is unknown, always maintain at least 20 feet (6 m) of separation between equipment and power lines. If the voltage is known, OSHA regulations outline the required minimum separation. If necessary, place highly visible markers on either side of the overhead hazard or designate an individual to notify equipment operators as they approach. Response to Events If an existing utility is struck during the drilling operation, emergency procedures must be initiated to reduce the likelihood of human injury. Procedures to follow in the even of utility strikes are summarized below by type of utility. Electrical Strike If an electrical strike occurs, workers should not move. The voltage difference between the equipment and the ground, or between a person s feet may be sufficient to cause injury or death. Do not touch the machine, hoses, drill pipe, or anything connected to the drill as these items may be highly charged. The drill operator should remain calm and reverse the direction of advance in an attempt to break contact with the electrical line. Contact the electrical utility company immediately. The drill operator should follow the manufacturer s procedure to determine if the drill is electrically charged before attempting to dismount the drill. Gas Strike If a gas line strike occurs, evacuate the area immediately. The drill operator should shut down all engines and under no circumstance should the operator attempt to reverse the bore to break contact as further movement may cause a spark. Contact emergency services and the gas utility company immediately. Page 20

21 MCM-4000 Operators Manual Safety Safety Information Fiber Optic Strike If a fiber-optic strike occurs, do not look into the cut ends of the cable. This can cause severe eye damage. Stop drilling immediately and contact the utility owner. Communications Line Strike If a communications line strike occurs, stop drilling immediately and contact the utility company. Sanitary/Storm Sewer and Water Strike If a water or sewer line strike occurs, stop drilling immediately. Warn all bystanders that a strike has occurred and that they should stay away. Obtain medical attention for personnel who have come into contact with sewage. As with any strike, contact the utility owner immediately. Operator General Precautions It is the responsibility of the operator to read and understand the Operator s Manual and other information provided and use the correct operating procedure. Machines should be operated only by qualified operators and trained helpers. Furthermore, it is the operator s responsibility to: Make sure that all protective guards, doors, etc. are in place and secure. Remove all loose objects stored in or on the machine. Remove all objects which do not belong in or on the machine and its equipment. Point out each of the safety signs on the machine and insure the crew understands the importance of adhering to each of the safety signs. Know that all underground utilities have been located before the well is started, and avoid them by using proper drilling techniques. Know and obey all federal, state, and local codes and regulations. Make sure all personnel know and stay in their prescribed areas to insure a safe operation. Starting and Stopping Precautions Do not start machine until all personnel are clearly away from any rotating or moving parts. Check operation of all machine controls before using the machine. Make sure all servicing as prescribed in this Operator s Manual as well as the manuals for the engines and genset has been completed. Make sure all fluid lines are securely connected before starting the machine. When shutting down the machine, follow manufacturer s recommended procedure. Shut power source down, relieve system pressure, and remove the starter key (if so equipped). Operating Precautions Make sure all operating personnel observe and use safe operating practices, including adhering to all safety signs. Watch that all personnel and objects are clearly away from any rotating or moving parts. Never leave operator station while machine is in operation. Do not operate machine unless protective guards, doors, etc. are in place. Shut down machine at first sign of malfunction or hazardous condition. Page 21

22 Safety Maintenance Precautions MCM-4000 Operators Manual Safety Information Shut down the power source and relieve system pressures before doing any maintenance. Observe manufacturer s recommended maintenance procedures. Allow only properly trained personnel to perform maintenance activities. Do not modify the machine in any way. Repair or replace damaged or missing protective guards, doors, etc. Replace all missing, illegible, or damaged safety signs. Keep all safety signs clean. Use a piece of cardboard or wood to check for pressurized leaks to prevent fluid penetrating the skin. Seek medical attention immediately if hydraulic fluid escaping under pressure has penetrated the skin. This is a serious condition which can cause serious injury and possibly death. Prompt medical treatment by a physician familiar with this injury is essential. Dangerous Zones -- Safe Distances A dangerous zone is any zone inside or near the machine where health, safety and security risks exist. All personnel on the jobsite should be advised of these zones, the hazards they may encounter and the safety precautions which are required or recommended. Hazardous Area: All areas from which a person could handle parts of the machine when it is operating or when maintenance is being performed. Wear appropriate protective equipment. Electrically Charged Safe Distance: 25 feet (8 m) from the drill hole. Personnel in this zone during drilling operations are at risk in the event an electric line is struck. Wear appropriate protective equipment. 25 ft (7620 mm) MCM-4000 Ground (earth) Barricade NOTICE American Augers disclaims any responsibility for damages to persons or property caused by operation in violation of safety advice contained in the manual. Page 22

23 MCM-4000 Operators Manual Safety Safety Information Safety Awareness Program Understanding Operation Safety: BE AWARE OF SAFETY INFORMATION This is the safety alert symbol. This symbol is placed in the manual to alert you to the potential for bodily injury or death. UNDERSTAND SIGNAL WORDS Signal words are used to identify safety information within the text of this manual, and are used on the hazard alert signs used on the machine. DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious personal injury. WARNING indicates a potential hazard or unsafe situation which, if not avoided, could result in death or serious personal injury. CAUTION indicates a potential hazard or unsafe practice which, if not avoided, may result in minor personal injury, product, or property damage. NOTICE Safety Alert Decals The following hazard alert signs are placed on the machine to inform your operator and other personnel of potential hazards that exist while these machines are in operation. These decals should be kept clean and legible. Replacement decals are available from American Augers. Page 23

24 Safety MCM-4000 Operators Manual Safety Alerts Safety Alerts Page 24

25 MCM-4000 Operators Manual Safety Safety Alerts (1) Precautions about electrocution hazard. (2) Precautions about machine being electrically charged. (3) Precautions about voltage level. (4) Precautions about hazard to unauthorized personnel. (5) Precautions about electrical shock hazard. (6) Precautions about diesel exhaust. (7) Precautions about locking out switches. (8) Precautions about rotating parts. Page 25

26 Safety MCM-4000 Operators Manual Safety Alerts Page 26

27 MCM-4000 Operators Manual Safety Safety Alerts (1) Precautions about electrocution hazard. (2) Precautions about machine being electrically charged. (4) Precautions about hazard to unauthorized personnel. (9) Precautions about voltage levels. (13) Precautions about locking out electrical switches. Page 27

28 Safety MCM-4000 Operators Manual Safety Alerts Page 28

29 MCM-4000 Operators Manual Safety Safety Alerts (2) Precautions about machine being electrically charged. (3) Precautions about voltage level. (4) Precautions about hazard to unauthorized personnel. (5) Precautions about electrical shock hazard. (7) Precautions about locking out switches. (11) Precautions about voltage level. (12) Precautions about electrical shock hazard. Page 29

30 Notes MCM-4000 Operators Manual Notes NOTES: Page 30

31 MCM-4000 Operators Manual Site Preparations Operations Operations The Operations Section presents information on Site Preparation, Controls, Set Up and Drilling Fluid Mixing and Recycling. Directional Drill MCM-4000 Return Mud Pit Aux. Mud Pump Typical MCM-4000 Set Up Site Preparation When arriving at the work site, find a level place on which to position the MCM-4000 relative to the directional drill it is to support. The attachment point for the mud hoses to the directional drill is determined based on the entry point of the drill into the ground. Position the MCM to 75 feet (15 m to 23 m) from the point where the mud hoses attach to the directional drill. The MCM-4000 has no leveling jacks. Therefore, it is very important to make the pad the unit is to set on as level as possible. Scrape an area 10 feet x 50 feet (3 m x 15 m) to a level grade with a dozer. Swamp Mats In any situation where the MCM-4000 is setting on dirt, American Augers recommends the use of swamp mats. Swamp mats are rectangles of material approximately 6 feet x 8 feet (2 m x 3 m) that are placed under each axle and the trailer jacks of the MCM Select the proper swamp mat for the soil condition at the site. General Dirt Conditions Swamp mats made of wood can be used for dirt or clay-type conditions. Stack two layers of 2 x 6 s or 2 x 8 s together as shown in the drawing below. Nail or screw them together. You will need 210 lineal feet (65 m) of 2 x 6 material or 164 lineal feet (50 m) of 2 x 8 material for each swamp mat. 8 feet 6 feet Track mats or tire mats can be purchased, rented or leased. Locate suppliers on the internet by searching the topic heavy equipment transport mats. You can also find commercial mat suppliers in driller s trade newspapers. Page 31

32 Operations MCM-4000 Operators Manual Site Preparations Loamy or Swampy Conditions If the worksite is a loamy bog or swamp, lay down two or three 12 inch x 12 inch x 8 feet (304 mm x 304 mm x 2.5 m) railroad ties or wood beams. Then, build a swamp mat of railroad ties over the top of these beams to form a supported decking. Tie the railroad ties together by drilling holes in the ends of the ties and threading a wire rope cable through the holes as shown in the drawing below. Lift Loop Position the MCM-4000 with a swamp mat under each wheel and each trailer jack. Mats Mats Trash Pump Contractor must provide a trash pump (maximum 10 Hp) to pump spent drilling fluid from the Returns Pit to the Drilling Fluid Cleaning System for recycling. Crew The driller operates the MCM-4000 Drilling Fluid Cleaning System from the control panels mounted on the MCM The trash pump can be started and stopped using the pendant. The offload pump can be started and stopped using the pendant. Qualification of the Operator After delivery of the machine, a technician from American Augers is available for training the operators. American Augers is available for further information or instruction. It is expected that customer personnel will be available and ready for training upon the scheduled arrival of the American Augers trainer. Page 32

33 MCM-4000 Operators Manual Operations Detailed Controls Safety Switches There are five (1) Emergency Stop push buttons on the Drilling Fluid Cleaning System controls. 1 MCM-4000 Motor Control Panel - Stops the pumps powered by the genset but does not power down the genset engine 1 MCM-4000 Remote Control Panel - Stops the pumps powered by the genset but does not power down the genset engine Page 33

34 Operations MCM-4000 Operators Manual Detailed Controls 1 Genset Control Panel - Immediately powers down the genset engine but does not disconnect the generator. MCM-4000 Trash Pump Remote - Stops the trash pump Page 34

35 MCM-4000 Operators Manual Operations Detailed Controls MCM-4000 Offload Valve Remote - Stops the pump suppling the Offload piping. Page 35

36 Operations MCM-4000 Operators Manual Detailed Controls MCM-4000 Motor Control Panel AC CONTROLS PULL ON PUSH OFF MIX/AGIT/OFFLOAD START MIX/AGIT/OFFLOAD STOP START STOP 1 6a SHAKER NO. 1 START SHAKER NO. 1 STOP 6b START STOP 2a SHAKER NO. 2 SHAKER NO. 2 2b START STOP START STOP 3a TRASH PUMP TRASH PUMP 3b START STOP START STOP 7a 7b CONE SUPPLY CONE SUPPLY START STOP START STOP 5a 5b 4a WASHDOWN START START WASHDOWN STOP STOP 4b 1) The Emergency Stop push button stops the pumps and shakers powered by the genset but does not power down the genset engine. Push in to stop the pumps and shakers. This control needs to be pulled out when starting the genset engine. 2) The Shaker #1 Control is used to start (2a) and stop (2b) Shaker #1. 3) The Shaker #2 Control is used to start (3a) and stop (3b) Shaker #2. 4) The Washdown Pump Control starts (4a) and stops (4b) the optional washdown pump that supplies a pressure washer for cleaning the machine and the shaker screens. 5) The Cone Supply Control is used to start (5a) and stop (5b) the Cone Supply system which pumps drill fluid through the desilter cones. 6) The Mix/Agit/Offload Control is used to start (6a) and stop (6b) the Mix/Agit/Offload pump. 7) The Trash Pump Control turns on (7a) and off (7b) the pump which is plugged into the cord under the Control Panel labeled Trash Pump. Page 36

37 MCM-4000 Operators Manual Operations Detailed Controls MCM-4000 Remote Control Panel AC CONTROLS PULL ON PUSH OFF MIXING / AGITATION START 5a CONE SUPPLY START 7a TRASH PUMP START START START START 5b 1 6a MIXING / AGITATION STOP CONE SUPPLY STOP TRASH PUMP STOP 6b STOP STOP STOP SHAKER NO. 1 START SHAKER NO. 2 START WASHDOWN START 7b 2a START START START 3a SHAKER NO. 1 STOP SHAKER NO. 2 STOP WASHDOWN STOP 4a STOP STOP STOP 2b 3b 4b 1) The Emergency Stop push button stops the pumps and shakers powered by the genset but does not power down the genset engine. Push in to stop the pumps and shakers. This control needs to be pulled out when starting the genset engine. 2) The Shaker #1 Control is used to start (2a) and stop (2b) Shaker #1. 3) The Shaker #2 Control is used to start (3a)and stop (3b) Shaker #2. 4) The Washdown Pump Control starts (4a) and stops (4b) the optional washdown pump that supplies a pressure washer for cleaning the machine and the shaker screens. 5) The Cone Supply Control is used to start (5a) and stop (5b) the Cone Supply system which pumps drill fluid through the desilter cones. 6) The Mix/Agitation Control is used to start (6a) and (6b) stop the Mix/Agit/Offload pump. 7) The Trash Pump Control turns on (7a) and off (7b) the pump which is plugged into the cord under the Control Panel labeled Trash Pump. Page 37

38 Operations Genset Control Panel MCM-4000 Operators Manual Detailed Controls ) The Stop/Emergency Stop button powers down the genset engine. The button must be pulled out to be able to start the engine. 2) The Battery Switch disconnects the battery from the control panel but does not disconnect the battery from the balance of the circuits. 3) The Generator On/Off switch starts the generator which supplies AC power for the centrifugal pump motors, shakers, and lights on the Drilling Fluid Cleaning System. The genset engine must be running before starting the generator. Note: The genset control panel on your Drilling Fluid Cleaning System may be different from this drawing. Consult your genset owner/operator s manual for specific information. Page 38

39 MCM-4000 Operators Manual Operations Detailed Controls Remote Control Pendants 2 1) Stops the pump suppling the Offload piping or the Trash Pump. 2) Starts the pump suppling the Offload piping or the Trash Pump. Light Switches The work lights receive power from the genset. Switches to turn the lights OFF and ON are located in the distribution panel which is next to the Genset. Page 39

40 Operations Valves and Piping MCM-4000 Operators Manual Detailed Controls First Cutting Tank 1 14 Clean Tank ) Fresh Water Valve 2) Clean Tank Delivery Valve 3) Fresh Water Inport 4) Bentonite Mixing Valve 5) Shutoff Valve, Cone Inlet 6) Supercharge (Offload) Port 7) Supercharge (Offload) Valve 8) Shutoff Valve, Agitation Nozzles 9) Shutoff Valve, Circulation 10) Clean Tank Pump 11) Butterfly Valve 12) Cone Supply / First Cuttings Tank Agitation Pump 13) Trash Pump Port 14) Butterfly Valve 15) Desilting Cones 16) First Cutting Butterfly Valve 17) Bentonite Mixing Hopper All valves in this illustration are shown in the closed position. Page 40

41 MCM-4000 Operators Manual Operations Set Up MCM-4000 Set Up Install the ground stake into the ground per local regulations. WARNING The ground stake must be installed before starting the engine. Drive the ground stake into the ground per local codes or regulations. Start the genset engine and the generator (Review Starting the Genset Engine and Generator on page 46 and follow the procedures in the detailed engine and generator manuals you received with your Drilling Fluid Cleaning System.) Raise the work light posts. Remove the brackets that secure the shakers during transport. There are two brackets on each side of both shakers. There are a total of four brackets per shaker. Page 41

42 Operations MCM-4000 Operators Manual Set Up If desired, you can use the trash pump controls on the Control Panel and the trash pump remote to operate your trash pump. Locate the cord under the Control Panel labeled Trash Pump. Plug your trash pump (maximum 10 Hp) into this outlet. Trash Pump Plug Washdown Pump Plug Position the shaker chutes so larger particles separated from the drilling fluid are removed away from the MCM-4000 system. Chutes Page 42

43 MCM-4000 Operators Manual Operations Set Up Entry Pit and Returns Pit Construction The entry pit is where the drill stem of the directional drill enters the ground. It is also where the drilling fluid returns after downhole usage. The returns pit should be positioned 5 to 8 feet (2 to 3 m) from the entry pit. It should be connected to the entry pit by a trench. Suspend the contractor supplied trash pump into the returns pit from a timber or pipe strong enough to support its weight. The trash pump pumps drilling fluid back to the Mud System for cleaning. Clean out the returns pit periodically to insure an unobstructed flow around the trash pump. The following drawing shows the recommended minimum dimensions of the entry pit, returns pit and the trench connecting them. Constructing larger pits allows more returns to settle out of the drilling fluid before it is pumped into the Mud System improving the efficiency of the Drilling Fluid Cleaning System. Entry Pit Returns Pit 3 ft. 5-8 ft. 4 ft. 5 ft. 5 ft. 1 ft. x 1 ft. Trench 8 ft. 16 ft. Page 43

44 Operations MCM-4000 Operators Manual Hose Connections from Trash Pump to Inlet Port Set Up WARNING Liquid contents of these hoses is under high pressure. Only work on hoses when pump is off. Connect the hoses which will bring spent fluid from the trash pump to the Drilling Fluid Cleaning System for cleaning. Fit the female cam and groove fitting onto the male cam and groove coupling on the trash pump. Push the two levers on the sides of the hose end inward to lock the hose end to the trash pump (1). Unroll the hose toward the Drilling Fluid Cleaning System weir box inlet port located on the side of the tank (2). Attach the female cam and groove fitting onto the male cam and groove coupling on the inlet port. The hose should be laying flat with as few bends as possible. Sharp bends in the hose restrict the flow to the first shaker on the mud pump. 2 1 Page 44

45 MCM-4000 Operators Manual Operations Set Up High Pressure Discharge Hoses WARNING Liquid contents of these hoses is under high pressure. Only work on hoses when pump is off. Discharge hoses are provided with the MCM Link together as many sections as necessary to cover the distance between the MCM-4000 and the directional drill or auxiliary mud pump. Thread the hose together. Then strike the ears of the hammer union with a hand sledge hammer until the collar is tight. This draws the taper joint inside the hammer unions together for a dry seal. Make sure any valves in the mud piping are in the proper position so as not to damage the system when the MCM-4000 is started. Before Operating the Machine The MCM-4000 Drilling Fluid Cleaning System has one engine: the genset engine. The genset engine runs a generator which provides AC power for the centrifugal pumps, shakers, and lights. A factory instruction manual for the generator and engine is supplied with the MCM-4000 Drilling Fluid Cleaning System. The following instructions cover general engine starting and stopping procedures. Consult the factory manuals for detailed starting and stopping procedures, engine maintenance and repair instructions. Open all suction and discharge butterfly valves on centrifugal pumps. Page 45

46 Operations MCM-4000 Operators Manual Starting the Genset Engine and Generator Set Up WARNING The ground stake must be installed before starting the engines. Drive the ground stake into the ground per local codes or regulations. If you have not already done so, install the ground stake into the ground per local regulations. Be sure the Battery Disconnect Switch on the genset is in the ON position. Check the Control Panels to be sure that all switches are in the OFF position and the emergency stop buttons are pulled OUT. Make sure the breaker switch (3) on the control panel of the generator is in the OFF position and the emergency stop button (1) is pulled OUT. Be sure you have checked the oil level in the engine compartment and the diesel fuel level. Start each day with a full tank of #2 diesel fuel. Never let the diesel engine fuel tank run dry. If the tank is dry, bleed the fuel system as outlined in the engine manual. Make all other preliminary or daily checks as specified in the manual for the engine and the section, 10 Hour Inspection and Maintenance on Page 64, of this manual. Make all necessary repairs. Be sure all fuel supply valves are fully open. Follow starting procedures described in the Owner s Manual for the genset engine. After the engine is running and warmed up, turn on the generator. This enables all switches on the Control Panels Page 46

47 MCM-4000 Operators Manual Operations Set Up NOTES: Page 47

48 Operations MCM-4000 Operators Manual Operating the Drilling Fluid Clean System Preparing Drilling Fluid Prior to starting drilling operations, fill the tanks with clean water and mix in bentonite to prepare the drilling fluid. There are two ways to fill the tanks. Follow procedures in Starting the Genset Engine and Generator on page 46 and have the generator running. Filling Tanks from a Lake or River Place the trash pump in a water source such as a lake or river. Connect the hose from the trash pump to the 6 inch (152 mm) cam and groove (13) port. Open valve (16). Turn the Shaker 1 (2a) control on the Control Panel to the START position and release when start is confirmed. Turn on your trash pump. (If you have connected your trash pump to the MCM- 4000, you can use the control (7a) on the Control Panel.) Water will be pumped into the cam and groove port (13) and routed over the first-cut shaker, through the screens and into the first cut tank. Filling Tanks from a Hydrant or Water Truck Alternatively, connect a 3 inch (76 mm) cam and groove end hose to the 3 inch (76 mm) fill port (3). Attach the 3 inch (76 mm) hose to a fire hydrant or water tank truck.open valve (1). Turn the Shaker 2 (3a) control on the Control Panel to the START position and release when start is confirmed. Water will be pumped into the second cut shaker screen into the clean tank. Page 48

49 MCM-4000 Operators Manual Operations Operating the Drilling Fluid Clean System a 2a 3a 7a 2a 3a Page 49

50 Operations MCM-4000 Operators Manual Adding Bentonite and Agitation Operating the Drilling Fluid Clean System Open the butterfly valve (11). Start the Mix/Agitation pump by turning the Mix/Agitation Start control (6a) on the Control Panel to Start and release when start is confirmed. This pump draws the fluid out of the clean tank, sends it to the agitation outlets in the clean tank and also supplies fluid to the mix hopper. Open the butterfly valve (4) at the base of the hopper and the inlet valve (2) to the jet of the hopper. Pour the bentonite into the mix hopper (17) to reach or maintain desired viscosity. Mix the drilling fluid by combining water in the clean tank with bentonite. Agitate it into a 60-second drilling fluid (Marsh Funnel Rating Viscosity). Ideal viscosity varies according to drilling conditions. Test kits and additional information are available from your drilling fluid supplier. Continue agitating the drilling fluid so the bentonite does not settle out. Page 50

51 MCM-4000 Operators Manual Operations Operating the Drilling Fluid Clean System a 6a Page 51

52 Operations MCM-4000 Operators Manual Ongoing Drilling Fluid Supply Operating the Drilling Fluid Clean System After you have established a return flow of used drilling fluid from the rig through the returns pit, use the Mud System to clean the spent drilling fluid and provide a clean water supply. Periodically you will need to add more bentonite to the clean water as needed for your drilling conditions. Check the sand content using a sand kit. Maintain sand content as low as possible. Do not exceed 1/2% sand. CAUTION Sand content in excess of 1/2% can cause excessive wear and damage to the equipment. If the sand content is 1/2% or higher, check the screens on the shakers and replace or repair if necessary. Allow the clean tank to overflow over the top of the divider into the mud tank and run the drilling fluid through the desilting cones again. Consider using finer mesh screens. Fluid Pumping Checklist Review the following checklist before pumping fluid to the directional drill: Have a full tank of 60 second drilling fluid (Marsh Funnel Rating Viscosity) agitating in the clean tank. Check that the hammer unions connecting each section of the high pressure mud hoses running from the offload port on the MCM-4000 to the directional drill are tightened securely. Check the oil and coolant levels in the genset engine. The fuel tank should be full before starting work each day. Run a hose from the returns pit to the MCM-4000 in order to establish a returns flow or have a water tank ready to pump water into the first cut tank so more drilling fluid can be mixed to replace the drill fluid that is first pumped. Have the genset engine on and warmed to operating temperature. Pumping Fluid to a Directional Drill or Mud Pump Connect the directional drill or mud pump to the cam and groove port (6). Make sure valve (2) and (4) are closed. Open valves (7) and (11). Start the Clean Tank Pump using pushbutton (5a) on the control panels. Page 52

53 MCM-4000 Operators Manual Operations Operating the Drilling Fluid Clean System a 5a Page 53

54 Operations MCM-4000 Operators Manual Cleaning Drilling Fluid Returns from the Entry Pit Operating the Drilling Fluid Clean System When the Returns pit is getting full or the tanks with drilling fluid are getting low, establish a return flow to the drilling fluid cleaning system to clean and recycle the material. Be sure the genset engine is running and the generator is ON. The trash pump should be suspended in the returns pit. The hose should be securely connected from the trash pump to the cam and groove port (13). Open valve (11) On the Control Panels, pull the Emergency Stop button (1) out. Turn Shaker #1 (2a) and Shaker #2 (3a) controls to Start. Release when start is confirmed. Turn on your Trash Pump. (If you have connected your trash pump to the drilling fluid cleaning system, you can use the control (7a) on the Control Panel.) This will begin a return flow of drilling fluid to the drilling fluid cleaning system. It is screened by 30 to 50 mesh screens. The screened fluid passes through the screens and into the First Cut Tank. Agitation jets keep the remaining solids in the fluid suspended. Turn the Desilter (5a) control to Start. Release when start is confirmed. This starts the desilter pump which brings drilling fluid from the First CuttingsTank. The suction port of the centrifugal pump picks up the fluid and pumps it to the shaker topped by the 7-cone manifold. The fluid is pumped into the cones and cleaned to 15 micron. The solids fall down out of the narrow end of the cone onto the shaker screens. The screens are 140 mesh or finer. Cleaned fluid is forced upward into the manifold and routed to the Clean Tank. Solids shaken off the shaker screens fall on to the chutes and either to the ground or into a container or bin. They should be properly disposed of per local regulations. The clean tank also has a series of agitation jets to keep the solids from settling out of the fluid. The fluid is ready to be pumped to the mix hopper where bentonite is added. This prepared drilling fluid is held in the clean tank. Page 54

55 MCM-4000 Operators Manual Operations Operating the Drilling Fluid Clean System a 1 1 5a Page 55

56 Operations Stopping the Genset Engine MCM-4000 Operators Manual Operating the Drilling Fluid Clean System Turn off all the shakers, centrifugal pumps, trash pump, washdown system and any auxiliary electrical tools that are running off the genset. All these operations can be done at the Control Panels. Go to the genset. Open the rear door. Turn off the circuit breaker switch (3). This disconnects power to the machine. Push in the Stop/Emergency Stop pushbutton (1). Turn the Battery Switch (2) to OFF Page 56

57 MCM-4000 Operators Manual Machine Storage and Transport Storage and Transportation Storage and Transportation Minimum Storage Space Required Level 462 x 100 inches, height 159 inches (11.7 x 2.5 m, height 4 m), weight pounds (11603 kg) Storage Clean all mud and other foreign materials off the machine. Position the machine on a level surface. Turn off the electrical system by turning the Battery Disconnect Switch on the Genset Control panel to the OFF position. For periods longer than 30 days: Follow steps to prepare machine for transport. Place the machine in a covered and dry site, and follow the instructions* for storing the engine. Disconnect battery and store where the temperature will remain between 32 F and 105 F (0 C to 45 C). Eliminate sediment and water from the tanks (diesel fuel and oil). Top off all gear boxes. Protect the machine from salty or acid environments, solvents, gas and flammable liquids and explosives. *Refer to: Attachment 1, Engine Manufacturers Manual. Drain or Protect the Fluid Course Drain water or bentonite slurry out of the pumps and hoses. If you expect freezing temperatures, pump antifreeze through the system. Transport WARNING Transport of the machine must be carried out by trained and authorized personnel only, after learning the information supplied in the manual. Preliminary Operations for Transportation of the Machine WARNING Do not direct water spray inside the muffler or the air filter, against electric components or control panels. Page 57

58 Storage and Transportation MCM-4000 Operators Manual Machine Storage and Transport CAUTION Tanks must be empty before transport. Drilling fluid is heavy. Damage to the Mud System trailer or rear axle could result from an overweight condition. Clean all mud and other foreign materials off the machine. Pump all drilling fluid and clean water out of tanks. All tanks must be empty before transporting the Drilling Fluid Cleaning System. The 4,000 U. S. gallons (15,142 liters) of drilling fluid, in both tanks, will add 40,000 pounds (18,144 kg) to the weight of the trailer. This means the rig will be overweight. Damage to the trailer drawbar and rear axle areas could result. WARNING Tanks may qualify as confined spaces. Follow appropriate confined space entry regulations. Clean residual drilling mud out of the tanks. You may enter the tanks through the clean out ports on the side of the unit. Disconnect and clean out hoses. Dispose of drilling mud following local regulations. Secure the shaker chutes. Secure the shakers for transport with the brackets as shown in the photo below. Lower work light posts. Do not drive with the work light posts extended. Page 58

59 MCM-4000 Operators Manual Storage and Transportation Machine Storage and Transport Disconnect the trash pump and washdown system from the plugs under the Control Panel (if used). Turn off Genset and genset engine. Disconnect the battery. Remove and stow safety railings. Lower walkway and secure in place. Remove ground stake. Raise the jacks to elevate the Drilling Fluid Cleaning System trailer. Hitch to tractor trailer cab and secure. Then lower the jacks. Transportation Responsibility The transporter is responsible for using the proper method of transport in conformity with local regulations. WARNING Make sure that all personnel keep a safe distance while loading the machine for transport. Lifting the Machine If the machine must be lifted, for example to load on a ship, use the lifting eyes at the front and rear of the machine to connect to the lifting system being used. Type of front lifting eye found on a gooseneck trailer configuration. Type of front lifting eye found on a pintle trailer configuration. Rear lifting eye common to both pintle and gooseneck trailer configurations. Page 59

60 Notes MCM-4000 Operators Manual Notes NOTES: Page 60

61 MCM-4000 Operators Manual General Maintenance Maintenance Maintenance Maintenance WARNING Perform maintenance when there is no power to the machine and the controls. Clean the machine and lock movable parts. DANGER Make sure personnel keep a safe distance during maintenance operations. Hydraulic oil, gearbox oil, diesel engine oil, pin and bearing greases, diesel engine cooling liquid, battery liquids and fuel should be handled with care. Consult Material Safety Data Sheets. Dispose of spent fluids according to EPA and appropriate state and local regulations. Engines, muffler, gearboxes and the hydraulic system can reach very high temperatures. Do not attempt maintenance immediately after stopping work. Wait until the parts are cool. Qualification of the Technician The maintenance technician must be trained in mud system operations. The maintenance technician is responsible for conducting maintenance with suitable test and repair equipment, personal protective equipment and attention to safety hazards. Any special repairs that cannot be made by the maintenance technician should be reported to appropriate management personnel for prompt attention. Welding WARNING Do not perform welding near the tanks and flammable liquids. CAUTION Failure to follow welding procedure can cause damage to electric and mechanical components. Damage to components due to improper procedures is not covered under warranty. CAUTION Disconnect ground terminal first. Reconnect ground terminal last. Page 61

62 Maintenance MCM-4000 Operators Manual General Maintenance Welding must be done with the ground wire connected directly to the component where the weld is made. Failure to follow the above instruction could damage electric and hydraulic components, cylinders, gears and bearings due to internal arcing. Cleaning Cleaning Plastic and Resin Parts Avoid using gasoline, kerosene, paint thinner and similar materials when cleaning the instrument cluster, gauges, console, plastic windows, etc. These materials will cause discoloration, cracking or deformation of the part being cleaned. Use ONLY water, mild soap and a soft cloth when you clean these parts. Pressure Washing the Machine CAUTION Don t direct the water spray inside the muffler or the air filter or against electric components or control panels. Approved Replacement Fluids NOTICE Refer to the table below for approved replacement fluids. Approved Replacement Fluids (Ambient temperature 0 Degree F to 110 Degree F [-18 Degree C to 44 Degree C]) Consult factory for specifications at low temperatures Engine Oil Shell Rotella T AA Specification 401 Hydraulic Oil Shell Tellus T ISO 46 AA Specification 202 Grease Shell Retinax LC-2 AA Specification 301 Engine Antifreeze Shellzone 60%, Water 40% AA Specification 601 Water Course Antifreeze Pitt-Penn RV Antifreeze AA Specification 603 To order fluids from other suppliers, consult the American Augers Lubrication Specifications. Page 62

63 MCM-4000 Operators Manual Maintenance Scheduled Maintenance Maintenance Schedule MCM-4000 Maintenance Schedule After 10* 50* 500* 1000* 2600* Function each job hours hours hours hours hours Check Fuel Level X Check for Leaks X Electrical Systems X Gauges and Instruments X Check Emergency Stop and Safety Switches X Check Battery Water Level X Check Engine Crankcase Oil Level X Check Radiator Coolant Level X Inspect Air Filter Stoppage Indicator X Inspect Shaker Screens X Inspect Shaker Loop Isolators X Clean or Replace Air Filters X** Change Engine Oil and Filters X,E Inspect Motor Couplers X Change Engine Fuel Filters E Drain and Refill Engine Coolant X,E Lubricate Electric Motors X NOTES: E, Consult engine manual on methods and materials. K, Consult pump manual on methods and materials * Do not exceed the indicated number of hours without performing the required maintenance **, Unless filter indicator shows change required at a more frequent interval Page 63

64 Maintenance 10 Hour Inspection and Maintenance MCM-4000 Operators Manual Scheduled Maintenance After every 10 hours or before beginning operations, inspect and perform maintenance items as indicated on the Maintenance Schedule. WARNING Machine batteries contain acid. Use proper precautions and follow the instructions listed below. Check the level of the electrolyte in the battery and add distilled water if the level is too low. Check the battery cables and verify that there are no abrasions or indentations; if necessary, replace the battery cables. Check that the battery terminals are not corroded. Clean and replace them if necessary. The voltage of the battery is 12 volts. Clean corrosion off battery terminals. A paste made of sodium bicarbonate and water is normally enough to clean terminals. After cleaning, rinse thoroughly with clean water. Coat the terminals with grease in order to prevent future corrosion. The batteries contain sulfuric acid. Protect eyes, face, and hands during maintenance work. Do not pour battery acid on clothes, skin, or eyes. If the acid reaches the skin, flood with water. If the acid reaches the eyes, wash with plenty of water and go to the doctor immediately. In case of ingestion, drink water or milk and seek medical attention immediately. Batteries can produce explosive gas. Do not smoke near a battery: keep away ignition source, sparks, or flames. Charge the batteries only in well ventilated areas. WARNING Before checking or changing coolant wait for engine to cool. Check that the level of the radiator coolant in the genset is at correct level and that there is no contamination. Refer to Attachment 1, Engine Manufacturers Manual about coolant and cooling system. WARNING Before checking or changing engine crankcase lube oil wait for the engine to cool. Check that the engine oil in the genset engine is at the correct level and that there is no contamination. Refer to Attachment 1, Engine Manufacturers Manual for correct crankcase lube oil to use if more oil is required. WARNING Wait for engine to cool Check the air filter stoppage indicator. A stoppage indicator signals the need to clean or replace the filter. In extremely dusty conditions, the maintenance of engine air filter should be increased. Use the procedures indicated in Attachment 1, Engine Manufacturers Manual. Page 64

65 MCM-4000 Operators Manual Maintenance Scheduled Maintenance WARNING Wait for engine to cool Clean and inspect shaker screens. Replace if worn. Page 65

66 Maintenance 50 Hour Inspection and Maintenance MCM-4000 Operators Manual Scheduled Maintenance Perform 10 Hour Inspection and Maintenance items, plus: Inspect loop isolator belts that support the shaker basket. They may become stretched, frayed or worn. Replace as required. Page 66

67 MCM-4000 Operators Manual Maintenance Scheduled Maintenance 500 Hour Inspection and Maintenance Perform 10 hour and 50 hour inspection and maintenance items, plus: WARNING Before checking or changing engine crankcase lube oil wait for the engine to cool. Change the engine oil and filters. Refer to Attachment 1, Engine Manufacturers Manual for methods and materials. WARNING Wait for engine to cool Clean or replace air filters. Refer to Attachment 1, Engine Manufacturers Manual for methods and materials. Inspect motor couplers and replace if worn. Page 67

68 Maintenance MCM-4000 Operators Manual 1000 Hour Inspection and Maintenance Scheduled Maintenance Perform 10 hour, 50 hour and 500 hour inspection and maintenance items, plus: WARNING Before checking or changing engine fuel filters wait for the engine to cool. Change engine fuel filters. Refer to Attachment 1, Engine Manufacturers Manual for methods and materials. Page 68

69 MCM-4000 Operators Manual Maintenance Scheduled Maintenance 2600 Hour Inspection and Maintenance Perform 10 hour, 50 hour, 500 hour and 1000 hour inspection and maintenance items. Page 69

70 Notes MCM-4000 Operators Manual Notes NOTES: Page 70

71 MCM-4000 Operators Manual Specifications Specifications Specifications Machine Dimensions / Weight Length: 38 feet 6 inches (11.7 m) Width: 8 feet 3 inches (2.5 m) Height: 13 feet 3 inches (4 m) Estimated Weight: 25,580 pounds (11,603 kg) Configuration: Tandem axle pintle hitch trailer standard Generator Set Generator: Fuel Capacity: Caterpillar D125-6 / 114 kw Prime Power/ 480 V 42 U. S. Gallon (159 liters) Controls Remote Controls: Pendant for Offload Valve Start / Stop Pendant for Trash Pump Start / Stop Pump, Mixing/Agitation Pump Design: Estimated Output Centrifugal, 30 Hp electric motor 950 gpm at 75 ft head (3595 Lpm at 23 m head) Pump, Cone Supply Pump Design: Estimated Output Centrifugal, 20 Hp electric motor 500 gpm at 90 ft head (1890 Lpm at 27 m head) Accessories Two, 50 foot (15.5 m) hoses with cam and groove fittings Two, 500 W quartz work lights Washdown pump, 5 Hp (optional) Page 71