MPR Hz Operation & Safety Instruction Manual

Transcription

1 MPR Hz 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 MPR Hz Mud 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 MPR Hz Operators Manual Introduction INTRODUCTION Since 1970, American Augers has been a devoted manufacturer of trenchless technology equipment; customers worldwide will recognize the MPR Hz Mud System as a premier piece of equipment that is a vital accessory to our 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 MPR Hz 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 6000MPR10200 Released September 2008 Revision 01 Page 2

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

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

5 MPR Hz Operators Manual Forward Machine Serial Number Locations Location of Machine Serial Number Plate Machine Serial Number Page 5

6 Forward MPR Hz Operators Manual Machine Serial Number Locations Location of Machine Serial Number Plate Machine Serial Number Page 6

7 MPR Hz Operators Manual Forward Revision Record Revision to Manual Revision Number Description of Change Date 00 New Release, May 2008; Includes serial number MP /22/ Minor content and format revisions, September 2008; Includes serial 9/18/2008 numbers MPR and MPR Page 7

8 Forward MPR Hz Operators Manual Revision Record Revision to Manual, Continued Revision Number Description of Change Date Page 8

9 MPR Hz Operators Manual Forward To The Owner To The Owner Thank you for your purchase of the American Augers MPR Hz Mud 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 Mud 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 9

10 Forward MPR Hz Operators Manual NOTICE Before using this manual, familiarize yourself with the Description Of Components (page 15). American Augers encourages use of the One-Call system. NOTICE Mud Systems have a number of hazards unique to their operation. A series of safety alert decals are provided on American Augers Mud 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 10

11 MPR Hz Operators Manual Table of Contents Table of Contents Forward... 2 Introduction... 2 Machine Serial Number Locations... 3 Revision Record... 7 To The Owner... 9 Overview MPR Hz 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 11

12 Table of Contents MPR Hz Operators Manual Electrical Strike...25 Gas Strike...25 Fiber Optic Strike...25 Communications Line Strike...25 Sanitary/Storm Sewer and Water Strike...25 Operator General Precautions...25 Starting and Stopping Precautions...26 Operating Precautions...26 Maintenance Precautions...26 Hazardous Chemicals...26 Dangerous Zones -- Safe Distances...27 Safety Awareness Program...27 Safety Alerts...30 Safety Alerts...30 Site Preparations...41 Site Preparation...41 Swamp Mats...41 Trash Pump...42 Crew...42 Qualification of the Operator...42 Detailed Controls...43 Safety Switches...43 Battery Disconnect Switch...46 MPR Hz Control Panel...47 Genset Control Panel...48 MPR Hz Main Junction Box...49 MPR Hz Portable Operator s Console...50 MPR Hz Mud Pump Control Panel...51 Caterpillar Engine Control Panel...52 Caterpillar Messenger...53 Light Switches...53 Set Up...54 MPR Hz Mud System Set Up...54 Entry Pit and Returns Pit Construction...57 Page 12

13 MPR Hz Operators Manual Table of Contents Hose Connections from Trash Pump to Inlet Port High Pressure Discharge Hoses Starting the Mud System Operating in Hot Weather Operating Under Ambient Temperatures between -40 F to + 5 F (-40 C to +15 C) 60 Before Operating the Machine Starting the Mud Pump Engine Starting the Genset Engine and Generator Operating the Mud System Preparing Drilling Fluid Adding Bentonite and Agitation Ongoing Drilling Fluid Supply Fluid Pumping Checklist Pumping Fluid to a Directional Drill Mud Pump Pressure Relief Valve Operation When Adding or Removing Drill Pipe Cleaning Drilling Fluid Returns from the Entry Pit End of Pumping Operations Stopping the Mud Pump Engine 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 Qualification of the Technician Cleaning Welding Approved Replacement Fluids Page 13

14 Table of Contents MPR Hz Operators Manual Scheduled Maintenance...82 Maintenance Schedule Hour Inspection and Maintenance Hour Inspection and Maintenance Hour Inspection and Maintenance Hour Inspection and Maintenance Hour Inspection and Maintenance...90 Specifications...91 Machine Dimensions / Weight...91 Power Train...91 Generator...91 Pump...91 Pump, Liner Wash...91 Pump, Supercharge...91 Pump, Mix-Agitation...91 Pump, Cone Supply...92 Pump, Hydraulic Jack...92 Controls...92 Accessories...92 Limited Warranty...93 Page 14

15 MPR Hz Operators Manual Overview Overview Overview MPR Hz Components ) Generator Set (genset) 2) Genset Control Cabinet 3) Liner Wash System 4) Supercharge Centrifugal Pump 5) Clean Tank 6) Mud Tank 7) Clean Water Fill Inlet 8) Trash Pump Inlet 9) First Cut Tank 10) Fold-Down Walkway 11) Mix/Agitation Centrifugal Pump (not visible in this view) 12) Desilter Centrifugal Pump 13) Safety Railing Storage 14) Breaker Box 15) Chain Reducer Page 15

16 Overview MPR Hz Operators Manual MPR Hz Components (Continued) Overview ) Quintiplex Mud Pump 2) Control Panel 3) Desilting Cones over Shaker #2 4) Shaker #1 5) Mix Hopper 6) Transport Jack Hydraulic Pump 7) Transport Jack Control Levers 8) Transport Jack 9) Cleanout Openings 10) Shaker Chutes 11) Discharge Opening to Directional Drill 12) Drive Shaft and Drive Shaft Guard Page 16

17 MPR Hz Operators Manual Overview Overview MPR Hz Components (Continued) ) Battery Disconnect Switch 2) Portable Operator s Console 3) Diesel Fuel Fill 4) Junction Box 5) Ground Wire Attachment Point 6) Cable Holder 7) Transmission 8) Mud Pump Control 9) Caterpillar Engine Control Panel and Caterpillar Messenger Display 10) Caterpillar C-15 Engine Page 17

18 Notes MPR Hz Operators Manual Notes NOTES: Page 18

19 MPR Hz Operators Manual Overview General Information Operation and Maintenance Manual TITLE: MPR Hz Mud System Operation & Safety Instruction Manual EDITION: 2008 Part Number: 6000MPR10200 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: Mud System MPR Hz Found on identification plate Incorporated as part of the serial number. Location of identification plates: See illustrations on pages 3 through 6. 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 19

20 Overview EC-Declaration of Conformity MPR Hz Operators Manual General Information 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, recycling and pumping 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: Operating Under Ambient Temperatures between -40 F to + 5 F (- 40 C to +15 C) on page 60. 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 20

21 MPR Hz Operators Manual Overview General Information Machine Handling Procedures Use If you are the owner, operator, or the helper using an American Augers Mud 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 Mud 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 is shown on the hour meter of the Caterpillar 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 Mud 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 21

22 Notes MPR Hz Operators Manual Notes NOTES: Page 22

23 MPR Hz Operators Manual Safety Information Safety Safety Safety Standard This manual contains important information about the safety practices and safe operation of the MPR Hz Mud System. All operators must read and understand the Operation and Safety Instruction Manual before starting the Mud System. 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. Make sure your machine has the correct equipment required by the local laws and regulations. Furthermore, it is the responsibility of each person working with this equipment to learn and follow all applicable local, state, provincial and national safety regulations. NOTICE American Augers disclaims any responsibility for damages to persons or property caused by operation in violation of safety advice contained in the manual. Basic Safety Guidelines 1) Before using the MPR Hz, 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) All new, inexperienced employees should 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. NOTICE American Augers disclaims any responsibility for damages to persons or property caused by the operation of the machine by untrained personnel. 5) The meaning of the hazard alert signs on the equipment is explained in the "Safety Alerts" section of this manual. 6) Follow all national, state, provincial 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 23

24 Safety MPR Hz 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. In other countries, the operator is responsible for determining which national and local laws govern operations at the jobsite. 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 WARNING If personal protective equipment is not used, serious injury or death of personnel can occur. 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 event of utility strikes are summarized below by type of utility. Page 24

25 MPR Hz Operators Manual Safety Safety Information 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. Shut down all engines. Extinguish all flame and sparks immediately. Escaping gas is both flammable and explosive. DO NOT, under any circumstances, attempt to reverse the bore to break contact as further movement may cause a spark. Contact emergency services and the gas utility company immediately. 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, treat the strike as an electrical strike and follow the procedure for electric line contact until verified that the strike is not electrical. Stop drilling immediately and contact the utility company. Sanitary/Storm Sewer and Water Strike If a water or sewer line strike occurs, there is an immediate flood hazard. Stop drilling immediately. Warn all bystanders that a strike has occurred and keep them from entering the danger area. 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: Verify 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 national, provincial, state, and local codes and regulations. Ensure that all personnel know and stay in their prescribed areas. Page 25

26 Safety MPR Hz Operators Manual Starting and Stopping Precautions Safety Information 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. Complete all servicing as prescribed in this Operator s Manual as well as the manuals for the engine and genset. Securely connect all fluid lines before starting the machine. When shutting down the machine, follow manufacturer s recommended procedure. Procedure for shut down. 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 s station while machine is in operation. Do not operate the machine unless protective guards, doors, etc. are in place. Do not operate the machine while under the influence of alcohol or drugs Shut down machine at the first sign of malfunction or hazardous condition. Maintenance Precautions Shut down the power source and relieve system pressures before doing any maintenance. Allow the machine to cool before servicing. Hydraulic components, engine, radiator and exhaust systems can get hot enough to cause serious injury. 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 when checking 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. Hazardous Chemicals The fluids, lubricants, paints, adhesives, coolants, etc. used with your machine can be hazardous. Contact with hazardous chemicals can cause serious injury. Consult Material Safety Data Sheets. Wear proper protective equipment when working with these materials. DO NOT drain these fluids on the ground or dump them into sewage systems, streams, rivers, lakes, or the sea. DO NOT use containers that can leak. Always follow laws and regulations for proper disposal of waste materials. WARNING Do not carry out welding near tanks and flammable liquids. WARNING Do not use flammable solvents near fire, sparks or other ignition sources. Page 26

27 MPR Hz Operators Manual Safety Safety Information WARNING Machine batteries contain acid. Use proper precautions and dispose of properly. Additional information about safety practices when working with batteries is discussed in 10 Hour Inspection and Maintenance on page 83. 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. All other personnel must stay out of this zone during drilling or backreaming or any time when an electric line could be struck. 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. Page 27

28 Safety MPR Hz Operators Manual Safety Information 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 28

29 MPR Hz Operators Manual Notes Notes NOTES: Page 29

30 Safety MPR Hz Operators Manual Safety Alerts Safety Alerts Page 30

31 MPR Hz Operators Manual Safety Safety Alerts (1) Precautions about electrocution hazard (5) Precautions about rotating parts (8) Precautions about machine being electrically charged (9) Precautions about underground utilities (12) Precautions about running pump dry (36) Reminder about proper procedures to lift the MPR Hz during transport Page 31

32 Safety MPR Hz Operators Manual Safety Alerts Page 32

33 MPR Hz Operators Manual Safety Safety Alerts (8) Precautions about machine being electrically charged (9) Precautions about underground utilities (10) Precautions about diesel exhaust (12) Precautions about running pump dry (17) Precautions about electric shock hazards (22) Precautions about hazard to unauthorized personnel (25) Precautions about damage to pump seals Page 33

34 Safety MPR Hz Operators Manual Safety Alerts Page 34

35 MPR Hz Operators Manual Safety Safety Alerts (1) Precautions about electrocution hazard (5) Precautions about rotating parts (8) Precautions about machine being electrically charged (9) Precautions about underground utilities (14) Precautions about electric shock warnings (located inside panel) (22) Precautions about hazard to unauthorized personnel (25) Precautions about damage to pump seals (29) Precautions about locking out switches Page 35

36 Safety MPR Hz Operators Manual Safety Alerts Page 36

37 MPR Hz Operators Manual Safety Safety Alerts (34) Precautions about arc flash and shock (35) Precautions about locking out switches Page 37

38 Safety MPR Hz Operators Manual Safety Alerts Page 38

39 MPR Hz Operators Manual Safety Safety Alerts (5) Precautions about rotating parts (9) Precautions about underground utilities Page 39

40 Notes MPR Hz Operators Manual Notes NOTES: Page 40

41 MPR Hz Operators Manual Site Preparations Operations Operations The Operations Section presents information on site preparation, controls, set up and drilling fluid mixing, recycling and pumping operations. Site Preparation When arriving at the work site, find a level place on which to position the MPR Hz 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 MPR Hz 50 to 75 feet (15 m to 23 m) from the point where the mud hoses attach to the directional drill. The MPR Hz has no leveling jacks. Transport Lift Jacks in the front should not be used to level the unit. 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 MPR Hz 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 Transport Lift Jacks of the MRP Hz. 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 (0.6 m x 1.8 m) or 2 x 8 s (0.6 m x 2.5 m) 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 (2.5 m) 6 feet (1.8 m) 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 41

42 Operations MPR Hz 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 Mud System with a swamp mat under each wheel and each Transport Jack. mats Trash Pump Contractor must provide a trash pump (maximum 10 Hp) to pump spent drilling fluid from the Returns Pit to the Mud System for recycling. Crew The driller operates the MPR Hz Mud System from the control room using the portable Operator s Console. 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 42

43 MPR Hz Operators Manual Operations Detailed Controls Safety Switches There are seven (1) Emergency Stop push buttons on the Mud System controls. 1 EMERGENCY STOP SUPERCHARGER RUNNING LINER WASH RUNNING TRASH PUMP THERMAL OVERLOAD DESILTER STOP ON START MIX/AGITATION STOP ON START TRASH PUMP HYD JACKS PUMP STOP ON START SHAKER #1 STOP ON START SHAKER #2 STOP ON START WASHDOWN PUMP STOP ON START MPR Hz Control Panel - Stops the pumps powered by the genset but does not power down the genset engine Genset Control Panel - Immediately powers down the genset engine 1 Page 43

44 Operations MPR Hz Operators Manual Detailed Controls ENGINE TACHOMETER MUD FLOW (GPM-LPM) SUPERCHARGER RUNNING MUD PUMP CLUTCH ENGAGED OVER 10 MIN. MUD PUMP START MUD PUMP THROTTLE FAST SLOW CLUTCH HORN MUD PUMP STOP PUSH IN PULL OUT 1 MPR Hz Operator s Console - Immediately stops the mud pump engine MUD PUMP STOP 1 20 AMP MPR Hz Main Junction Box - Immediately stops the mud pump engine Page 44

45 MPR Hz Operators Manual Operations Detailed Controls MUD PUMP CLUTCH PUSH IN PULL OUT HORN EMERG STOP 1 MPR HZ Mud Pump Control - Immediately stops the mud pump engine 1 Caterpillar Engine Control Panel - Immediately stops the mud pump engine Page 45

46 Operations MPR Hz Operators Manual Detailed Controls START STOP 1 MPR Hz Trash Pump Remote - Stops the trash pump Battery Disconnect Switch The battery disconnect switch is located at the fluid end of the pump as shown in the drawing below. The switch connects and disconnects the batteries from the electrical system. Rotate to the right to connect. Rotate left to disconnect. The battery switch must be in the ON position before starting the mud pump engine and the genset engine. Do not disconnect the batteries while either engine is running. Page 46

47 MPR Hz Operators Manual Operations Detailed Controls MPR Hz Control Panel 1 EMERGENCY STOP 8 9 SUPERCHARGER RUNNING LINER WASH RUNNING TRASH PUMP THERMAL OVERLOAD 10 DESILTER STOP ON START MIX/AGITATION STOP ON START TRASH PUMP HYD JACKS PUMP STOP ON START 5 7 SHAKER #1 STOP ON START SHAKER #2 STOP ON START WASHDOWN PUMP STOP ON START ) 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. 2) The Shaker #1 Control is used to start and stop Shaker #1. 3) The Shaker #2 Control is used to start and stop Shaker #2. 4) The Washdown Pump Control starts the optional washdown pump that supplies a pressure washer for cleaning the machine and the shaker screens. 5) The Desilter Control is used to start and stop the Desilter system which pumps drill fluid through the desilter cones. 6) The Mix/Agitation Control is used to start and stop the Mix/Agitation pump. 7) The Trash Pump, Hyd. Jacks Pump Control turns on the pump which is plugged into the cord under the Control Panel labeled Trash Pump Hyd. Jacks Pump, 480 V AC-3PH. 8) The Supercharger Running light is lit when the supercharge pump is running. 9) The Liner Wash Running light is lit when the Liner Wash System is operating. 10) The Trash Pump Thermal Overload light is lit when the trash pump motor is overloaded. Page 47

48 Operations Genset Control Panel MPR Hz Operators Manual Detailed Controls 2 1 1) 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 Generator On/Off switch starts the generator that supplies AC provides power for the centrifugal pump motors, shakers, and lights on the Mud System. The genset engine must be running before starting the generator. Note: The genset control panel on your Mud System may be different from this drawing. Consult your genset owner/operator s manual for specific information. Page 48

49 MPR Hz Operators Manual Operations Detailed Controls MPR Hz Main Junction Box MUD PUMP STOP AMP 1) The Mud Pump Stop push button stops the Mud Pump engine from this location. Push in to immediately stop the engine. The button must be pulled out to be able to start the engine. 2) A 20 Amp Fuse protects the electrical system. Page 49

50 Operations MPR Hz Operators Manual Detailed Controls MPR Hz Portable Operator s Console ENGINE TACHOMETER 7 MUD FLOW (GPM-LPM) 8 SUPERCHARGER RUNNING 6 MUD PUMP CLUTCH ENGAGED OVER 10 MIN. MUD PUMP START MUD PUMP THROTTLE FAST 9 5 SLOW CLUTCH HORN MUD PUMP STOP PUSH IN PULL OUT ) The Mud Pump Stop push button stops the mud pump engine from this location. Push in to immediately stop the engine. The button must be pulled out to be able to start the engine. 2) The Horn push button is used to give an audible warning before starting the Mud Pump. 3) The Clutch push button remotely engages and disengages the Mud Pump clutch. Push in (like you would push the clutch pedal on an automobile) so you can shift into gear or neutral. Pull out with the engine in neutral to idle or with the engine in gear to begin mud pump flow. 4) The Mud Pump Start push button starts the engine from this location. Note that the ignition switch on the Caterpillar control panel must be in the On position to start the pump from the Operator s Console. Push in to start the engine. 5) The Mud Pump Throttle increases or decreases engine speed. This also decreases the Mud Pump flow rate. Push up to increase the speed. Pull down to decrease speed. 6) The Mud Pump Flow (GPM-LPM) displays the Mud Pump flow rate in Gallons per Minute (GPM) or Liters per Minute (LPM). It is set at the factory to GPM. 7) The Engine Tachometer displays the engine speed in rpm. The tachometer also shows the working hours. 8) The Supercharger Running light is lit when the supercharge pump is running. 9) The Mud Pump clutch Engaged Over 10 Min. is an audible alarm to alert the operator that the Mud Pump clutch is pushed in and the engine has been running in gear for over 10 minutes. Either pull out the clutch button and begin mud pump flow, shift into neutral to idle the engine or turn off the engine. Page 50

51 MPR Hz Operators Manual Operations Detailed Controls MPR Hz Mud Pump Control Panel MUD PUMP CLUTCH PUSH IN PULL OUT 3 HORN 2 EMERG STOP 1 1) The Emergency Stop push button stops the Mud Pump engine from this location. Push in to immediately stop the engine. The button must be pulled out to be able to start the engine. 2) The Horn push button is used to warn personnel that the Mud Pump is going to be started. 3) The Clutch push button remotely engages and disengages the Mud Pump clutch. Push in (like you would push the clutch pedal on an automobile) so you can shift into gear or neutral. Pull out with the engine in neutral to run at idle or with the engine in gear to begin mud pump flow. Page 51

52 Operations MPR Hz Operators Manual Caterpillar Engine Control Panel Detailed Controls ) The Engine Emergency Stop push button stops the engine from this location. Push in to stop the engine. The button must be pulled out to be able to start the engine. 2) The Key Ignition Switch has three positions. The Stop Position is straight up. The Run Position is rotated 45 degrees right. The Start Position is 90 degrees right. 3) If the yellow Diagnostic Warning light turns on, contact your Caterpillar technician. 4) If the red Warning light turns on, contact your Caterpillar technician. 5) The Throttle changes the engine speed. Push up to increase engine speed. Pull down to decrease engine speed. 6) The Engine Hours meter displays the number of accumulated hours on the Caterpillar engine. 7) Two 15 amp circuit breakers protect the engine. Note: If your system is not equipped with a Caterpillar diesel engine, you may not have an Engine Control Panel or it may look different than this drawing. *Refer to: Attachment 1, Engine Manufacturers Manual for details about your machine. Page 52

53 MPR Hz Operators Manual Operations Detailed Controls Caterpillar Messenger The Caterpillar Messenger display allows the operator to monitor engine information while the engine is operating. For a complete explanation of how to access and use the display, consult the separate attachment about the Caterpillar Messenger. Note: If your system is not equipped with a Caterpillar diesel engine, you will not have a Caterpillar Messenger. *Refer to: Attachment 1, Engine Manufacturers Manual for details about your machine. Light Switches The work lights receive power from the genset. Switches to turn the lights OFF and On are located in the breaker box which is next to the Control Panel. Page 53

54 Operations MPR Hz Operators Manual Set Up MPR Hz Mud System Set Up Install the ground stake into the ground per local regulations. WARNING The ground stake must be installed before starting either 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 63 and follow the procedures in the detailed engine and generator manuals you received with your Mud System.) On the Control Panel, turn the Hyd. Jacks Pump control (7) to Start. Release when start is confirmed. EMERGENCY STOP SUPERCHARGER RUNNING LINER WASH RUNNING TRASH PUMP THERMAL OVERLOAD DESILTER STOP ON START MIX/AGITATION STOP ON START TRASH PUMP HYD JACKS PUMP STOP ON START 7 SHAKER #1 STOP ON START SHAKER #2 STOP ON START WASHDOWN PUMP STOP ON START Page 54

55 MPR Hz Operators Manual Operations Set Up Using the Transport Jack control levers, extend the jacks to support the trailer. Remove the tractor trailer cab. Lower the jacks until the Mud System trailer rests on the ground. To prevent overheating the hydraulic system, turn off the Hydraulic Jacks Pump when the jacks are not being operated. Jack farthest from controls Jack nearest the controls Lower the side ladder. Raise the walkway and install the safety railings. Raise the work light posts. Remove the brackets that secure the shakers during transport. In the drawing below, only one bracket on each shaker is pointed out. There are two brackets on each side of both shakers. There is a total of four brackets per shaker. Page 55

56 Operations MPR Hz 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 Hyd. Jacks Pump, 480 V AC-3PH. Unplug the Hydraulic Jacks Pump. Plug your trash pump (maximum 10 Hp) into this outlet. Bottom of Control Panel Trash Pump Hyd. Jacks Outlet Hydraulic Jacks Plug Position the shaker chutes (10) so larger particles separated from the drilling fluid are removed from the MPR Hz system. 10 Take the Portable Operator s Console to the Driller s Cabin. Page 56

57 MPR Hz 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. 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 57

58 Operations MPR Hz 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 Mud 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 Mud 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 58

59 MPR Hz 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. Four discharge hoses are provided with the MPR Hz Mud System. Link together as many sections as necessary to cover the distance between the Mud System and the directional drill. Thread the hose together. Then strike the ears (1) 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. 1 To Directional Drill Make sure any valves in the mud piping are in the proper position to avoid damaging the system when the mud pump is started. Page 59

60 Operations MPR Hz Operators Manual Starting the Mud System Operating in Hot Weather To prevent damage to the machine when operating in hot weather, take the following precautions: 1) *Refer to: Attachment 1, Engine Manufacturers Manual for operating the engine in hot weather. 2) Use the appropriate mixture of coolant and water for the temperature range in which you are working. Test the coolant periodically. Keep the coolant at the correct level in the radiator and the reservoir. 3) Use the recommended engine oil viscosity for the operating conditions as specified in your diesel engine manual. Operating Under Ambient Temperatures between -40 F to + 5 F (-40 C to +15 C) Only machines especially configured at the factory can work under ambient temperatures between -40 F to +5 F (40 C and -15 C). Materials (rubber, gaskets, oils, grease) that withstand the effects of cold temperatures must be selected. Some machines are equipped with an engine preheater to maintain the minimum temperature needed for starting the diesel engine. Follow the specifications of oils and cooling liquids for the diesel engine. *Refer to: Attachment 1: Engine Manufacturers Manual for specific information. Other precautions and special procedures for operating in cold weather are: 1) Have the battery fully charged. 2) Use the recommended engine oil viscosity for the operating conditions as specified in your diesel engine manual. 3) Use the proper cold weather fuel. Check for and remove water in the fuel system. Cold temperatures can cause water to collect in the fuel tank. 4) Use the appropriate mixture of coolant and water for the temperature range in which you are working. Test the coolant periodically. Keep the coolant at the correct level in the radiator and the reservoir. 5) Warm the engine thoroughly before beginning operations. The engine and hydraulic fluid should be thoroughly warmed before operating the pump and the hydraulic controls (e.g., the transport jacks). 6) Thoroughly clean the system and drain water and drilling fluid out of the system and replace with antifreeze when cold temperatures are expected. Page 60

61 MPR Hz Operators Manual Operations Starting the Mud System Before Operating the Machine The MPR Hz Mud System has two engines: the genset engine and the mud pump engine. The genset engine runs a generator which provides AC power for the centrifugal pumps, shakers, and lights. The mud pump engine powers the quintiplex mud pump. A factory instruction manual for the generator and both engines is supplied with the MPR Hz Mud 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. Start the mud pump engine first to allow time for it to warm-up. During the warm-up period, start the genset engine. Starting the Mud Pump Engine 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. Unplug the block heater, if connected. Disconnect battery chargers that are attached to the battery. Plug the cable from the Mud System cable holder into the Operator s Console as shown in the photograph below. Open all suction and discharge butterfly valves on centrifugal pumps. Make sure the Mud Pump stop buttons on the Operator s Console, Junction Box and Mud Pump Control are pulled OUT. Make sure the Caterpillar Engine Control Panel stop button is also pulled OUT. Page 61

62 Operations MPR Hz Operators Manual Starting the Mud System Check 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 83 of this manual. Make all necessary repairs. Confirm that all fluid connections to and from the pump are correct. Check that any valves in the piping are in the correct position to prevent damage to the system when the pump is started. Fully open all fuel supply valves. WARNING Engine exhaust contains products of combustion which may be harmful to your health. Always start and operate the engine in a well-ventilated area or if working in an enclosed area, vent exhaust to the outside. Verify that all guards are in place. Replace lost or missing guards. Turn the battery switch to the ON position. The Check Engine/Diagnostic light will turn on. It will remain on while the engine is cranking. The light will go out when oil pressure is present. Make sure the gear shift lever on the mud pump transmission is in neutral. The transmission has a neutral switch which allows starting only in neutral. On the engine panel located in front of the gear shift, turn the ignition key (2) to the right to start the engine. When the engine starts, release the key. No throttle action is required during starting. The engine system provides the correct amount of fuel. If the engine fails to start in 30 seconds, release the key switch and wait 2 minutes. This will allow the starter motor to cool. Then repeat the start process. 2 1 Allow the mud pump engine to run at idle (900 rpm) for at least ten minutes for proper warm-up and to build pressure in the air circuit. During the warm-up period, start the genset engine. Page 62

63 MPR Hz Operators Manual Operations Starting the Mud System COLD WEATHER NOTE: The block heater on the engine should be set at 85 F (30 C) if it is an adjustable thermostat type. Newer models are preset at the factory and have no adjustment. These block heaters are 240 volt models and require a similar power source. Plug in the block heater at the end of the day s shift. The heater will keep the water jacket coolant warm to 85 F (30 C) which will make starting the engine easier. *Refer to: Attachment 1, Engine Manufacturers Manual for information on using the engine block heater. Starting the Genset Engine and Generator 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 are starting the genset engine and generator before starting the diesel engine: 1) Install the ground stake into the ground per local regulations. 2) Turn the Battery Disconnect Switch on the Mud System to the ON position. 3) Check the Control Console to be sure that all switches are in the OFF position and the emergency stop button is pulled OUT. 4) Turn the breaker switch on the control panel of the generator to the OFF position and pull OUT the emergency stop button. 5) Check 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 83 of this manual. Make all necessary repairs. 6) Fully open all fuel supply valves. 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 Console. Page 63

64 Operations MPR Hz Operators Manual Operating the Mud 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 63 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 (4) port. Turn the Shaker 1 (2) and Shaker 2 (3) controls 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 Mud System, you can use the control (7) on the Control Panel.) Water will be pumped into the cam and groove port (4) 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 (5). Attach the 3 inch (76 mm) hose to a fire hydrant or water tank truck. Turn the Shaker 1 (2) and Shaker 2 (3) controls 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. EMERGENCY STOP SUPERCHARGER RUNNING LINER WASH RUNNING TRASH PUMP THERMAL OVERLOAD 7 DESILTER STOP ON START MIX/AGITATION STOP ON START TRASH PUMP HYD JACKS PUMP STOP ON START SHAKER #1 STOP ON START SHAKER #2 STOP ON START WASHDOWN PUMP STOP ON START Page 64

65 MPR Hz Operators Manual Operations Operating the Mud System Adding Bentonite and Agitation Start the Mix/Agitation pump by turning the Mix/Agitation Start control (6) 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 (1) at the base of the hopper and the inlet valve (2) to the jet of the hopper. EMERGENCY STOP SUPERCHARGER RUNNING LINER WASH RUNNING TRASH PUMP THERMAL OVERLOAD DESILTER STOP ON START MIX/AGITATION STOP ON START TRASH PUMP HYD JACKS PUMP STOP ON START SHAKER #1 STOP ON START SHAKER #2 STOP ON START WASHDOWN PUMP STOP ON START Pour the bentonite into the mix hopper (3) 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. Ongoing Drilling Fluid Supply 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 required by your drilling conditions. Page 65

66 Operations MPR Hz Operators Manual Operating the Mud System 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 discharge port on the quintiplex mud pump to the directional drill are tightened securely. Check the oil and coolant levels in both engines on the Mud System. The fuel tank should be full before starting work each day. Run a hose from the returns pit to the Mud System 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 mud pump engine and the genset engine on and warmed to operating temperature. Determine the proper transmission gear to get the desired mud pump flow rate. Use this method to calculate the engine speed for a specific gpm desired: If you want to pump an intermediate gpm like 400 gpm, use the formula: Engine rpm = 5 X gpm desired X gear ratio 1.55 Where gear ratio is the gear ratio from CHART 1 (below) of the gear that has the closest gpm over the gpm you desire. Page 66

67 MPR Hz Operators Manual Operations Operating the Mud System Example: If you want to pump 400 gpm, find the gear with the gpm closest and over 400 gpm in CHART 1. Eighth (8th) gear pumps 472 gpm. The corresponding gear ratio is Using this in the formula, Engine rpm = 5 X 400 X Chart 1 GEAR GPM GEAR RATIO So engine rpm equals 1,754.8 or 1,755 rpm. Therefore, operating in 8th gear at 1,755 engine rpm will pump 400 gpm. Page 67

68 Operations MPR Hz Operators Manual Operating the Mud System Pumping Fluid to a Directional Drill With the mud pump engine at idle (900 rpm), push the clutch button (3) IN on either the Mud Pump Control, the Caterpillar Engine Control Panel or the Operator s Console (all shown below). Shift the transmission into the selected gear. Pull the clutch button (3) OUT. Slowly push the throttle lever (5) forward to bring the engine to 2100 rpm to achieve the gpm flow on the chart. MUD PUMP CLUTCH 3 ENGINE TACHOMETER HORN 7 EMERG STOP SUPERCHARGER MUD FLOW (GPM-LPM) RUNNING 8 6 MUD PUMP CLUTCH ENGAGED MUD PUMP MUD PUMP OVER 10 MIN. START THROTTLE FAST 9 5 SLOW HORN MUD PUMP STOP PUSH IN CLUTCH PULL OUT Mud Pump Control, Caterpillar Engine Control Panel and Operator s Console Page 68

69 MPR Hz Operators Manual Operations Operating the Mud System Shifting the transmission (14) into gear automatically turns on the supercharge pump (11). This pump draws drilling fluid from the clean tank (12) and pumps it directly to the suction port of the quintiplex mud pump (13). The indicator light (8) on the control panel lights when the supercharge pump is running. Note that the supercharge pump will not operate if the engine is shifted into reverse. When the supercharge pump is operating the liner wash pump turns on automatically and the Liner Wash Running light (9) should be lit. The liner wash system consists of a tank filled with RV antifreeze and a small motor pump assembly. The antifreeze is pumped from the tank into a sprayer system which sprays RV antifreeze into each piston liner. This cools as well as washes each liner. EMERGENCY STOP 8 9 SUPERCHARGER RUNNING LINER WASH RUNNING TRASH PUMP THERMAL OVERLOAD DESILTER STOP ON START MIX/AGITATION STOP ON START TRASH PUMP HYD JACKS PUMP STOP ON START 6 SHAKER #1 STOP ON START SHAKER #2 STOP ON START WASHDOWN PUMP STOP ON START Page 69

70 Operations MPR Hz Operators Manual Mud Pump Pressure Relief Valve Operating the Mud System The variable setting pressure relief valve (1) is set at the factory to 1750 psi (120 bar). 1 CAUTION Do not set pressure relief higher than 1750 psi (120 bar). Doing so could void the warranty on the pump. If a clog downhole results in a pressure back-up, the pressure will spike and shear the pin on the relief valve. This will allow fluid to pass through the relief valve, back into the mud tank. Shut down the mud tank and resolve the reason for the relief valve tripping. Before resuming operations, replace the shear pin. Insert it under the cap through the bar with holes at 1750 psi. A pack of 10 shear pins is provided. Additional pins can be ordered from the American Augers Parts Department. Operation When Adding or Removing Drill Pipe Throttle the mud pump engine down to an idle (900 rpm). Push the clutch button IN. This will stop the pump from rotating and pumping. Shift the transmission into neutral. Pull the clutch button OUT with the transmission in neutral, taking pressure off the throw-out bearing. After the drill pipe is installed or removed, push in the clutch button. Shift the transmission into the desired gear. Pull out the clutch button to engage the clutch and move the throttle lever to bring the engine up to 2100 or the desired rpm. Shifting back into gear will restart the flow of drilling fluid from the supercharge pump from the mud pump to the directional drill. Page 70

71 MPR Hz Operators Manual Operations Operating the Mud System Cleaning Drilling Fluid Returns from the Entry Pit When the Returns pit is getting full or the tanks with drilling fluid are getting low, establish a return flow to the Mud 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 on the Mud System. 1 EMERGENCY STOP SUPERCHARGER RUNNING LINER WASH RUNNING TRASH PUMP THERMAL OVERLOAD 7 DESILTER STOP ON START MIX/AGITATION STOP ON START TRASH PUMP HYD JACKS PUMP STOP ON START 5 SHAKER #1 STOP ON START SHAKER #2 STOP ON START WASHDOWN PUMP STOP ON START 2 3 On the Control Panel, pull the Emergency Stop button (1) OUT. Turn Shaker #1 (2) and Shaker #2 (3) controls to START. Release when start is confirmed. Turn on your Trash Pump. (If you have connected your trash pump to the Mud System, you can use the control (7) on the Control Panel.) This will begin a return flow of drilling fluid to the Mud System. Turn the Desilter (5) control to START. Release when start is confirmed. This starts the desilter pump which brings drilling fluid from the Mud Tank to the weir box of Shaker #1. 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. The suction port of the centrifugal pump picks up the fluid and pumps it to the shaker topped by the 9- 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 through the chutes 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 71

72 Operations MPR Hz Operators Manual End of Pumping Operations Stopping the Mud Pump Engine Throttle (5) the mud pump engine down to an idle (900 rpm). Push the Clutch button (3) IN. Shift the transmission to neutral. Pull the Clutch button (3) OUT with the transmission in neutral, taking pressure off the throw-out bearing. Run at idle speed for 5 to 10 minutes to cool down the engine. If you expect freezing temperatures, flush the pump with clear water, and add antifreeze to the pump. Turn the pump over 3 or 4 revolutions. Turn the ignition key (2) to OFF to shut down the engine. MUD PUMP CLUTCH 3 ENGINE TACHOMETER HORN EMERG STOP SUPERCHARGER RUNNING MUD FLOW (GPM-LPM) MUD PUMP CLUTCH ENGAGED MUD PUMP MUD PUMP OVER 10 MIN. START THROTTLE FAST 5 SLOW HORN MUD PUMP STOP PUSH IN CLUTCH PULL OUT 3 2 Page 72

73 MPR Hz Operators Manual Operations End of Pumping Operations Stopping the Genset Engine 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 Console. Go to the genset. Open the rear door. Turn off the circuit breaker switch. This disconnects power to the machine. Turn the selector to OFF. Turn the Battery Disconnect Switch to OFF. Page 73

74 Notes MPR Hz Operators Manual Notes NOTES: Page 74

75 MPR Hz Operators Manual Storage and Transportation Machine Storage and Transport Storage and Transportation Minimum Storage Space Required Level 618 x 100 inches, height 157 inches (16 x 2.6 m, height 4 m), weight pounds (25400 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 at the battery box 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 a Caterpillar engine. Disconnect batteries and store them 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 mud pump 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. 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. Page 75

76 Storage and Transportation MPR Hz Operators Manual Machine Storage and Transport Clean the machine. Pump all drilling fluid and clean water out of tanks. All tanks must be empty before transporting the Mud System. The 6,000 U.S. gallon (22712 liter) mud tank filled with drilling fluid will add 48,000 pounds (21772 kg) to the weight of the trailer. This means the rig will be overweight. Damage to the trailer gooseneck 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 cleanout 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 NOTE drive with the work light posts extended. Disconnect the trash pump from the plug under the Control Panel (if you have been using) and reconnect the hydraulic jacks pump. Raise the jacks to elevate the Mud System trailer. Hitch to tractor trailer cab and secure. Turn off Hydraulic Jacks Pump, genset and genset engine. Page 76

77 MPR Hz Operators Manual Storage and Transportation Machine Storage and Transport Switch Battery Disconnect Switch to OFF. Remove and stow safety railings. Lower walkway and secure in place. Raise side ladder. Remove ground stake. 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 spreader bars to ensure that the lifting lines do not come in contact with the machine and the load is evenly balanced. The spreader bars should have a minimum length of 45 feet (14 m). Page 77

78 Notes MPR Hz Operators Manual Notes NOTES: Page 78

79 MPR Hz Operators Manual General 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. 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. Clean the machine after each use and before performing maintenance activities. Thoroughly clean the machine, empty the tanks and flush all piping before moving and storing. Page 79

80 Maintenance Welding MPR Hz Operators Manual General Maintenance 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. WARNING Disconnect all electrical connections before welding. Damage can occur to processor and electrical system if electrical components are connected during welding. CAUTION Disconnect ground terminal first. Reconnect ground terminal last. Disconnect the battery (both terminals) before welding any part of the machine. Remove the negative (-) GROUND cable first; then remove the positive (+). Welding must be done with the ground wire connected directly to the component where the weld is made. Failure to follow the above instructions could damage electric and hydraulic components, cylinders, gears and bearings due to internal arcing. Page 80

81 MPR Hz Operators Manual Maintenance General Maintenance 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 Mud Pump Oil Shell Spirax EW 75W-90 Transmission Oil Shell Spirax GSX SAE 50 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 81

82 Maintenance MPR Hz Operators Manual Scheduled Maintenance Maintenance Schedule MPR Hz 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 Drive Shaft X Check Pump Crankcase Oil Level X, K Check Liner Wash Level X Check Pump Chainbox Oil Level X Inspect Shaker Screens X Check Transmission Fluid Level X Lubricate Drive Shaft X Change Pump Crankcase Oil X, K Ventilate Surge Chamber on Discharge Dampener X Tighten Pump Flange Bolts X Inspect Shaker Loop Isolators X Tighten Drive Shaft X Check Pump Valve and Seat Condition X, K Clean or Replace Air Filters X** Change Engine Oil and Filters X,E Inspect Motor Couplers X Inspect Pump Bearing Insert / Wrist Pin Bushing X, K Check Pump Crankshaft Endplay X, K Change Pump Chainbox Oil X Change Engine Fuel Filters E Tighten Drive Shaft Fasteners X Change Transmission Fluid X 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 82

83 MPR Hz Operators Manual Maintenance Scheduled Maintenance 10 Hour Inspection and 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 batteries 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 and battery box. 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 and mud pump engines is at maximum and that there is no contamination. *Refer to: Attachment 1, Engine Manufacturers Manual for information about coolants 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 and mud pump engines is at the maximum 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. Check the fluid level in the liner wash reservoir using the transparent gauge mounted on the tank. It should be full. Refill with RV antifreeze as required (or clean water or a mixture can be used). 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. *Refer to: Attachment 1, Engine Manufacturers Manual for detailed procedures. Page 83

84 Maintenance MPR Hz Operators Manual Scheduled Maintenance WARNING Wait for engine to cool Inspect drive shaft from engine to chainbox. Replace if worn. Retighten any loose fasteners. Check the pump crankcase oil level by removing the oil level plug shown in the following photo. Oil should just run out the port after removing the plug. If the level is too low, add oil until oil just flows from the level port. Use a synthetic SAE 75W-90 oil. The level must be checked when the pump is not operating. If contaminated, flush and change immediately. Use the procedures indicated in Attachment 2, Pump Specifications. WARNING Do not attempt any repairs while the pump is running Page 84

85 MPR Hz Operators Manual Maintenance Scheduled Maintenance Check the chainbox oil level using the transparent gauge mounted on the chainbox. The oil level should be to the midpoint of the gauge. Add oil as necessary. The level must be checked when the pump is not operating. If contaminated or milky, flush and change immediately. Clean and inspect shaker screens. Replace if worn. Observe power end seal while the pump is operating at normal temperature. Check for leakage. Pay particular attention to the pony rod gland seals. Although a small amount of dripping from the seals is normal, replace the seals when excessive leakage occurs. WARNING Do not attempt any repairs while the pump is running Observe liquid end seal while the pump is operating at normal pressure. Check for leakage. If Cover Caps are leaking, ensure the Cap/Cap Fasteners are in good condition and properly torqued. If properly torqued and still leaking, replace the Cap seals. Observe the liquid end packing. A slight leak is normal and extends the packing life. If excessive leaking occurs with adjustable packing, try adjusting the Stuffing Box Nut. If excessive leakage persists, replace the packing. Use the procedures indicated in Attachment 2, Pump Specifications. WARNING Do not attempt any repairs while the pump is running Visually inspect plungers. Worn or damaged plungers will cause premature packing failure/wear and an increase in the NPSHR (Net Positive Suction Head Required). Look for excessive grooving, or pits, or flaking in the plunger coating. Use the procedures indicated in Attachment 2, Pump Specifications. Ensure all external fasteners are secure. Ensure drive coupling is secure and properly adjusted. Page 85

86 Maintenance MPR Hz Operators Manual 50 Hour Inspection and Maintenance Scheduled Maintenance Perform 10 Hour Inspection and Maintenance items, plus: Check transmission fluid level. The level/fill port is on the side of the transmission. See photo. The fluid should be level with the bottom of the port. Lubricate drive shaft between engine and pump. Access drive shaft grease fittings by removing the drive shaft guard. Tighten pump flange bolts. Inspect loop isolator belts that support the shaker basket. They may become stretched, frayed or worn. Replace as required. Change pump crankcase oil. Using diesel fuel or solvent, flush and clean the entire crankcase area. If contaminants are observed during inspection, determine the cause and repair before using the pump. Use a synthetic SAE 75W-90 oil. The fill port is shown in the right hand photo. Use the procedures indicated in Attachment 2, Pump Specifications. Page 86

87 MPR Hz Operators Manual Maintenance Scheduled Maintenance Ventilate the surge chamber (1) on the mud pump discharge dampener. The discharge dampener dampens surges of the mud pump. The standard surge chamber is an air chamber where the mud compresses the air to dampen movement of the discharge hose. The mud gradually absorbs the air in the surge chamber. Remove the plug on top (2) of the surge chamber to allow air into the chamber when the pump is not running. Reinstall the plug before resuming operations. An optional nitrogen filled, bladdered surge chamber is available. 2 1 Page 87

88 Maintenance MPR Hz Operators Manual 500 Hour Inspection and Maintenance Scheduled 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. Tighten drive shaft. Check pump valve and seal condition. Inspect motor couplers and replace if worn. Page 88

89 MPR Hz Operators Manual Maintenance Scheduled Maintenance 1000 Hour Inspection and 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. Tighten drive shaft fasteners. Inspect pump bearing insert and wrist pin bushing. Check pump crankshaft endplay. Tighten drive shaft fasteners. Change pump chainbox oil. Oil can be added using either the access panels or the vent port shown in the above photo. If the vent port is used then caution must be exercised not block the vent holes when the vent cap is replaced. Page 89

90 Maintenance MPR Hz Operators Manual 2600 Hour Inspection and Maintenance Scheduled Maintenance Perform 10 hour, 50 hour, 500 hour and 1000 hour inspection and maintenance items, plus: Change transmission fluid. The drain port is located on the right side of transmission when facing the rear of the engine. See photo. Page 90