MCR-10000 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 MCR-10000. All operators and ground personnel 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. Telephone: 419-869-7107 or 800-324-4930 (USA Toll Free)
Foreword Foreword MCR-10000 Operators Manual Introduction INTRODUCTION Since 1970, American Augers has been a devoted manufacturer of trenchless technology equipment; customers worldwide recognize the MCR-10000 as a premier piece of equipment that is a vital accessory to our directional drilling equipment. American Augers provides its equipment with worldwide technical support, parts and service. American Augers encourages customers to contact the factory with any operational or assistance needs. 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 may be 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. Every effort has been made to adequately cover the operation of the MCR-10000 in this manual. If you have any questions about any of the features of your specific machine, contact the factory (Telephone: 419-869-7107 or 800-324-4930 (USA Toll Free). Wiggle Steer, es!lok and Quiet-Pak are registered trademarks of American Augers, Inc. All other trademarks are the property of their respective owners. Original Instructions Manual Part Number 99MCR10000 Released September 2012 Revision 01 Page 2
MCR-10000 Operators Manual Foreword Limited Warranty Limited Warranty This warranty is extended by American Augers, Incorporated in respect of equipment & products sold. American Augers warrants to the initial purchaser that this Equipment will be free of defects in material and/or workmanship for a period of 2 years from date of shipment to the initial purchaser, or 2000 hours of operation (Engines 2 years/3000 hours, Rack and Pinion 5 years/10,000 hours), whichever occurs first. Once the equipment is placed into service as a retail sale, rental or lease, a properly completed Warranty Registration Certificate must be submitted to American Augers to start and validate warranty coverage. The Limited Warranty does not include (1) batteries, lamp bulbs, fuses, various types of gaskets and packing, filter elements, oil lubricants, fluids, track chain, track drive sprockets, Drill Pipe, Auger sections, die holders, wrench wear parts, guide bushings, shaft seals, mud swivel assemblies, valves, piston liners, centrifugal pumps, shaker screens, and other normal wearing or aging parts, (2) engines, (3) transmissions not manufactured by American Augers, and (4) down hole tools & accessories. American Augers extends to the initial purchaser the benefits of any warranty (if any) of the manufacturers or suppliers of any of the excluded items. Claims for defects in material and workmanship shall be made in writing by the initial purchaser to American Augers within ten days of defect discovery. American Augers reserves the right to send a service representative, contract an authorized representative, or request that the equipment is returned to the factory for product inspections. Failure on the behalf of the purchaser to permit such above action can cause a voiding of warranty coverage. Within the warranty period, American Augers will repair or replace, at its option, free of charge any portion of parts of the new Equipment, which are found by American Augers to be defective in material or workmanship. Replacement or repaired parts provided under the terms hereof are guaranteed in like fashion for the remainder of the warranty period. Any parts replaced under the terms of this warranty become the property of American Augers and upon written request, must be returned, transportation prepaid, to American Augers. In no event shall American Augers liability exceed the purchase price of the Equipment. American Augers reserves the right to fully satisfy its warranty obligation by refunding to the Buyer the full purchase price of the Equipment upon the return of the Equipment by the Buyer, transportation prepaid, to American Augers. This warranty applies only if the alleged defective Equipment has been properly maintained and operated as specified by American Augers. This warranty will not apply if the alleged defect is attributable to an unauthorized modification or service repair made, a component part installed, improper equipment storage, neglect or abuse of the equipment on the behalf of the purchaser or their representatives, improper product operation or use of the product exceeding the design limitations, or an attachment supplied, by a party other than American Augers or its subsidiaries, or the authorized representative of any of the foregoing. If any tests are conducted to ascertain or demonstrate defects in material or workmanship, such test shall be conducted after reasonable notice to American Augers and upon conditions mutually agreed upon in advance of the test, and American Augers may be represented at any test that shall be made. American Augers, at its option may charge the Customer for any tests performed by American Augers at the request of the Customer in respect to the merchandise sold hereunder. THE REMEDIES IN THIS WARRANTY SHALL BE EXCLUSIVE AND SOLE REMEDIES OF THE BUYER. THERE ARE NO OTHER WARRANTIES, EXPRESSED OR IMPLIED, OF ANY KIND, INCLUDING BUT WITH- OUT LIMITATION, ANY WARRANTY THAT THE EQUIPMENT IS OF MERCHANTABLE QUALITY OR THAT THE EQUIPMENT IS FIT FOR ANY PARTICULAR PURPOSE. AMERICAN AUGERS WILL HAVE NO MONE- TARY LIABILITY WHATSOEVER FOR ANY DAMAGE, LOSS COSTS, OR EXPENSE (WHETHER GENERAL, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL) SUFFERED BY THE BUYER AS A RESULT OF OR CONNEC- TION WITH THE EQUIPMENT, IN NO EVENT SHALL AMERICAN AUGERS BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT LIMITED TO, FREIGHT CHARGES, TRANSPORTATION CHARGES, DOWNTIME OR OTHER PARTS INCIDENTAL TO THE REMOVAL AND REPLACEMENT OF PARTS REPAIRED OR REPLACED UNDER THIS WARRANTY. American Augers reserves the right to modify, alter, and improve any product or parts without incurring any obligation to replace any product or parts previously sold with such modified, altered or improved product or parts. No person is authorized to alter or extend this warranty unless made in writing and signed by an officer of American Augers. Used products and equipment delivered by American Augers or picked up by American Augers are sold without conditions or warranties, express or implied, as is, where is, unless there is a clear agreement with the Customer in writing to the contrary. The Customer agrees to inspect all such equipment before purchase is completed and to accept same without any warranty of merchantability or fitness for a particular purpose. By acceptance hereof, the Customer covenants and agrees that in the event any products purchased hereunder are resold either in their original form or as a component of another system, the LIMITED WARRANTIES provision set forth above will be included in all sales documents by which the Customer resells any such products. In all such cases, the sales documents by which a purchaser from the Customer purchases and accepts delivery of the products sold hereunder will include from such LIMITED WARRANTIES and prior to any such sale or delivery and authorized representative of the subsequent purchaser will be made aware of the limitations on the warranty of American Augers or other manufacturer of the products and that the disclaimers of American Augers apply to the resale of such products. The Customer agrees to indemnify and hold harmless American Augers from any such loss, claim or damage. Including attorney s fees and expenses resulting from a breach of the foregoing covenant. Page 3
Foreword MCR-10000 Operators Manual Machine Serial Number Locations 99mc1011 - SN Plate Used on machines made prior to 2010 Used on machines made after 2009 Location of Machine Serial Number Plate Machine Serial Number Page 4
MCR-10000 Operators Manual Foreword Safety Awareness Program Understanding Operation Safety This manual is part of the safety system of the equipment. Use it when training personnel who will operate the machine or work on the jobsite. Ensure that a copy is always available with the machine and that the operators have read it understand it, and have access to it. Carefully follow the instructions, advice and procedures it contains. Safety is everyone s responsibility. Mud systems have a number of unavoidable hazards unique to their operation. Safety alert decals are provided on American Augers equipment to alert the operator to hazards of the machines. The Safety Alerts section beginning on page 30 shows these hazard alert signs. Signal Words Signal words are used to identify safety information within the text of this manual. They are reserved for personal injury hazards. injury. is used for a hazard with a high level of risk which, if not avoided, will result in death or serious serious injury. is used for a hazard with a medium level of risk which, if not avoided, could result in death or is used for a hazard with a low level of risk which, if not avoided, could result in a minor or moderate injury. NOTICE: 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 (Telephone: 419-869-7107 or 800-324-4930 (USA Toll Free)). Page 5
Notes MCR-10000 Operators Manual Notes NOTES: Page 6
MCR-10000 Operators Manual Foreword Revision Record Revision to Manual Revision Number Description of Change Date 00 New Release 5/16/2008 01 Updated content, format, CE compliance information, Declaration of 9/13/2012 Conformity letter; Expanded to include machines manufactured under top level 99MC1011 from serial number MCR10000011008 Page 7
Foreword MCR-10000 Operators Manual Revision Record Revision to Manual, Continued Revision Number Description of Change Date Page 8
MCR-10000 Operators Manual Foreword To The Owner To The Owner Thank you for your purchase of the American Augers MCR-10000. This is an authorized accessory for use with our vertical drilling rigs and directional drills. This manual contains important information that will help you and your crew set up and safely operate the MCR-10000. 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. Do not make unauthorized modifications. 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
Foreword MCR-10000 Operators Manual NOTICE Before using this manual, familiarize yourself with the Description Of Components beginning on page 15. 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
MCR-10000 Operators Manual Table of Contents Table of Contents Foreword... 2 Introduction... 2 Limited Warranty... 3 Machine Serial Number Locations... 4 Safety Awareness Program... 5 Revision Record... 7 To The Owner... 9 Overview... 15 MCR-10000 Components... 15 Operation and Maintenance Manual... 17 Ownership of Information... 17 Manufacturer Identification Data... 17 Machine Identification Data... 17 Scope of Document... 17 Qualification of Personnel... 18 Declaration of Conformity... 18 Use of Personal Protective Equipment... 18 Legal Disclaimer... 18 Purpose of Machine... 18 Ground Leveling... 18 Ambient Conditions... 19 Transport... 19 Operation... 19 Warranty: General Conditions... 19 Limitations of Warranty... 19 Request for Service/Support... 19 Warranty and Service for Diesel Engine/Genset... 19 Instruction Manuals... 20 Safety Information... 21 Safety Regulations and Practices... 21 Emergency Procedures... 21 Basic Safety Guidelines... 22 Overhead Hazards... 23 Page 11
Table of Contents MCR-10000 Operators Manual Before Starting the Machine...23 Operating Precautions...23 Operator s Responsibilities...24 Maintenance Precautions...24 Transporting Precautions...24 Welding Safety...25 Hazardous Chemicals...25 Noise Level Safety...26 Arc Flash Safety...26 Ladder Safety...27 Danger Zones -- Safe Distances...27 Confined Space Entry...27 Grounding...28 Safety Alerts...30 Machine Controls... 33 Safety Switches...33 Battery Switch...35 MCR-10000 Main Control Panel...36 MCR-10000 Remote Control Panel...38 Remote Junction Boxes #3, #4 and #5...40 Genset Control Panel...41 Hydraulic Jack Remote Control...42 Supercharger and Trash Pump Remotes...43 Preparation... 45 Site Preparation...45 Swamp Mats...45 Trash Pump...46 Set-Up... 47 Set-Up...47 Entry Pit and Returns Pit Construction...49 Hose Connections from Trash Pump to Inlet Port...50 Connecting and Operating the Supercharge Pump...51 Before Operating the Machine...53 Starting the MCR-10000...53 Page 12
MCR-10000 Operators Manual Table of Contents Operating the MCR-10000... 54 Preparing Drilling Fluid... 54 Adding Bentonite and Agitation... 55 Ongoing Drilling Fluid Supply... 55 Using the Washdown Pump... 56 Fluid Pumping Checklist... 56 End of Job... 57 Dismantling the MCR-10000... 57 Operating in Different Climates... 59 Operating in Hot Weather... 59 Operating in Cold Weather... 59 Machine Storage and Transport... 61 Minimum Storage Space Required... 61 Storage Site Conditions... 61 Preparations for Storage... 61 Transportation... 62 Lifting the Machine... 62 General Maintenance... 63 Qualification of the Technician... 63 Cleaning... 64 Welding... 65 Engine and Genset Maintenance... 65 Approved Replacement Fluids... 65 Scheduled Maintenance... 66 10 Hour Inspection and Maintenance... 67 50 Hour Inspection and Maintenance... 70 250 Hour Inspection and Maintenance... 70 500 Hour Inspection and Maintenance... 71 2600 Hour Inspection and Maintenance... 71 Before Each Job... 71 Specifications... 73 Machine Dimensions / Weight... 73 Page 13
Table of Contents MCR-10000 Operators Manual Generator...73 Pump, Supercharge with fabricated or skid base...73 Pump, Mix-Agitation...73 Pump, Cone Supply...73 Pump, Hydraulic Jack...73 Washdown System...73 Accessories...73 Appendix...75 Appendix A: List of Attachments...77 Sample Declaration of Conformity... 79 Page 14
MCR-10000 Operators Manual Overview Overview Overview MCR-10000 Components 7 99mc1011-overall-left 6 5 4 2 1 8 9 10 11 12 13 17 14 13 18 15 16 3 1. Generator Set (genset) 2. Main Controls Cabinet 3. Breaker Box 4. Desander/Desilter Cones 5. Desander/Desilter Cones 6. Railings 7. Remote Control Box 8. Mix/Agitate Centrifugal Pump 9. Folding Walkway 10. First Cut Tank 11. Cleanout Opening 12. Trash Pump Inlet 13. Clean Water Fill Inlet 14. Clean Tank 15. Off-Load/Supercharge Connection 16. Heat Tube Entry/Exit 17. Shaker #4 - Final Cut 18. Shaker #5 - Final Cut Page 15
Overview MCR-10000 Components (Continued) MCR-10000 Operators Manual Overview 99mc1011-overall-right 3 2 1 4 5 7 6 10 9 8 1. Shaker #1 - First Cut 2. Shaker #2 - First Cut 3. Shaker #3 - First Cut 4. Mix Hopper 5. Desander/Desilter Centrifugal Pump 6. Jacks Motors/Hydraulic Pump 7. Jacks Control Levers 8. Jacks 9. Chute 10. Cleanout Openings Page 16
MCR-10000 Operators Manual Overview Overview Operation and Maintenance Manual TITLE: MCR-10000 Operation & Safety Instruction Manual EDITION: 2012 Part Number: 99MCR10000 Ownership of Information American Augers, Inc. reserves all rights to the information in this manual. The use of the manual is restricted to the customer who received it 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 under Machine Identification Data below. 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 44287 USA Tel. 419-869-7107 Fax 419-869-7425 Web Site: www.americanaugers.com Machine Identification Data Type: Mud System Model: MCR-10000 Serial number: Found on identification plate Year of manufacture: Incorporated as part of the serial number on machines prior to 2010 Listed on serial number plate on machines after 2009 Location of identification plate: See drawing on page 3. Scope of Document This manual covers operation, safety and maintenance of the MCR-10000. Topics related to operating directional drills or vertical drilling rigs, planning the bore path, selecting drilling fluid and mixing recipe, and selecting and operating a guidance system are outside the scope of this document. Consult equipment suppliers, engineers and the American Augers factory for additional assistance. Page 17
Overview MCR-10000 Operators Manual Overview Qualification of Personnel Improper operation can result in serious injury, death and damage to the equipment. Personnel should read and understand the manual and obtain appropriate training based on their duties. Owner must ensure that all personnel receive instructions about safety. Owner must review all warnings on machine with all personnel. Only skilled and authorized personnel should be permitted to transport, operate and maintain the machine. Training is available by contacting the American Augers factory. NOTICE: American Augers disclaims any responsibility for damages to persons or property caused by the operation of the machine by untrained personnel or use of the machine in an unauthorized manner. Contact American Augers if you have any questions about any aspect of machine operation or safety, if you need further information or instruction, or if you need additional copies of the manual or replacement decals (Telephone: 419-869-7107 or 800-324-4930 (USA Toll Free)). Declaration of Conformity If required, the Declaration of Conformity is issued at consignment of the machine. A sample document is reproduced on page 79. The Declaration of Conformity is not required in most countries. Use of Personal Protective Equipment If personal protective equipment is not used, serious injury or death of personnel can occur. The operator and all other personnel on the jobsite 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 this machine in violation of the instructions contained in this manual. Purpose of Machine The machine was designed solely for mixing, recycling and pumping drilling fluid. Ground Leveling It is very important to make the pad the machine is to set on as level as possible. Scrape an area 10 feet x 55 feet (3 m x 17 m) to a level grade with a dozer. Page 18
MCR-10000 Operators Manual Overview Overview Ambient Conditions Temperature limits: The machine, with factory fill of lubricants, is designed to work in temperatures from +5 F to +110 F (-15 C and +43 C). For temperatures not included in this range, contact American Augers. Refer to Operating in Hot Weather on page 59 and Operating in Cold Weather on page 59 for additional information. 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. Transport The machine should be transported by a truck tractor in accordance with local and national transportation laws. Operation The operator should be the only person operating the controls. Other trained personnel may work on or near the machine only if they are wearing appropriate personal protective equipment and follow the safety instructions in this manual. Further, the operator must remain aware of the location of all other personnel while operating the machine. Warranty: General Conditions Warranty is provided with the understanding that all safety warnings and instructions will be reviewed by all personnel. Warranty is subject to the conditions and limitations specified in the warranty certificate. The warranty certificate is located on page 3 of this manual. If you have questions about the warranty or any part of the machine operation, please contact American Augers (Telephone: 419-869-7107 or 800-324-4930 (USA Toll Free)). NOTICE: Modifications to the equipment made by the customer will reduce warranty coverage. See Limited Warranty on page 3. Limitations of Warranty The warranty for all components that are not manufactured by American Augers are subject to the original warranties of their manufacturers and not by American Augers. Request for Service/Support For service support in or out of the warranty period, contact American Augers. Provide machine model number, serial number and number of operating hours. Warranty and Service for Diesel Engine/Genset The warranty on the engine is valid worldwide and is supplied by the engine/genset dealer in the area where the machine is sold. Only diesel engine dealers are authorized to perform repairs under warranty, provide service and supply spare parts. Page 19
Overview Instruction Manuals MCR-10000 Operators Manual Overview Manuals for components not manufactured by American Augers (e.g., the genset) are included as attachments to this manual. For translations of any of the attachments to this Manual, contact the respective equipment manufacturers. Page 20
MCR-10000 Operators Manual Safety Safety Information Safety Safety Regulations and Practices This manual contains important information about the safety practices and safe operation of the MCR-10000. All operators must read and understand the Operation and Safety Instruction Manual before starting the machine. Careful adherence to the safety and operating instructions in this manual will help ensure a safe and productive jobsite. The safety information in this Manual does not replace safety codes, insurance needs, national, provincial, state and local laws. Ensure that your machine has the correct equipment required by the local laws and regulations. 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 instructions contained in the manual. Emergency Procedures EMERGENCY SHUTDOWN: Push the red Emergency Stop button on the genset control panel to stop the genset and its engine. Push the stop button on the Main Control Panel or the Remote Control Panel to stop the pumps and shakers powered by the genset. All workers should know the locations of the Emergency Stop/Stop buttons before starting the machine on the jobsite. Response to 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, water system, mud mixing system or anything connected to the drill as these items may be highly charged. Response to a Gas Strike If a gas line strike occurs, evacuate the area immediately. Shut down all engines. Extinguish all flame and sparks immediately. Do not attempt to reverse the bore to break contact as further movement may cause a spark. Contact emergency services and the gas utility company immediately. Response to a Fiber Optic Strike If a fiber-optic strike occurs, stop drilling immediately. Do not look into the cut ends of the cable. This can cause severe eye damage. Notify the utility owner. Response to a Communications Line Strike If a communications line strike occurs, stop drilling immediately and notify the utility company. Page 21
Safety MCR-10000 Operators Manual Safety Information Response to a 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. Notify the utility owner immediately. Basic Safety Guidelines Jobsite hazards could result in serious injury or death. All personnel on the jobsite must use proper protective equipment according to their duties. 1. Before using the MCR-10000, 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 with the machine 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 or 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. 5. The meaning of the hazard alert signs on the equipment is explained in the Safety Alerts section beginning on page 30. 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 and power tools Traffic control Communications Power tools Verification of utilities Fall protection Security of jobsite and isolation of hazards Material handling Manual lifting In the United States, workplace safety is regulated by the Occupational Safety and Health 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, provincial, state and local laws govern operations at the jobsite. Page 22
MCR-10000 Operators Manual Safety Safety Information 7. Use required or recommended protective equipment which meets applicable standards when operating this machine: Hard hats Safety glasses, goggles, or face shields Work boots Work gloves Highly visible reflective clothing Hearing protection Boots and gloves having electrical insulation Any additional safety equipment mandated by other rules or required by the Owner or regulatory agency 8. If a hazardous situation is suspected, stop work until appropriate corrective action is taken. 9. Use hand signals required for specific jobs. 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 in the United States. If necessary, place highly visible markers on either side of the overhead hazard or designate an individual to notify equipment operators as they approach. Before Starting the Machine Complete all servicing prescribed in this Operator s Manual and Attachment A: Diesel Engine/Genset Manual. Securely connect all fluid lines before starting the machine. Check that all hydraulic fittings, bolts, and nuts are tight. 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. Ensure all protective guards, doors, etc. are in place. Ensure all safety devices are in place and in working order. Know the location of all personnel on the worksite. Operating Precautions Place all machine controls in the neutral or OFF position before starting the engine. Do not start the machine until all personnel are away from rotating or moving parts. Check the operation of all machine controls before using the machine. Page 23
Safety MCR-10000 Operators Manual Safety Information Operator s Responsibilities It is the responsibility of the operator to read, understand, and follow 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. Assess the situation using common sense and the benefit of experience and proceed if and only if the work can be safety performed. Understand and obey all applicable national, provincial, state, and local codes and regulations. Point out each of the safety signs on the machine and ensure that the crew understand them. Make sure all personnel stay in their prescribed areas. Ensure that all personnel and objects stay away from rotating or moving parts. Do not operate the machine while under the influence of alcohol or drugs. Ensure all safety devices are in place and in working order. Visually verify that all personnel and objects are clear of the machine before startup. Turn off the machine at the first sign of malfunction or hazardous condition. Maintenance Precautions Eliminate all power sources (turn off machine, remove key) and relieve system pressures before doing maintenance. Allow the machine to cool before servicing. Hydraulic components, engine, radiator and exhaust systems can get hot enough to cause serious injury. Use proper lockout and tagout procedures when doing maintenance. Follow 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. Even if the injury seems minor, prompt medical treatment by a physician familiar with this injury is essential. This is a serious condition which can cause serious injury and possibly death. Transporting Precautions Inspect all tractor trailers being used to transport the machine, including but not limited to checking the brakes, tires, tire pressure and lights. Remove or properly secure loose items so they cannot fall off during transport. Page 24
MCR-10000 Operators Manual Safety Safety Information Welding Safety Workers can encounter hot surfaces, fire, noxious fumes and other hazards when welding. Hazardous Chemicals These practices can help increase safety when welding: Follow established welding safety practices and regulations Assign another worker to fire watch Do not leave a welder alone Wear appropriate protective equipment (face shield, fire resistant clothing, etc.) Ensure adequate ventilation Have a first aid kit nearby If welding in a confined space, follow all confined space regulations and procedures Explosion hazard. Flammable solvents could ignite if placed near fire, sparks or other ignition sources. Keep flammable solvents in closed containers and away from fire, sparks and ignition sources. Inhalation hazard. Dust from drilling fluid additives such as bentonite may irritate the respiratory system or lungs. Prolonged exposure may damage the respiratory system. Use respiratory protection and dust resistant safety goggles. IMPORTANT: Do not use containers that can leak. Do not drain fluids on the ground or dump them into sewage systems, streams, rivers, lakes or the sea. Always follow laws and regulations for proper disposal of waste materials. Page 25
Safety MCR-10000 Operators Manual Safety Information Noise Level Safety Exposure to high noise levels may cause hearing loss. Wear appropriate hearing protection. The sound pressure measured according to ISO 11202:1993, ISO 3746:1995, IEC 651:1979 and IEC 804:1985 does not exceed 102 db(a). Arc Flash Safety Arc flash hazard. Personnel are at risk when working on equipment that is not de-energized. Arc flash can damage eyesight, damage hearing and cause severe burns. Follow safety precautions and use recommended personal protective equipment. Arc flash hazard is a dangerous condition associated with the possible release of energy caused by an electric arc. Arc flash can occur in any electrical device, regardless of voltage, in which the energy is high enough to sustain an arc. Effects include a high-intensity flash that can damage eyesight, pressure waves that can damage hearing and a superheated ball of gas that can cause severe burns. OSHA 29CFR1910 Subpart S, NFPA Standard 70 and Standard 70E give guidelines concerning arc flash and appropriate steps to minimize the possible devastating effects from this hazard. Some of the key points are presented below. See these standards and/or other local regulations for information regarding any work involving electrical hazards. American Augers equipment may be supplied with electric motors, transformers, control centers, switch panels, etc. that may require maintenance or repair. When work or repairs must be performed: De-energize all circuits before performing maintenance activities Follow proper lockout and tagout procedures. Ensure that only qualified personnel perform the work. If work will be performed on a live circuit above 50 volts: Ensure that a qualified professional performs an assessment of the Hazard/Risk Category, the Arc Flash Protections Boundary and the Arc Rating. Provide training based on the assessment results. Apply appropriate warning labels to the equipment. Ensure that employees use insulated tools and wear appropriate personal protective equipment including flame-resistant clothing. Follow procedures in applicable government and industry standards. Page 26
MCR-10000 Operators Manual Safety Safety Information Ladder Safety Falls from heights can cause serious injury and death. Use required fall protection equipment when working at heights above grade. When working at heights above 4-6 feet (1.2 to 1.8 m) other precautions may be necessary. Follow established ladder safety practices and regulations. Do not use ladders during thunderstorm activity or if conditions are such that lightning could occur. Danger Zones -- Safe Distances Electrocution Hazard. Personnel are at risk of serious injury or death if an electric line is struck during drilling. All personnel must wear appropriate protective equipment (electrical insulating boots and gloves) on the job site. A danger 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 touch parts of the machine when it is operating or when maintenance is being performed. On electrical jobsites, 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. On electrical jobsites, wear appropriate protective equipment (insulated boots and gloves). All other personnel must stay out of this zone during drilling or backreaming or any time when an electric line could be struck. Confined Space Entry Workers can encounter hazardous atmospheres in confined spaces. Workers may be unable to move to safety when working in a confined space. Serious injury or death can result. These practices can help increase safety when working in a confined space: Monitor for hazardous gases Ensure adequate ventilation Establish appropriate rescue procedures Use the buddy system where a worker outside the confined space receives frequent verbal feedback from the worker in the confined space Use a safety harness and lifeline Page 27
Safety MCR-10000 Operators Manual Safety Information A confined space has limited openings for entry and exit and poor ventilation which could contain or produce air contaminants 1. Entering confined spaces should be avoided if possible. However when cleaning the machine, it may be necessary for a worker to enter the tanks, a confined space. If workers will need to enter confined spaces, plan ahead and provide training in confined space procedures. Follow all national, state, provincial and local regulations regarding confined space entry. Obtain the proper permits when required. Grounding Electrocution hazard. Improperly grounded components may become electrically charged. Serious injury or death could occur. Bond all fixtures together and ground to a single stake before starting the engine.. Follow all local and national codes and regulations with regard to bonding and grounding. Metal components on a drill rig site can become electrically charged for a number of reasons: faulty or damaged wiring, inductive capacitance from generators, motors, motor drives, transformers, contact with local distribution wiring or underground cables etc. Care should be taken to avoid electrocution. All metal components on a drill rig site should be bonded together as shown in the drawing below. Bonding will reduce the electric potential difference between components with respect to any other components on the site. Current will not flow between two sections that are at the same electric potential. All remote equipment that is in close proximity to the drill rig must also be electrically bonded to the drill rig, i.e. pipe racks, mud pumps etc. This will reduce the risk of shock to any personnel who might contact both the drill rig and the remote equipment. IMPORTANT: For additional information on electrical hazards, bonding and grounding, consult publications from the U.S. Occupational Safety and Health Administration. a b a. Controlling Electrical Hazards, U.S. Department of Labor, OSHA 3075. b. Protection from Step and Touch Potentials, 29CFR1910.269 Appendix C. 1. http://www.cdc.gov/niosh/topics/confinedspace Page 28
MCR-10000 Operators Manual Safety Safety Information Dumpster Bonding Cable Mud System Crane Drill Pipe Drill Rig Pit Power Unit Cabin Bore Path Bonding Cable Bonding Cable Ground Stake Typical Bonding Scheme Page 29
Safety MCR-10000 Operators Manual Safety Alerts Electrocution hazard exists if machine becomes electrically charged Precautions to prevent machine from becoming electrically charged Electrical equipment should only be serviced by authorized personnel procedures Use proper lockout and tagout High voltage hazard High voltage hazard Page 30
MCR-10000 Operators Manual Safety Safety Information Arc flash hazards exist. Follow proper procedures procedures Use proper lockout and tagout Diesel engine exhaust warning Use proper lockout and tagout procedures before servicing Use proper lockout and tagout before servicing Arc flash hazards exist. Follow proper procedures Page 31
Safety MCR-10000 Operators Manual Safety Information digging Locate buried hazards before Arc flash hazards exist. Follow proper procedures Use proper procedures to prevent damage to pumps Use proper guarding over rotating parts Page 32
MCR-10000 Operators Manual Machine Controls Controls Controls Safety Switches There are three push buttons which stop the MCR-10000. Typical Genset Control Panel - Immediately powers down the genset engine; If your genset control panel looks different, be sure to locate the emergency stop button on your machine before beginning operations. 99MC9712-MainCtrlPanel 99mc1011 - SN Plate MCR-10000 Main Control Panel - Stops the pumps and shakers powered by the genset but does not stop the genset engine Page 33
Controls MCR-10000 Operators Manual Machine Controls 99MC9712-RemoteCtrlPanel MCR-10000 Remote Control Panel - Stops the pumps and shakers powered by the genset but does the not stop the genset engine. Page 34
MCR-10000 Operators Manual Controls Machine Controls Battery Switch IMPORTANT: DO NOT disconnect the batteries while the engine is running. DO NOT try to stop the engine with this switch. You can damage the electrical system. During maintenance, turn the switch OFF and use proper lockout and tagout procedures. The battery switch is located on the outside of the genset cabinet (see drawing below for typical location). The switch connects and disconnects the batteries from the electrical system. Rotate the switch to the right to connect. Rotate left to disconnect. The battery switch must be in the ON position before starting the genset engine. When performing maintenance, install a padlock through the tab and follow proper lockout-tagout procedures. 90mc1011-batt discon Lockout Tab 8ep02900-2=24505-T[1]-BattDisconLockout TRIMMED ON OFF Battery Switch Typical location of Battery Switch Page 35
Controls MCR-10000 Main Control Panel MCR-10000 Operators Manual Machine Controls 1 AC CONTROLS STOP 3 99MC9712-MainCtrlPanel 2 DE-SANDER/DE-SILTER STOP ON START MIX/AGITATE STOP ON START HYDRAULIC JACKS STOP ON START 4 SHAKER #1 STOP ON START SHAKER #2 STOP ON START SHAKER #3 STOP ON START 5 SHAKER #4 STOP ON START SHAKER #5 STOP ON START 7 6 SUPERCHARGER STOP ON START TRASH PUMP STOP ON START WASHDOWN PUMP STOP ON START 8 1. AC Controls Stop Button 2. De-Sander/De-Silter 3. Mix/Agitate 4. Hydraulic Jacks 5. Shakers #1 thru #5 6. Supercharger 7. Trash Pump 8. Washdown Pump Page 36
MCR-10000 Operators Manual Controls Machine Controls Control Icon Function 1. AC Controls - Stop Stop pumps and shakers powered by the genset: push button STOP Note: does not turn off the genset engine. 2.De-Sander/De-Silter De-Sander/De-Silter system pumps drill fluid through the de-sander and/de-silter cones. Stop: turn switch to the left Start: turn switch to the right and release On: switch is in center when system is running 3. Mix/Agitate Stop mix/agitate pump: turn switch to the left Start mix/agitate pump: turn switch to the right and release On: switch is in center when pump is running 4. Hydraulic Jacks Stop hydraulic jacks pump: turn switch to the left Start hydraulic jacks pump: turn switch to the right and release On: switch is in center when pump is running 5. Shaker #1 -Shaker #5 Each control operates a single shaker unit (#1 - #5) Stop shaker: turn switch to the left Start shaker: turn switch to the right and release On: switch is in center when shaker is running 6. Supercharger Stop supercharge pump: turn switch to the left Start supercharge pump: turn switch to the right and release On: switch is in center when pump is running 7. Trash Pump Stop trash pump: turn switch to the left Start trash pump: turn switch to the right and release On: switch is in center when pump is running Trash pump is optional equipment 8. Washdown Pump Stop washdown pump: turn switch to the left Start washdown pump: turn switch to the right and release On: switch is in center when pump is running Page 37
Controls MCR-10000 Remote Control Panel MCR-10000 Operators Manual Machine Controls 2 99MC9712-RemoteCtrlPanel 1 AC CONTROLS STOP DE-SANDER/DE-SILTER STOP ON START MIX/AGITATE STOP ON START 3 SHAKER #1 STOP ON START SHAKER #2 STOP ON START SHAKER #3 STOP ON START 4 SHAKER #4 STOP ON START SHAKER #5 STOP ON START 6 5 SUPERCHARGER STOP ON START TRASH PUMP STOP ON START WASHDOWN PUMP STOP ON START 7 1. AC Controls Stop Button 2. De-Sander/De-Silter 3. Mix/Agitate 4. Shakers #1 thru #5 5. Supercharger 6. Trash Pump 7. Washdown Pump Page 38
MCR-10000 Operators Manual Controls Machine Controls Control Icon Function 1. AC Controls - Stop Stop pumps and shakers powered by the genset: push button STOP Note: does not turn off the genset engine. 2.De-Sander/De-Silter De-Sander/De-Silter system pumps drill fluid through the de-sander and/de-silter cones. Stop: turn switch to the left Start: turn switch to the right and release On: switch is in center when system is running 3. Mix/Agitate Stop mix/agitate pump: turn switch to the left Start mix/agitate pump: turn switch to the right and release On: switch is in center when pump is running 4. Shaker #1 -Shaker #5 Each control operates a single shaker unit (#1 - #5) Stop shaker: turn switch to the left Start shaker: turn switch to the right and release On: switch is in center when shaker is running 6. Supercharger Stop supercharge pump: turn switch to the left Start supercharge pump: turn switch to the right and release On: switch is in center when pump is running 7. Trash Pump Stop trash pump: turn switch to the left Start trash pump: turn switch to the right and release On: switch is in center when pump is running Trash pump is optional equipment 8. Washdown Pump Stop washdown pump: turn switch to the left Start washdown pump: turn switch to the right and release On: switch is in center when pump is running Page 39
Controls MCR-10000 Operators Manual Machine Controls Remote Junction Boxes #3, #4 and #5 Remote Junction Box #3 and #4 Remote Junction Box #5 SHAKER SHAKER MED HIGH SHAKER MED HIGH LOW MED HIGH BOOST LOW BOOST LOW BOOST 99MC9710-VarSpeed Box 3 99MC9710-VarSpeed Box 5 NOTE: Remote Junction Boxes #3, #4 and #5 with shaker controls were used on machines with serial numbers MCR10000011008 thru MCR10000050811. Shaker speed control has been eliminated. Boxes have been replaced with smaller boxes for terminals that have no external controls for the customer to operate. Control Function Remote Junction Box #3 Located between Shaker #1 and Shaker #2 Left selector switch controls Shaker #1 operation speed Right selector switch controls Shaker #2 operation speed Remote Junction Box #4 Located between Shaker #3 and Shaker #4 Left selector switch controls Shaker #3 operation speed Right selector switch controls Shaker #4 operation speed Remote Junction Box #5 Located next to Shaker #5 Selector switch controls Shaker #5 operation speed Page 40
MCR-10000 Operators Manual Controls Machine Controls Genset Control Panel Genset Control IMG_0249-Gen-Tech Ctrl Panel 2 1 2 1 Note: Drawings represent typical genset control panels. The control panel on your machine may differ. Consult your genset operator s manual for specific information. Control 1. Stop/Emergency Stop Push Button Function Turn off the genset: push button Enable engine start: button must be pulled out 2. Generator On/Off Switch This switch starts the generator that supplies AC power for the centrifugal pump motors, shakers, hydraulic pump for the jacks and lights. The genset engine must be running before starting the generator. Page 41
Controls Hydraulic Jack Remote Control MCR-10000 Operators Manual Machine Controls 99MC9712-Remote 1 2 Remote is mounted under the stairs near the hydraulic jacks pump Control Function 1. Stop Stop hydraulic jacks pump: push button 2. Start Start hydraulic jacks pump: push button Page 42
MCR-10000 Operators Manual Controls Machine Controls Supercharger and Trash Pump Remotes 6EE12016-trashsuperRemote 2 1 One remote for the supercharger; one remote for the optional trash pump Control Function 1. Stop Stop supercharger/trash pump: push button 2. Start Start supercharger/trash jacks pump: push button Page 43
Notes MCR-10000 Operators Manual Notes NOTES: Page 44
MCR-10000 Operators Manual Preparation Operations Operations Site Preparation When arriving at the work site, find a level place on which to position the MCR-10000 relative to the drill it is to support. The attachment point for the mud hoses to the drill is determined based on the entry point of the drill into the ground. Position the MCR-10000 50 to 75 feet (15 m to 23 m) from the point where the mud hoses attach to the drill. The MCR-10000 does not have 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 55 feet (3 m x 17 m) to a level grade with a dozer. Swamp Mats In any situation where the MCR-10000 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 the full length of the MCR-10000. 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. mats-dirt 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 45
Operations MCR-10000 Operators Manual Preparation 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. mats-swamp Lift Loop Position the machine with swamp mats under its full length. MCR-10000 Swamp Matts Swamp Mats Trash Pump Customer must provide a trash pump (with a flow rate up to 1000 GPM) to pump spent drilling fluid from the returns pit to the mud system for recycling. For best results, a diesel-driven trash pump is recommended. The main control panel includes a start/stop switch and circuit breaker so an electric-driven trash pump (20 Hp maximum) can be powered using the MCR-10000 genset. Consult the factory for additional trash pump control option packages. Page 46
MCR-10000 Operators Manual Operations Set-Up Set-Up Extending the transport jacks to support the trailer creates a danger of crushing. Keep all personnel a safe distance away until the jacks are completely lowered. 1. Start the genset engine and the generator (Review Starting the MCR-10000 on page 53 and follow the procedures in the detailed engine and generator manual you received with your machine.) 2. Check the hydraulic fluid level. Fill if necessary. 3. On the Main Control Box, turn the Hydraulic Jacks Pump control to Start. Release when start is confirmed. Alternatively, push the start button on the Hydraulic Jacks Remote to turn the Hydraulic Jacks Pump on. 4. Using the Transport Jack control levers, extend the jacks to support the trailer. Remove the tractor trailer cab. Lower the jacks until the trailer rests on the ground. IMPORTANT: To prevent overheating the hydraulic system, turn off the Hydraulic Jacks Pump when the jacks are not being operated. Transport Jacks Controls-rev Jack farthest from controls Jack nearest the controls 5. Lower the side ladder. Raise the walkways and install the safety railings. 6. Raise the work light posts. Page 47
Operations MCR-10000 Operators Manual Set-Up 7. Remove the brackets that secure the shakers during transport (if so equipped). In the drawing below, only one bracket on each shaker is pointed out. There are four brackets on each of the shakers, two per side. Shipping Brackets-rev Transport Position Operating Position 8. Position the shaker chutes so particles separated from the drilling fluid fall away from the MCR-10000 system. Lock the chutes using spring latches. unknown shaker chutes Page 48
MCR-10000 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 6 to 10 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 MCR-10000 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 performance of the machine. Entry Pit Entry-Returns Pit Returns Pit 4 ft. 6-10 ft. 5 ft. 6 ft. 6 ft. 1 ft. x 1 ft. Trench 12 ft. 20 ft. Page 49
Operations MCR-10000 Operators Manual Set-Up Hose Connections from Trash Pump to Inlet Port IMPORTANT: Liquid contents of these hoses is under high pressure. Work on these hoses only when the pump is off. Pumping drilling fluid with sand content greater than 1/2% can cause excessive wear to the fluid pumping system. Ensure valves in the mud piping are in the proper position so as not to damage the system when the mud pump is started. 1. Connect the hoses which will bring spent fluid from the trash pump to the MCR-10000 for cleaning. 2. Fit the female cam and groove fitting onto the male cam and groove coupling on the trash pump. 3. Push the two levers on the sides of the hose end inward to lock the hose end to the trash pump. 4. Unroll the hose toward the MCR-10000 weir box inlet port located on the side of the tank. 5. 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 cut shakers on the mud system. unknown Inlet Port Trash Pump Page 50
MCR-10000 Operators Manual Operations Set-Up Connecting and Operating the Supercharge Pump 1. Connect a 6 inch (15.2 cm) hose between the offload port on the MCR-10000 and the suction port on the supercharge pump. 2. Connect a 6 inch (15.2 cm) hose between the discharge port on the supercharge pump and the suction port on the mud pump (the mud pump in the diagram below is an American Augers P-750). MCR-10000 Supercharge Pump P-750 Mud Pump Offload Port Discharge Port Suction Port Suction Port mcr-10000_p-750_layout 3. Connect the 480 V plug supplied with the supercharge pump into the receptacle on the side of the main control box. 4. Visually verify that all valves are open. 5. Operate the pump in one of the following ways: Connect the supplied start/stop remote pendant to the main control box. Use the buttons on the pendant to operate the pump. Use the switch on the front of the main control box or the switch on the Remote box to operate the pump. Directly connect the mud pump remote contacts to the main control box. Use the drop cable to start and stop the pump. Page 51
Operations MCR-10000 Operators Manual Set-Up If you have an American Augers P-600 or P-750 mud pump, make the connections as follows: Directly connect the supplied 98 foot (30 m) remote cable to the CR4 contacts on the P-600 or P-750 mud pump junction box following the MCR-10000 schematic. Connect the Remote Cable to the Remote Mud Pump plug on the MCR-10000 main control box. The cable and CR4 will automatically start and stop the supercharger when the mud pump needs fluid flow. Operators must be aware that the supercharger will start and stop at any time based on the mud pump s operational needs. 99MC9712c-supercharger connections Supercharger Local Start/Stop Switch Supercharger Remote Start/Stop Switch Supercharger PG3RC2 Remote Mud Pump Optional: Remote mud pump dry contact relay in remote mud pump junction box to automatically start/ stop supercharger when clutch is out, transmission in gear and engine running. PG3RC2 Cable = 8EC70320-30M to P500/P600/P750 Pump Page 52
MCR-10000 Operators Manual Operations Set-Up Before Operating the Machine The MCR-10000 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 genset is supplied with the MCR-10000. 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. Starting the MCR-10000 Signal lights and operator displays warn of potential operating problems. If ignored, damage to the machine could result. In case of unusual noise, abnormal pressure values, or if signal lights appear or alarm sounds, stop the engine immediately and carry out necessary repairs. Do not use starting fluid (ether). Immediate engine damage and personal injury may result. A manufacturer's manual for the diesel engine is supplied with the MCR-10000. The following instructions cover general engine starting procedures. Consult the manufacturer s manual for detailed starting and stopping procedures, engine maintenance and repair instructions. 1. If you have not already done so, verify that the ground stake is installed properly. 2. Confirm that all the fluid connections to and from the machine are correct. Check that the valves in the piping are in the correct position to prevent damage to the system when the system is started. 3. Unplug the block heater, if connected. 4. Disconnect all battery chargers. 5. Plug the cable from the mud pump cable holder into the Operator s Console. 6. Pull OUT the emergency stop buttons on the Operator s Console and in the Engine Control Panel. The engine will not start if any emergency stop button is pushed in. 7. Check the engine oil level, coolant level and the diesel fuel level. DO NOT let the diesel engine fuel tank run dry. If the tank is dry, bleed the fuel system. Refer to Attachment 1: Genset Manual for instructions. 8. Switch all controls OFF or put them in neutral. 9. Turn the Battery switch to the ON position. 10. Follow starting procedures in the genset engine owner s manual. 11. After the genset engine is running and warmed up, turn on the generator. This enables all switches on the Control Boxes. Page 53
Operations MCR-10000 Operators Manual Operating the MCR-10000 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 MCR-10000 on page 53 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 port. Turn the Shaker 1, Shaker 2, and Shaker 3 controls on the Main Control Panel or on the Remote 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 MCR-10000, you can use the control on the Control Panel.) Water will be pumped into the cam and groove port and routed over the first-cut shakers, through the screens and into the first cut tank. See the port illustration below. Filling Tanks from a Hydrant or Water Truck Alternatively, connect a 3 inch (76 mm) cam and groove end hose to one of the 3 inch (76 mm) fill ports. Attach the 3 inch (76 mm) hose to a fire hydrant or water tank truck. See the port illustration below. Turn the Shaker 5 controls on the Main Control Panel or on the Remote 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 - OR - Turn the Shaker 2 controls on the Main Control Panel or on the Remote Control Panel to the START position and release when start is confirmed. Water will be pumped into the first cut shaker screen into the dirty tank. 99mc1011-fillports 6 Inch Port 3 Inch Port 3 Inch Port Page 54
MCR-10000 Operators Manual Operations Operating the Mud System Adding Bentonite and Agitation Start the Mix/Agitation pump by turning the Mix/Agitation Start control on the Main 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 at the base of the hopper and the inlet valve to the jet of the hopper. Mix Hopper Inlet Valve unknown Butterfly Valve Pour the bentonite into the mix hopper to reach or maintain desired viscosity. Mix the drilling fluid by combining water in the clean tank with bentonite. Agitate it into a drilling fluid (Marsh Funnel Rating Viscosity) or other 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 Adjust the jacks on the front of the shakers to find the optimum screen deck angle and to level the flow coming off of the shaker. Adjusting the angle up will allow the fluid to stay on the shaker for a longer period. This will make the spoils drier. Adjusting the angle down will allow the fluid to move off the shaker faster. The optimum angle is best determined by the operator and depends on the type of drilling fluid and the drilling conditions. After you have established a return flow of used drilling fluid from the rig through the returns pit, use the MCR-10000 to clean the spent drilling fluid and provide a clean fluid supply. Periodically you will need to add more bentonite to the clean fluid as required by your drilling conditions. Check the sand content using a sand kit. Maintain sand content as low as possible. Do not exceed 1/2% sand. If the sand content is 1/2% or higher, check the screens on the shakers frequently 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. Page 55
Operations MCR-10000 Operators Manual Operating the Mud System Using the Washdown Pump 1. Fill the tank with water. 2. Connect the 480 V plug to the main control box. 3. Start/stop the pump using the switch on the main control box or the remote control box near the mix hopper. Wash Wand Washdown Pump Cord and Plug 99MC9712-MainCtrlPanel Washdown Tank Washdown Switch washdown1-100_0688 Fluid Pumping Checklist Review the following checklist before pumping fluid to the directional drill: Have a full tank of proper viscosity 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 mud system to the mud pump to the directional drill are tightened securely. Check the oil and coolant levels in genset engine on the machine. The fuel tank should be full before starting work each day. Run a hose from the returns pit to the MCR-10000 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. Page 56
MCR-10000 Operators Manual Operations End of Job Dismantling the MCR-10000 Tanks may qualify as confined spaces. Workers can encounter hazardous atmospheres in confined spaces. Workers may be unable to move to safety when working in a confined space. Death and serious injury can result. These practices can help increase safety when working in a confined space: Monitor for hazardous gases Ensure adequate ventilation Establish appropriate rescue procedures Use the buddy system where a worker outside the confined space receives frequent verbal feedback from the worker in the confined space Use a safety harness and lifeline IMPORTANT: Tanks must be empty before moving the machine. Drilling fluid is heavy. Damage to the trailer or rear axle could result from an overweight condition. 1. Pump all drilling fluid and clean water out of the tanks. All tanks must be empty before moving the MCR- 10000. The mud tanks filled with drilling fluid could add as much as 80,000 pounds (36,000 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. 2. Clean residual drilling mud out of the tanks. Enter the tanks through the cleanout ports on the side of the unit. 3. Disconnect and clean out hoses. 4. Dispose of drilling mud following local regulations. 5. Secure the shaker chutes. 6. Secure the shakers for transport with the brackets as shown below (if so equipped). Shipping Brackets Transport-rev Page 57
Operations MCR-10000 Operators Manual End of Job 7. Lower and secure work light posts. DO NOT drive with the work light posts extended. 8. Raise the jacks to elevate the trailer. 9. Hitch to tractor trailer cab and secure. 10. Turn off Hydraulic Jacks Pump, genset and genset engine. 11. Switch Battery Switch to Off. 12. Remove and stow safety railings. 13. Lower walkway and secure in place. 14. Raise side ladder. 15. Remove ground stake. Page 58
MCR-10000 Operators Manual Operations Operating in Different Climates Operating in Hot Weather To prevent damage to the machine when operating in hot weather, take the following precautions: Follow instructions in the Genset Manual (Attachment 1) for operating the genset s engine in hot weather. 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. Use the recommended engine oil viscosity for the operating conditions as specified in your diesel engine and genset manual. Operating in Cold Weather Only machines especially configured at the factory can work under ambient temperatures between -40 F to +5 F (-40 C and -15 C). Some machines are equipped with an engine preheater which will ease starting the diesel engine in cold temperatures. Use appropriate oils and cooling liquids for the diesel engine. For specific information, see your diesel engine manual (attachment 1). Other precautions and special procedures for operating in cold weather are: Ensure that the battery is fully charged. Use the recommended engine oil viscosity for the operating conditions as specified in your diesel engine manual. Use the proper cold weather fuel. Cold temperatures can cause water to collect in the fuel tank. Check the collection bowl at the bottom of the fuel-water separator near the fuel system on the engine. Drain water from the collection bowl using the drain valve at the bottom of the bowl. 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. Warm the engine thoroughly before beginning operations. The engine and hydraulic fluid should be thoroughly warmed before operating the mud system and the hydraulic controls (e.g., the transport jacks). Thoroughly clean the system and drain water and drilling fluid out of the system and replace with antifreeze when cold temperatures are expected. Warm the Remote Control Boxes by operating the generator for several minutes. The Remote Control Boxes may not operate correctly or operate erratically if their temperature is below 32 F. Page 59
Notes MCR-10000 Operators Manual Notes NOTES: Page 60
MCR-10000 Operators Manual Storage and Transport Machine Storage and Transport Storage and Transport Minimum Storage Space Required Level 636 x 100 inches, height 157 inches (16.2 x 2.6 m, height 4 m), weight 75000 pounds (34020 kg) Storage Site Conditions If the machine has been lubricated, it can be stored uncovered for up to 30 days. Protect the machine from salty or acid environments, solvents, gas, flammable liquids and explosives. For periods longer than 30 days, the machine should be stored in a covered, dry area. The temperature ranges recommended for storage are between 32 F and 120 F (0 C to 50 C). Refer to Attachment 1: Genset Manual for temperatures outside this range. Preparations for Storage For short-term storage, i.e., periods less than 30 days: 1. Clean all mud and other foreign materials off the machine. 2. Drain water or bentonite slurry out of the centrifugal pumps and hoses. If you expect freezing temperatures, pump antifreeze through the system. 3. Position the machine on a level surface. 4. Turn off the electrical system by turning the Battery Switch on the genset to the OFF position. For periods longer than 30 days, follow the procedures for short-term storage plus these additional steps: 1. Place the machine in a covered and dry site, and follow the instructions for storing the genset engine.* 2. Disconnect batteries and store them where the temperature will remain between 32 F and 105 F (0 C to 45 C). 3. Eliminate sediment and water from the tanks. 4. Protect the machine from salty or acid environments, solvents, gas and flammable liquids and explosives. Page 61
Storage and Transport MCR-10000 Operators Manual Machine Storage and Transport Transportation Improper operation of controls and use of unsafe techniques can result in serious injury, death and damage to the equipment. Personnel should read the manual and learn proper procedures to transport and lift the machine. The machine must be transported in accordance with national, state, provincial and local laws and regulations. All components must be properly secured on the machine. If the machine exceeds the overall dimensions allowed, they must be flagged according to the highway laws of the countries or states involved in the transport. The transporter is responsible for using the proper method of transport and following all other applicable regulations. Lifting the Machine Crush hazard from above. If the load shifts or falls it could crush you or kill you. Use appropriate lifting equipment for the size of the load. Use chain or cable suitable for the weight of the machine being lifted. Ensure load is stable and properly secured before lifting. All personnel must remain a safe distance away while the machine is being lifted. Use spreader bars to ensure that 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 49 feet (15 m). spreader_bar Page 62
MCR-10000 Operators Manual General Maintenance Maintenance Maintenance Failure to turn off the machine and lockout systems before doing maintenance work may result in personal injury or death. Turn off power, relieve system pressures and turn the Battery switch to the OFF Position. Remove the key from the Engine Start switch(es) and install a lock on the Battery switch (see drawing below). Use proper lockout and tagout procedures before working on the machine. 8ep02900-2=24505-T[1]-BattDisconLockout TRIMMED Lockout Tab Battery Switch ON OFF 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 laws and regulations. Take appropriate precautions to ensure that these fluids do not leak or spill on the ground or into sewage systems, streams, rivers, lakes or the sea. 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. For additional drawings, diagrams and explanations necessary for maintenance and repair, contact the factory. Qualification of the Technician Ensure that all field personnel conducting visual inspections of the machine have adequate training to enable them to identify existing problems and that they have read and understand this manual. The maintenance technician must be trained in drilling 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. Page 63
Maintenance Cleaning MCR-10000 Operators Manual General Maintenance Water can damage sensitive electronic components. Do not spray water against electronic components and control panels. General Cleaning Clean all the marking plates as well as all lighting devices. Do not direct the water spray inside the muffler or the air filter, against electric components and control panels or on caps and open tanks. Do not use acid or abrasive solutions. Keep caps and covers for hydraulic connections clean. Contamination of hydraulic oil will negatively impact performance of your MCR-10000. 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 or compressed air (maximum 30 psi (2 bar)) when you clean these parts. Cleaning Hydraulic Connections Hydraulic couplings and protective caps must be kept clean and free of all debris. Use an evaporative, petroleum-based aerosol cleaner. When hydraulic couplings are not connected, replace protective caps on the connectors and hose ends. Failure to keep the hydraulic couplings clean could impact equipment performance, cause serious damage and may void the product warranty. Cleaning Electrical Connections Electrical connectors and dust caps must be kept clean and dry. Use a high quality electrical contact cleaner. When electrical cables are disconnected, replace dust caps on the connections and cable ends. Failure to keep the electrical connectors clean could impact equipment performance, cause serious damage and may void the product warranty. Page 64
MCR-10000 Operators Manual Maintenance General Maintenance Welding IMPORTANT: Disconnect all electrical connections before welding. Damage can occur to processor and electrical system if electrical components are connected during welding. 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. Consult the factory for additional information about preheating or post weld heat treating requirements if welding is necessary in cooler temperatures. Welding should not be done when the ambient temperature is below 0 F. Engine and Genset Maintenance Engine and genset maintenance items are outside the scope of this manual. Consult Attachment 1: Genset Manual for recommended fluids (gasoline, engine oil, antifreeze) and inspection and maintenance schedules. Your engine may have specific requirements related to its emissions systems. Approved Replacement Fluids When adding or replacing fluids, use the same fluid that is in the system. Avoid mixing different fluids as they may be incompatible. Use the fluid in the table below or select an equivalent from the American Augers Specifications (see Attachment 2: American Augers Lubrication Guide Revision D). The compatibility table is a guideline. It lists the compatibility of the main thickener systems used in the industry. Contact the factory for advice on the compatibility of a new grease with the one in service. Fluids oils and greases have been selected specifically for their properties in colder temperatures. Consult the factory for specifications at temperatures outside the ambient temperature range. Approved Replacement Fluids (Ambient temperature 0 F to 110 F [-18 C to 44 C]) Hydraulic Oil Shell Tellus T ISO 46 AA Specification 202 Grease Shell Retinax LC-2 AA Specification 301 Water Course Antifreeze Pitt-Penn RV Antifreeze AA Specification 603 Page 65
Maintenance MCR-10000 Operators Manual Scheduled Maintenance MCR-10000 Maintenance Schedule After 10* 50* 250* 500* 2600* Function each job hours hours hours hours hours Cycle Emergency Stop Buttons X Genset: Check Fuel Level X,E Genset: Check Radiator Coolant Level X,E Genset: Check Engine Oil Level X,E Genset: Check Air Filter Service Indicator X,E Check Valves, Hoses and Fittings X Inspect Shaker Screens X Inspect Shaker Vibration Isolators X Check Battery Water Level X Inspect Motor Couplers on Pumps X Lubricate Shaker Electric Motors X Lifting Jacks: Maintenance Items X Lubricate Centrifugal Pump Electric Motors X** Lubricate Angle Adjustment Jacks (Shakers) X NOTES: E, Consult genset engine manual Page 5-2 for methods and materials. * Do not exceed the indicated number of hours without performing the required maintenance ** Do not exceed 20,000 hours on the 50 Hp motor or 14,000 hours on the 60 Hp motor. Page 66
MCR-10000 Operators Manual Maintenance Scheduled Maintenance 10 Hour Inspection and Maintenance Perform the 10 hour inspection and maintenance items in the Maintenance Schedule. Cycle Emergency Stop (Disable) Buttons Verify that all emergency stop buttons are working properly. Perform an operating check of all controls. Make necessary repairs before starting operations. Engine: Check Fuel Level Diesel fuel and fuel vapors are combustible. They ignite easily, burn rapidly and can cause serious personal injury. Turn off the engine when refueling. Never allow sparks, flames or smoking materials in the refueling area. Begin each shift with a full tank of fuel. To prevent dirt and water from reaching the injection parts which will cause damage and decrease performance, use clean fuel and service the fuel filter at regular intervals as prescribed in Attachment 1: Genset Manual. Engine: Check Coolant Level Hot coolant can spray out and cause serious injury. Never remove radiator cap while the engine is hot. Wait for the engine to cool. Slowly open the radiator cap and allow pressure to escape slowly. Always wear face protection (face shield or goggles) when cleaning radiator fins with compressed air or pressure washer. IMPORTANT: Water quality is important to the performance of the cooling system. Use distilled, deionized or demineralized water when mixing with coolant concentrate. Coolant should be checked while the coolant is cold. Check that the level of the coolant is at maximum and there is no contamination. Add coolant if the level is low. After filling is complete, install and tighten the filler cap. Engine: Check Engine Oil Level IMPORTANT: Before checking or changing engine crankcase lube oil, wait for the engine to cool. Refer to Attachment 1: Genset Manual for correct crankcase lube oil to use if more oil is required. Check that the engine oil is at the proper level and that there is no contamination. Add oil if the level is low. Select oil based on specifications in Attachment 1: Genset Manual. Page 67
Maintenance MCR-10000 Operators Manual Scheduled Maintenance Engine: Check Air Filter Service Indicator The air filter service indicator provides a quick check of the condition of the air filter(s). When the red marker on the air filter service indicator appears, the air filter is clogged with dust. This causes a substantial decrease in engine efficiency and can cause serious damage to inner mechanical parts. Clean or replace the filter elements. In extreme dusty conditions, increase the frequency of engine air filter maintenance. General Inspections Use of equipment with damaged hoses, fittings, loose or missing fasteners may result in damage to the machine, personal injury or death. Inspect the machine regularly. Replace or repair damaged or missing components promptly. Hot surfaces can cause burns. Do not touch until cool. Hydraulic fluid under pressure can cause serious personal injury and death if it penetrates the skin. Stay away from the jet. Use a piece of cardboard or wood to check for pressurized leaks to prevent fluid penetrating the skin. Seek immediate medical attention if hydraulic fluid has penetrated the skin even if the injury seems minor. Prompt medical treatment by a physician familiar with this injury is essential. Inspect the machine for leaks of gear oil and hydraulic oil. Leaks should be repaired. Allowing oil or other fluids to leak into the environment is unlawful in most locations. Visually inspect all hoses, fittings and pipes. Replace parts that are damaged. Inspect shaker screens. Worn or damaged shaker screens will impact machine performance. Repair or replace when necessary. Check that hydraulic cylinder rods and struts are not damaged and that they do not leak. Keep cylinder rods clean to prevent damage. Dirt can cause contamination of the hydraulic fluid and cause failure of shaft seals. Check all major fasteners, such as hose clamps, stakedown, tie downs, etc. Tighten all loose fasteners. Replace any that are missing or damaged. Check the control cable connections and ensure they are tight. Page 68
MCR-10000 Operators Manual Maintenance Scheduled Maintenance Lubricate Grease Fittings NOTE: Grease fittings should be kept clean so that contamination is not forced inside. Replace damaged fittings. Grease points must be lubricated daily. Two grease pumps are enough unless otherwise specified. Use the grease type specified in the Approved Replacement Fluids table. When working in very high or very low temperatures, consult the factory. Lubricate: Shaker Adjustment Jacks 99mc1011-lube1 One fitting on each adjustment jack Page 69
Maintenance MCR-10000 Operators Manual Scheduled Maintenance 50 Hour Inspection and Maintenance Perform 10 Hour Inspection and Maintenance items, plus: Inspect shaker isolators that support the shaker basket. They may become stretched, frayed or worn. Replace as required. 250 Hour Inspection and Maintenance Perform 10 Hour and 50 Hour Inspection and Maintenance items, plus: Check Battery and Battery Fluid Levels BATTERY ACID CAN CAUSE SEVERE BURNS. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Wear eye protection and gloves when working with batteries. ANTIDOTE: EXTERNAL: flush with water. INTERNAL: drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call Poison control and a physician immediately. EYES: flush with water for 15 minutes and get prompt medical attention. All exposed metal parts on a storage battery are live. Laying a metal object across the terminals may cause a spark, short circuit or explosion. Personal injury or damage to the equipment may result. Never lay a metal object across the battery terminals. IMPORTANT: When disconnecting battery terminals, remove the Negative (-) GROUND cable first; then remove the Positive (+). When connecting the cables, connect the Positive (+) first, then connect the Negative (-) GROUND cable last. To prevent damage to the battery, DO NOT over tighten the battery hold down. Check the level of the electrolyte in the batteries. Add distilled water until level is at the split ring of each cell opening 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 battery terminal grease or dielectric grease in order to prevent future corrosion. Page 70
MCR-10000 Operators Manual Maintenance Scheduled Maintenance 500 Hour Inspection and Maintenance Perform 10 hour, 50 hour and 250 hour inspection and maintenance items, plus: Inspect motor couplers on centrifugal pumps and replace if worn. 2600 Hour Inspection and Maintenance Lubricate shaker electric motors. Before Each Job Lubricate Centrifugal Pump Electric Motors Do not exceed 20,000 hours on the 50 Hp motor or 14,000 hours on the 60 Hp motor. Check Hydraulic Oil Level NOTE: Very small amounts of contamination of hydraulic oil can damage the system. 99mc1011-hyd tank Hydraulic Oil Reservoir Level Gauge After each job: Clean hydraulic cylinder rods before retracting them. Inspect the hydraulic oil. If the oil is cloudy or dirty, replace it. If the oil is clean, check the level as described in the steps below. It is best to check the fluid level when the ambient temperature is 50 F (10 C). Oil level will vary according to the effect of temperature (hot oil increases in volume) and the position of the hydraulic cylinders. 1. Position the machine on a flat surface. 2. Retract all cylinders. 3. Check the level in the tank using the gauge mounted on it. If the level is too low, add oil to the level indicated on the gauge. DO NOT overfill the reservoir. 4. After refilling, lock the tank cap. Page 71
Notes MCR-10000 Operators Manual Notes NOTES: Page 72
MCR-10000 Operators Manual Specifications Specifications Specifications Machine Dimensions / Weight Length: 53 feet (16.2 m) Width: 98.4 inches (2.5 m) Height: 13 feet 1 inch (4 m) Estimated Weight: 75000 pounds (34020 kg) Configuration: Triaxle king pin rockover style trailer Generator Output: 225 kw Prime power / 480 V / 60 Hz Pump, Supercharge with fabricated or skid base Pump Design: Centrifugal, 30 Hp electric motor Approximate Output*: 750 gpm at 35 psi (2840 liters/minute at 2.4 bar) *Depends on Mud Pump flow rate. Pump, Mix-Agitation Pump Design: Estimated Output: Centrifugal, 50 Hp electric motor 1200 gpm at 45 psi (4540 liters/minute at 3.1 bar) Pump, Cone Supply Pump Design: Estimated Output: Centrifugal, 60 Hp electric motor 1925 gpm at 32 psi (7290 liters/minute at 2.2 bar) Pump, Hydraulic Jack Pump Design: Approximate Output: Hydraulic, Gear, Hi-Lo, 10 Hp electric motor High flow - 14.0 gpm < 1150 psi (53 liters/minute < 79 bar) Low flow - 3.6 gpm at 3000 psi (13.6 liters/minute at 207 bar) Washdown System Pump Design: 5 Hp pump Accessories 25 foot (7.6 m) 6 inch hose with 6 inch female cam and groove fittings Four, 500 W quartz work lights Page 73
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MCR-10000 Operators Manual Appendix Appendix Appendix The appendix contains information the operator of the MCR-10000 will find useful to have available for reference during operation of the MCR-10000. The information is placed in the appendix because it is of general interest and/or it supplements the information in the body of the manual. Page 75
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MCR-10000 Operators Manual Appendix A: List of Attachments Appendix A Appendix A Attachment 1: Genset Manual Attachment 2: American Augers Lubrication Guide (current revision) Page 77
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MCR-10000 Operators Manual Declaration of Conformity Sample Declaration of Conformity DRILLING FLUID CLEANING SYSTEM MCR-10000 Page 79
American Augers, Inc. 135 US Route 42 P.O. Box 814 West Salem, Ohio 44287 www.americanaugers.com Always include machine serial number when ordering parts Due to our continuing product improvement, machine specifications are subject to change without notice. Original Instructions Manual Part Number 99MCR10000 Released September 2012 Revision 01