TRENCOR M-300DH Operation & Safety Instruction Manual PDF

M-300DH 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 M-300DH. 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)

M-300DH Operator’s Manual

Foreword

Introduction

Foreword

INTRODUCTION Since 1970, American Augers has been a devoted manufacturer of trenchless technology equipment; customers worldwide recognize the M-300DH 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.

Every effort has been made to adequately cover the operation of the M-300DH in this manual. If you have questions about any of the features of your specific machine, contact the factory (Telephone: 419-869-7107 or 800-324-4930 (USA Toll Free)).

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.

California Proposition 65 Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. www.P65warnings.ca.gov.

This product and its use may be covered by one or more patents at http://patents.charlesmachine.works 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 32MC10200 Released January 2020 Revision 00 Page 2

M-300DH Operator’s Manual

Foreword

Warranty Policy

AMERICAN AUGERS WARRANTY POLICY FORMͲ177 14January2015

NOTICE: This warranty policy applies to initial purchasers of American Augers, Inc. products (“Buyer”). This warranty policy includes American Augers, Inc. (“AA”) new and manufacturerͲcertified equipment, products, parts, materials and supplies branded American Augers and Trencor (“Equipment”).

In no event shall the liability of AA exceed the purchase price of the Equipment sold to the Buyer. AA 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.

THE REMEDIES IN THIS WARRANTY SHALL BE THE EXCLUSIVE AND SOLE REMEDIES OF THE BUYER. THERE ARE NO OTHER WARRANTIES, EXPRESSED OR IMPLIED, OF ANY KIND, INCLUDING BUT WITHOUT LIMITATION, ANY WARRANTY THAT THE EQUIPMENT IS OF MERCHANTABLE QUALITY OR THAT THE EQUIPMENT IS FIT FOR ANY PARTICULAR PURPOSE. AA WILL HAVE NO MONETARY LIABILITY WHATSOEVER FOR ANY DAMAGE, LOSS COSTS, OR EXPENSE (WHETHER GENERAL, SPECIAL, INCIDENTAL OR CONSEQUENTIAL) SUFFERED BY THE BUYER AS A RESULT OF OR IN CONNECTION WITH THE EQUIPMENT. IN NO EVENT SHALL AA 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.

WHO IS COVERED? I.

Any Buyer who takes delivery of Equipment from AA is covered under this warranty. The warranty may be transferable with inspection and written approval of AA.

II.

Used equipment manufactured by AA is sold without conditions or warranties, expressed or implied, and is considered “as is”, unless there is a clear agreement with the Buyer in writing to the contrary prior to the purchase. BUYER AGREES TO INSPECT ALL USED EQUIPMENT BEFORE THE PURCHASE IS COMPLETED AND TO ACCEPT SAME WITHOUT ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

WHAT IS COVERED? I.

This warranty is extended by AA in respect to Equipment sold by AA. AA warrants to the Buyer that Equipment will be free of defects in material and workmanship, as defined in this warranty, for a period of 2 years from date of shipment to the Buyer or 2000 hours of operation, whichever occurs first. At the time of startup as a retail sale, rental, or lease a properly completed Warranty Registration Certificate must be submitted to AA to validate the warranty coverage. In the event that there is a delay or postponement in the commissioning of the Equipment by more than 60 days from the date of receipt of the Equipment, the warranty terms and conditions may not apply. An inspection performed by a representative of AA may be required to reinstate the warranty of the Buyer.

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

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M-300DH Operator’s Manual

Foreword

Warranty Policy

Details of the Warranty Coverage

II.

Coverage is based on year(s) or engine hours, whichever occurs first.

PARTS: 2 YEARS / 2,000 HOURS LABOR: 1 YEAR / 1,000 HOURS ENGINE AND TRANSMISSION: 2 YEARS / 2,000 HOURS RACK AND PINION: 5 YEARS / 10,000 HOURS

a. Components and all engines as installed on all Equipment are covered, but only:

i. In accordance with the warranty offered by the manufacturer of the component or engine; ii. For the periods set forth in the warranty offered by the manufacturer of the component or engine; iii. When the component or engine is used in a normal and proper manner which was intended in the product’s design; iv. When the component or engine is used in accordance with the maintenance schedules recommended by AA and/or the manufacturer of the component or engine.

b. Upon the expiration of the periods stated in the warranty offered by the manufacturer of the component or engine; all warranties, expressed or implied, are terminated. AA in no way creates any additional warranties, either expressed or implied, with respect to any component or engine provided by the manufacturer. The ultimate determination of whether a warranty exists lies in the sole discretion of the manufacturer of such component or engine and not with AA.

c. If a defect in workmanship or material is determined by AA or any manufacturer of the component or engine during the appropriate warranty period as stated in the limited warranty and in the warranty offered by the manufacturer of components or engines, AA will provide:

i. New, manufactured or AA approved parts or components to correct the defect; ii. Lubricating oil, filters, antifreeze and other service items deemed necessary by AA to the repair or replacement to correct the defect; iii. AA will perform repairs and/or replace parts at an authorized service center or location approved by AA.

WHAT IS NOT COVERED?

I

II

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AA is not responsible for any repair, replacement or failure of Equipment caused by:

a) The installation of any component, engine, part, supplies, or materials (whether original or not) which is deemed by AA, in its sole discretion, to be inconsistent with the Equipment’s design or improper installation; b) The attachment or installation of accessory items and parts not sold by, authorized by, or recommended by AA; c) Abuse, neglect, or improper repair to Equipment. d) The failure to conduct any maintenance required or recommended by AA or by the manufacturer of any component, engine, part, supplies, or materials.

AA is not responsible for any repair or replacement which is delayed in any way including:

a) Delay by Buyer in notifying AA of the defect. b) Delay in making the Equipment available to AA after Buyer learns of the defect. c) Delay in the return to AA of a defective component.

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

M-300DH Operator’s Manual

Foreword

Warranty Policy

NOTE: Any component, Equipment or engine returned by the Buyer must be returned to AA no later than 30 calendar days from the date of failure of such component, equipment or engine. Failure on behalf of the Buyer to comply with this requirement can cause a voiding of warranty coverage. AA 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. Any return of parts or equipment must have prior approval of a representative of American Augers and/or a Return Material Authorization number.

III AA is not responsible for:

a) The cost of transporting the Equipment, component or engine; b) Premium or overtime labor; c) Local taxes for repairs or replacements, labor, components, engines, materials or Equipment; d) Evaluating the suspected defect if no defect is found by AA to exist or to be covered by a warranty offered by the manufacturer of any component or engine; e) Labor or parts required that are incidental to the removal or remounting of components, engines, or equipment repaired or replaced. f) If tests are conducted to ascertain or demonstrate defects in material or workmanship, such tests shall be conducted after reasonable notice to AA and upon conditions mutually agreed upon in advance of the test.

AA shall have the right to be present at any testing conducted by Buyer. AA at its option may charge the Buyer for any tests performed by AA at the request of the Buyer in respect to the merchandise sold hereunder.

IV AA is not responsible for the repair or replacement of consumables and wear items, including but not limited to the following:

a) Down hole tools and accessories, pockets, teeth, conveyor belts, boom, wear plates, hardware and fasteners, any ground engaging or wear components, digging chains, digging plates, sprockets, segments, truck wheel components, arc plates, rock guards, and crumbshoe components, batteries, lamp bulbs, fuses, various types of gaskets and packing, filter elements, oils, lubricants, fluids, track chain, track drive sprockets, drill pipe, auger sections, die holders, wrench wear parts, guide bushings, shaft seals, mud swivel assemblies, spindles, valves, piston liners, centrifugal pumps, shaker screens, cones, belts, buckets, bearings, cam followers, die inserts, die holders, brakes, rollers, drilling bits, auger boring heads, adapters, couplers, crossover subs, backreamer and pullback swivels, and other normal wearing or aging parts.

V OTHER LIMITATIONS: THIS WARRANTY IS IN LIEU OF ANY OTHER WARRANTY, EXPRESSED OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. No representative, employee, or agent of AA has the authority to make or imply any representation, promise or agreement which in any way alters, amends, modifies or waives the terms of this warranty unless such representation is made in writing and signed by an officer of AA. AA reserves the right to modify, alter, and improve any Equipment without incurring any obligation to replace any Equipment previously sold with such modified, altered or improved Equipment. 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.

VI COMPENSATION: This warranty does not provide any compensation to Buyer or any other person or entity for loss of time, loss of use of Equipment, loss of profits, inconvenience, loss of productions, delay in construction, delay in project completion, labor costs (except as specifically stated elsewhere in this warranty), loss of life or limb, personal injury or property damage, or any other type of incidental or consequential damages. ALL DAMAGES ARE LIMITED TO REPAIRS AND REPLACEMENTS DESCRIBED IN THIS WARRANTY. However, in some states this exclusion or limitation will not apply, so reference should be made to the appropriate and applicable state laws. In such jurisdictions, the parties stipulate and agree that damages are liquidated and limited to the cost of repair and replacement necessary to cure any defect.

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

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M-300DH Operator’s Manual

Foreword

Warranty Policy

VII THIS WARRANTY ACCOMPANIES A POTENTIALLY DANGEROUS PRODUCT

Please read and make certain that you understand all safety warnings, operation, and maintenance requirements.

a) AA is not responsible for any damage or injury to person or property caused by the use of this Equipment:

I. In a manner which is inconsistent with the Equipment’s intended design, purpose, or use; II. After the removal or alteration of the safety features of this Equipment or neglect of safety warnings and precautions; III. If the Buyer or any person fails to perform any maintenance as required or recommended by AA or the manufacturer of any component, engine, or Equipment which contributes to the cause of any damage or injury; IV. By an untrained, unskilled, or impaired operator.

WHAT MUST THE BUYER DO?

I.

Buyer’s Covenants and Responsibilities

COST TO BUYER: If it is not a defect in workmanship or material as determined by AA or its authorized dealer to exist during the warranty period, and if any repair or replacement is undertaken by AA, Buyer shall, in consideration for this limited warranty, be responsible for the following:

a) Any costs of transporting the Equipment, a component or engine, (except as specifically stated elsewhere in this warranty); b) Any premium or overtime labor costs; c) Any local taxes for repairs or replacements for labor, components, engines and Equipment; d) Any cost to evaluate the suspected defect if no defect is found by AA to exist or to be covered by a warranty; e) Any labor or parts required incidental to the removal or remounting of components or engines repaired or replaced; and, f) The invoice amount on any invoice issued with the shipment of Equipment, components or engines which were returned later than30 days from the date of failure of such Equipment, component or engine.

MAINTENANCE: Buyer shall be responsible for the performance and cost of all maintenance to the Equipment, components, and engines as directed by AA and/or the manufacturer of any component or engine. This warranty applies only if the alleged defective Equipment has been properly maintained and operated as specified by AA. 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 Buyer or its representatives, improper Equipment operation or use of the Equipment exceeding the design limitations or an attachment supplied by other than AA, its subsidiaries or the authorized representative of the foregoing.

TRAINING AND SAFE OPERATION: WARRANTY IS PROVIDED WITH THE UNDERSTANDING THAT ALL SAFETY WARNINGS AND INSTRUCTIONS WILL BE REVIEWED BY ALL PERSONNEL. THE BUYER SHALL BE RESPONSIBLE FOR PROVIDING APPROPRIATE TRAINING FOR OPERATORS OF ANY AA EQUIPMENT, AT BUYER’S SOLE COST. BUYER SHALL ENSURE THAT OPERATORS ARE AT ALL TIMES QUALIFIED TO OPERATE ANY AA EQUIPMENT AND THAT OPERATORS DO NOT SUFFER FROM ANY IMPAIRMENT WHICH WOULD PRECLUDE SAFE OPERATION OF

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M-300DH Operator’s Manual

Foreword

Warranty Policy

THE AA EQUIPMENT. IN THE EVENT THAT THE BUYER NEEDS ADDITIONAL TRAINING OF OPERATORS, THEY SHALL IMMEDIATELY CONTACT AA CUSTOMER SERVICE TO SCHEDULE AND PAY FOR THE REQUIRED TRAINING.

NOTIFICATION: Buyer agrees to notify AA promptly of any suspected defect and to cooperate fully in AA’s evaluation to determine whether any defect exists as per the warranty terms and conditions.

WAIVER: BUYER WAIVES THE RIGHT TO SEEK DAMAGES FOR ANY INJURY, LOSS, DAMAGE OR CLAIM OF ANY KIND RESULTING OR ARISING FROM ANY DEFECT ONCE BUYER ACCEPTS THE REPAIR AND REPLACEMENT NECESSARY TO CURE SUCH DEFECT.

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

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M-300DH Operator’s Manual

Foreword

Machine Serial Number Locations

Location of Machine Serial Number Plate Machine Serial Number

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M-300DH Operator’s 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.

When you see this safety alert sign, carefully read and follow all instructions. Safety 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. The “Safety Alerts” section beginning on page 35 shows these safety alert signs. These decals should be kept clean and legible. Replacement decals are available by calling American Augers (Telephone: 419-869-7107 or 800-324-4930 (USA Toll Free)).

YOUR SAFETY IS AT STAKE.

Signal Words Signal words are used to identify safety information within the text of this manual. They are reserved for personal injury hazards. indicate an imminently hazardous situation which, if not avoided, will result in death or serious injury. indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

Additional Definitions NOTICE indicates information considered important, but not hazard-related (e.g., messages relating to property damage).

IMPORTANT can help you do a better job or make your job easier in some way.

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

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Notes

M-300DH Operator’s Manual Notes

NOTES:

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M-300DH Operator’s Manual

Foreword

Revision Record

Revision to Manual Revision Number 00

Description of Change Serial numbers under top level 32MC1004 from M300D-29.

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

Date 1/27/2020

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M-300DH Operator’s Manual

Foreword

Revision Record

Revision to Manual, Continued Revision Number

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Description of Change

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Date

M-300DH Operator’s Manual

Foreword

To The Owner To The Owner Thank you for your purchase of the American Augers M-300DH. This is an authorized accessory for use with our directional drills.

This manual contains important information that will help you and your crew set up and safely operate the M-300DH. 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.

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.

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 regional safety requirements. Do not make unauthorized modifications. Unauthorized modifications could cause serious injury or death.

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

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Foreword

M-300DH Operator’s Manual

NOTICE Before using this manual, familiarize yourself with the Description Of Components (page 19).

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.

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M-300DH Operator’s Manual

Table of Contents

Table of Contents Foreword ............................................................................................. 2 Introduction.................................................................................................................. 2 Warranty Policy ........................................................................................................... 3 Machine Serial Number Locations............................................................................... 8 Safety Awareness Program......................................................................................... 9 Revision Record ........................................................................................................ 11 To The Owner............................................................................................................ 13

Overview ........................................................................................... 19 M-300DH Machine Components ............................................................................... 19 Operation and Maintenance Manual ......................................................................... 21 Ownership of Information .......................................................................................... 21 Manufacturer Identification Data................................................................................ 21 Machine Identification Data ....................................................................................... 21 Scope of Document ................................................................................................... 21 Declaration of Conformity .......................................................................................... 21 Legal Disclaimer ........................................................................................................ 22 Purpose of Machine................................................................................................... 22 Ground Leveling ........................................................................................................ 22 Ambient Conditions ................................................................................................... 22 Warranty: General Conditions ................................................................................... 22 Limitations of Warranty.............................................................................................. 22 Request for Service/Support ..................................................................................... 22 Warranty and Service for Diesel Engine/Genset ....................................................... 22 Instruction Manuals ................................................................................................... 23

Safety Information ........................................................................... 25 Safety Regulations and Practices.............................................................................. 25 Emergency Procedures ............................................................................................. 25 Qualification of Personnel.......................................................................................... 26 Basic Safety Guidelines............................................................................................. 26 Overhead Hazards .................................................................................................... 27 Before Starting the Machine ...................................................................................... 27 Operating Precautions............................................................................................... 28 Operator’s Responsibilities........................................................................................ 28 Refer to the Safety Awareness Program in this manual before attempting to operate this machine

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Table of Contents

M-300DH Operator’s Manual

Material Handling Precautions ...................................................................................28 Maintenance Precautions...........................................................................................28 Transporting Precautions ...........................................................................................29 Trailer Reporting Safety Defects ................................................................................29 Noise Level Safety .....................................................................................................29 Welding Safety ...........................................................................................................30 Hazardous Chemicals ................................................................................................31 Crystalline Silica (Quartz) Dust Precautions ..............................................................31 Ladder Safety .............................................................................................................32 Refueling Safety .........................................................................................................32 Arc Flash Safety .........................................................................................................33 Confined Space Entry ................................................................................................34 Danger Zones -- Safe Distances ................................................................................34 Grounding ..................................................................................................................35

Safety Alerts...................................................................................... 36 Machine Controls............................................................................. 39 Safety Switches..........................................................................................................39 Genset Control Panel .................................................................................................40 M-300DH Main Control Panel ....................................................................................42 Offload Pump Remote................................................................................................44 Battery Switch ............................................................................................................45 Service Lights.............................................................................................................45

Preparation ....................................................................................... 47 Site Preparation and Set Up ......................................................................................47 Pit Pump.....................................................................................................................47 Crew ...........................................................................................................................47 Entry Pit and Returns Pit Construction.......................................................................48 Hose Connections from Pit Pump to Inlet Port...........................................................49 Discharge Hoses ........................................................................................................50 Before Operating the Machine ...................................................................................50 Starting the M-300DH.................................................................................................51

Operating the M-300DH ..................................................................52 Preparing the Drilling Fluid .........................................................................................52 Adding Bentonite and Agitation ..................................................................................53 Page 16

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M-300DH Operator’s Manual

Table of Contents

Ongoing Drilling Fluid Supply .................................................................................... 54 Pumping Fluid to a Directional Drill or Mud Pump..................................................... 55 Fluid Pumping Checklist ............................................................................................ 55 Cleaning Drilling Fluid Returns from the Entry Pit ..................................................... 56 Stopping the Genset Engine...................................................................................... 57

End of Job ........................................................................................ 58 Dismantling the M-300DH ......................................................................................... 58

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 Preparations for Storage ........................................................................................... 61 Winterizing................................................................................................................. 62 Transportation ........................................................................................................... 63 Lifting the Machine .................................................................................................... 64

General Maintenance ...................................................................... 65 Qualification of the Technician .................................................................................. 65 Cleaning .................................................................................................................... 65 Welding...................................................................................................................... 67 Tier 4 Diesel Engine .................................................................................................. 67 Engine and Genset Maintenance .............................................................................. 68 Approved Replacement Fluids .................................................................................. 68

Scheduled Maintenance................................................................... 69 Maintenance Schedule .............................................................................................. 69 10 Hour Inspection and Maintenance........................................................................ 70 50 Hour Inspection and Maintenance........................................................................ 73 250 Hour Inspection and Maintenance...................................................................... 74 500 Hour Inspection and Maintenance...................................................................... 75 2600 Hour Inspection and Maintenance.................................................................... 75 Per Specifications...................................................................................................... 75

Specifications ................................................................................... 77

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Table of Contents

M-300DH Operator’s Manual

Machine Dimensions / Weight....................................................................................77 Generator Set.............................................................................................................77 Controls ......................................................................................................................77 Pump, Mixing/Agitation...............................................................................................77 Pump, Cone Supply ...................................................................................................77 Pump, Offload/Agitation .............................................................................................77 Accessories ................................................................................................................77 Fluid Capacities..........................................................................................................78

Appendix ...........................................................................................79 Appendix A: (List of Attachments) .............................................................................81

Sample Declaration of Conformity.................................................. 83

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M-300DH Operator’s Manual

Overview

Overview

Overview M-300DH Machine Components 2

1

3 4

9 5

8 6 7 10

1. Genset (if supplied by American Augers) 2. Shaker 3. Tank Cleanout 4. First Cut Tank 5. Drain 6. Clean Tank 7. Offload/Agitate Pump 8. Cone Supply/Agitate Pump 9. Mixer/Agitate Pump 10. Trailer (Optional)

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M-300DH Operator’s Manual

Overview

Overview M-300DH Machine Components (Continued)

4 2

1

3

8

5 6

7

1.

2.

3.

4.

5.

6.

7.

8.

Page 20

Control Panel Genset Control Panel Genset Battery Switch Work Lights Bentonite Mix Hopper and Wash Wand Pit Pump and Pit Pump Storage Location for Transport Chute Folding Walkway

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M-300DH Operator’s Manual

Overview

Overview Operation and Maintenance Manual TITLE: EDITION: Part Number:

M-300DH Operation & Safety Instruction Manual 2020 32MC10200

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: Model: Serial number: Year of manufacture:

Mud System M-300DH Found on identification plate Listed on serial number plate

Location of identification plate: See drawing on page 8.

Scope of Document This manual covers operation, safety and maintenance of the M-300DH. Topics related to 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.

Declaration of Conformity If required, the Declaration of Conformity is issued at consignment of the machine. A sample document is reproduced on page 83. The Declaration of Conformity is not required in most countries.

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

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M-300DH Operator’s Manual

Overview

Overview 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 the purpose of 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 30 feet (3 m x 9 m) to a level grade with a dozer. A larger area may be required if the M-300DH is going to remain on a tractor trailer.

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 to +43°C). For temperatures not included in this range, contact American Augers.

Refer to “Operating in Different Climates” on page 59 for additional information.

Relative humidity: 100% Maximum altitude: 6500 feet (1981 m) above sea level Atmospheric conditions should allow adequate visibility within the operating area.

The machine should not be operated when lightning is likely.

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 policy located page 3. 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. For complete terms of the warranty, see “Warranty Policy” 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 engine 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.

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M-300DH Operator’s Manual

Overview

Overview Instruction Manuals Manuals for components not manufactured by American Augers (e.g., the diesel engine) are included as attachments to this manual. For translations of any of the attachments to this Manual, contact the respective equipment manufacturers.

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Notes

M-300DH Operator’s Manual Notes

NOTES:

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M-300DH Operator’s Manual

Safety

Safety Information

Safety Safety Regulations and Practices This manual contains important information about the safety practices and safe operation of the M-300DH. 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 Engine Stop button on the genset to stop the engine. All workers should know how to stop the engine in an emergency 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. Wait until the utility company has been notified, the power turned off and the all-clear is given before moving.

Response to a Gas Strike If a gas line strike occurs, evacuate the area immediately. Turn off all engines. Remove any ignition sources. Do not smoke or do anything that could cause a spark. 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.

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

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M-300DH Operator’s Manual

Safety

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.

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, use 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)).

Basic Safety Guidelines 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.

1. Before using the M-300DH, 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 “Safety Alerts” section beginning on page 35.

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M-300DH Operator’s Manual

Safety

Safety Information 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 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. Safety and Health Regulations for Construction, OSHA Standard 1926, is relevant to operating the M-300DH. 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.

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 • Breathing 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: Genset Manuals.

• Securely connect all fluid lines before starting the machine.

• Check that all hydraulic fittings, bolts and nuts are tight.

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

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M-300DH Operator’s Manual

Safety

Safety Information • 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.

• Keep walkway surfaces clean and clear of obstructions.

• 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 jobsite.

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.

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 operating personnel stay in their prescribed areas.

• Ensure that all personnel 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.

Material Handling Precautions • Use appropriate lifting equipment for the size of the load.

• Discard and replace damaged or worn lifting equipment (e.g., slings, chains, ropes, etc.)

• Use a tether line to stabilize the load and minimize twisting and turning.

• Stand away from suspended loads. Do not approach the load until it has been lowered to hand-height.

• Use proper hand signals and know who has the responsibility for signaling.

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.

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M-300DH Operator’s Manual

Safety

Safety Information • 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

Trailer Reporting Safety Defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying the Product Safety Engineer at Charles Machine Works, Inc. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in any individual problems between you, your equipment dealer, or The Charles Machine Works, Inc. To contact NHTSA you may either call the Vehicle Safety Hotline toll-free at 1-888-327-4236 (TTY: 1800-424-9153); go to http://www.safercar.gov; or write to: Administrator NHTSA 1200 New Jersey Avenue, SEWashington, DC 20590

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 is 88 dB(A).

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

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M-300DH Operator’s Manual

Safety

Safety Information Welding Safety Workers can encounter hot surfaces, fire, noxious fumes and other hazards when welding.

These practices can help increase safety when welding: • Follow established welding safety practices and regulations • Assign another worker to “fire watch” • 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

Hazardous Chemicals 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.

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M-300DH Operator’s Manual

Safety

Safety Information Crystalline Silica (Quartz) Dust Precautions Inhalation hazard. Jobsite hazards could cause death or serious injury. Use correct equipment and work methods. Use and maintain proper safety equipment. To help avoid injury: • Use water spray or other means to control dust when cutting, drilling, or working materials such as concrete, sand, or rock containing quartz. The dust may contain silica.

• Workers exposed to dust must wear appropriate breathing protection, Silica dust may cause lung disease and is known to the State of California to cause cancer.

Follow OSHA or other guidelines for exposure to crystalline silica when trenching, sawing or drilling through material that might produce dust containing crystalline silica (quartz).

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.

Refueling Safety Explosion hazard. Ultra low sulfur diesel fuel poses a static ignition hazard. Death or serious injury from fire or explosion could result.

Ensure your fuel delivery system is properly bonded and grounded.

Diesel fuel with low sulfur content (ULSD) has an increased ability to store static charge. Static dissipating additives added to fuel by refiners may lose their effectiveness over time. Static charges can build up while the fuel is flowing. Static discharge when combustible vapors are present could cause explosion or fire.

There are several steps you can take to minimize the hazards this condition presents.

• Properly bond all components of your fuel delivery system (fuel supply tank, transfer pump and hose, nozzle, et al.).

• Equalize the static electric potential by connecting a wire from the fuel delivery system to the machine chassis.

• Ensure the fuel delivery system has an electrically conductive connection from the tank to earth ground.

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

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M-300DH Operator’s Manual

Safety

Safety Information • Consult your fuel or fuel system supplier to ensure the delivery system is in compliance with proper grounding and bonding practices.1

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.

1. Extracted from “ULSD...Not Your Same Old Diesel Fuel Anymore” Association of Equipment Manufacturers Best Practice Guidance Bulletin 6/13, revised 3 July 2013. Refer to this bulletin for more detailed information.

Available in several languages at http://www.aem.org/SRT/Technical/BestPracticeBulletins.

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M-300DH Operator’s Manual

Safety

Safety Information 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 A confined space has limited openings for entry and exit and poor ventilation which could contain or produce air contaminants2. 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.

Danger Zones -- Safe Distances Electrocution Hazard. Personnel are at risk of serious injury or death if an electric line is struck during drilling. If drilling within 10 feet of an electric line, 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: 10 feet (3 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.

2. http://www.cdc.gov/niosh/topics/confinedspace Refer to the Safety Awareness Program in this manual before attempting to operate this machine

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M-300DH Operator’s Manual

Safety

Safety Information 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.

Bonding Cable Dumpster Rod Loader Mud System

The location on the machine where bonding cables should be attached are marked with this sign

Drill Pipe

Drill Rig

Pit Bore Path

Typical Bonding Scheme

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M-300DH Operator’s Manual

Safety

Safety Alerts Refer to the M-300DH Parts Manual for the location of all safety alert signs.

High voltage hazard 8ED01480

High voltage hazard 8ED01480-3

Arc flash hazards exist. Follow proper procedures 8ED00009

Precautions to prevent machine from becoming electrically charged. 8NP41101

Electrical equipment should only be serviced by authorized personnel 8ED00001

Electrocution hazard exists if machine becomes electrically charged. 15GB7113

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

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M-300DH Operator’s Manual

Safety

Safety Alerts

Precautions about diesel exhaust. 8NP41209

Locate buried hazards before digging. 8NP71119

Electrical shock hazard 15GB7112

Use proper lockout and tagout before servicing 8NP41491

Use proper guarding over rotating parts 8NP41117

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Wear breathing protection.

2704952

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M-300DH Operator’s Manual

Safety

Safety Alerts

Wear hearing protection 700009

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

Page 37

Notes

M-300DH Operator’s Manual Notes

NOTES:

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M-300DH Operator’s Manual

Controls

Machine Controls

Controls Safety Switches NOTICE: Do not use an Engine Stop button for normal shutdown. The Engine Stop Button bypasses the engine cool-down and may cause genset damage.

Engine Stop

Engine Stop located on the genset control panel - Immediately powers down the genset engine. If your genset looks different, be sure to locate the engine stop button on your machine before beginning operations.

AC Controls Stop

AC Control Stop on M-300DH Control Panel - Stops the pumps and Derrick shaker powered by the genset but does not stop the genset engine. Note: Genset is still producing output voltage.

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

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M-300DH Operator’s Manual

Controls

Machine Controls Genset Control Panel

2

1

4

3 1.

2.

3.

4.

Engine Stop Main Breaker Genset Control Panel Ignition Switch

Consult Attachment 1: Genset Manuals for detailed information on the control panel and the specific start up and shut down procedures for the genset on your M-300DH.

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M-300DH Operator’s Manual

Controls

Machine Controls

Control 1. Engine Stop Push Button

Function • Turn off the genset and diesel engine immediately: push button • Bypasses cool down period • Not recommended for normal engine stop • Enable engine start: button must be pulled out

2. Main Breaker

• ON Position: Enable power to the Control Panel for the centrifugal pump motors, Derrick shaker and agitators. The genset engine must be running.

• OFF Position: Disable power to the Control Panel

3. Genset Control Panel

See Attachment 1: Genset Manuals for more information

4. Ignition Switch

• Stop: Turn the key straight up • Start/Run: Rotate key 90° to start engine. Release key and leave at 45° for the engine to remain running.

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

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M-300DH Operator’s Manual

Controls

Machine Controls M-300DH Main Control Panel

AC CONTROLS STOP

1 STOP

2

MIX/AGITATE STOP ON START

4

STOP

SHAKER ON START

6

5

STOP

OFFLOAD ON START

STOP

CONES ON START

STOP

PIT PUMP ON START

3

7 READ MANUAL

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M-300DH Operator’s Manual

Controls

Machine Controls Control Panel Functions

Control

Icon

1. AC Controls - Stop STOP

Function • Stop pumps and Derrick shaker powered by the genset: push button Note: does not turn off the genset engine.

2. Mix/Agitate

Switch controls tank agitation which mixes drilling fluid by combining water in the clean tank with bentonite from the mix hopper.

• Start: turn switch to the right and release when started • On: switch is in the center when component is running • Stop: turn switch to the left

3. Offload/Agitate

Switch controls offload tank agitation • Start: turn switch to the right and release when started • On: switch is in the center when component is running • Stop: turn switch to the left

4. Shaker

• Start: turn switch to the right and release when started • On: switch is in the center when component is running • Stop: turn switch to the left

5. Cones/Agitate

Switch controls dirty tank agitation which pumps drilling fluid through the desilter cone • Start: turn switch to the right and release when started • On: switch is in the center when component is running • Stop: turn switch to the left

6. Pit Pump

• Start: turn switch to the right and release when started • On: switch is in the center when component is running • Stop: turn switch to the left

7. Hour Meter

Displays number of accumulated hours that the M-300DH machine has been operating.

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

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M-300DH Operator’s Manual

Controls

Machine Controls Offload Pump Remote

2

START

1

STOP

Remote for the offload pump

Control

Function

1. Stop

• Stop offload pump: push button

2. Start

• Start offload pump: push button

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M-300DH Operator’s Manual

Controls

Machine Controls Battery Switch 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. Use proper lockout and tagout procedures before working on the machine.

NOTICE: • 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.

• DO NOT turn the battery switch off until the engine is off for at least 25 minutes.

The battery switch is located on the outside of the genset cabinet. 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.

• Before turning the battery switch OFF, the engine must be turned off and wait at least 25 minutes for the aftertreatment system to completely shutdown.

OFF

ON

Battery Switch

Lockout Tab ENGINE MUST BE OFF BEFORE DISCONNECTING

OFF

ON

Service Light Switch

BATTERY

Typical Location of Battery Switch

Service Lights The M-300DH provides for service lights which can be used when the battery is disconnected (i.e., the battery switch is OFF). The lighting circuit remains powered at all times. If the service lights are left on, they will drain the battery.

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

Page 45

Notes

M-300DH Operator’s Manual Notes

NOTES:

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M-300DH Operator’s Manual

Operations

Preparation

Operations Site Preparation and Set Up Scrape an area 10 feet x 30 feet (3 m x 9 m) to a level grade so that the M-300DH is located 50 to 75 feet (15.2 to 23 m) from the point where the mud hoses attach to the directional drill. If the M-300DH is going to remain on the tractor trailer, a larger level area may be required.

1. Position the stairs, folding walkway and end railing in operating position. Note: A bolt-on stair extension is included from the factory if the machine is going to remain on a trailer.

2. Raise the work light post and place the remote work lights where desired.

3. Connect all components on the drill site with a bonding cable and install a ground stake.

4. Position the shaker chute so larger particles separated from the drilling fluid are removed away from the machine.

Folding Walkway and End Railing

Work Lights

Shaker Chute

Stairs

Pit Pump A pit pump (7.5 Hp Pit Pump is included) is used to pump spent drilling fluid from the Returns Pit to the Drilling Fluid Cleaning System for recycling.

Crew The driller operates the M-300DH Drilling Fluid Cleaning System from the control panel mounted on the machine. The offload pump can be started and stopped using the remote control pendant.

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

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M-300DH Operator’s Manual

Operations

Operating the M-300DH 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 pit pump into the returns pit from a timber or pipe strong enough to support its weight. For lifting procedures, refer to Attachment 4: Manual for the Pit Pump. The pit pump must be in a vertical position and not laying on its side. Damage to the pit pump can occur if it is not operated in the vertical position. Clean out the returns pit periodically to ensure an unobstructed flow around the pit 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 cleaning efficiency of the M-300DH.

Entry Pit

Returns Pit

3 ft.

5-8 ft.

4 ft.

5 ft.

5 ft.

1 ft. x 1 ft. Trench 16 ft.

8 ft.

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M-300DH Operator’s Manual

Operations

Operating the M-300DH Hose Connections from Pit Pump to Inlet Port NOTICE: • 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 pit pump to the M-300DH for cleaning.

2. Fit the female cam and groove fitting onto the male cam and groove coupling on the pit pump.

3. Push the two levers on the sides of the hose end inward to lock the hose end to the pit pump.

4. Unroll the hose toward the M-300DH inlet port located near the pumps. Either inlet port can be used.

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 shaker on the mud system.

6. Ensure a cap is installed on the inlet port that is not being used.

Mud Inlet Port

Mud Inlet Port

Pit Pump

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

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M-300DH Operator’s Manual

Operations

Operating the M-300DH Discharge Hoses NOTICE: Liquid contents of these hoses is under pressure. Work on these hoses only when the pump is off.

Discharge hoses are provided with the M-300DH. Link together as many sections as necessary to cover the distance between the M-300DH and the directional drill or auxiliary mud pump.

For each pump, the suction valve must be open and at least one valve on the discharge side must be open so as not to damage the system when the M-300DH is started.

Before Operating the Machine The M-300DH has one engine: the genset engine. The genset engine runs a generator which provides AC power for the centrifugal pumps, Derrick shaker, and lights.

A factory instruction manual for the generator and engine is supplied with the M-300DH (Attachment 1).

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.

A factory instruction manual for the Derrick shaker is supplied with the M-300DH (Attachment 3). The following instructions cover general starting and stopping procedures. Consult the factory manuals for detailed procedures, maintenance and repair instructions.

Open all suction and discharge butterfly valves on centrifugal pumps.

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M-300DH Operator’s Manual

Operations

Operating the M-300DH Starting the M-300DH 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 genset is supplied with the M-300DH. 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. Verify that the ground stake is installed properly.

2. Check the oil level and coolant level in the engine and the diesel fuel level. Start each day with a full tank of ULSD (ultra low sulfur 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.

3. Check the DEF fluid level. Do not let the DEF tank run dry.

4. 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.

5. Unplug the block heater, if connected.

6. Disconnect all battery chargers.

7. Pull OUT the engine stop buttons on the Main Control Panel and in the Genset Control Panel. The engine will not start if the engine stop button is pushed in.

8. Switch all controls OFF or put them in neutral.

9. Turn the Battery switch to the ON position.

10. Fully open all fuel supply valves.

11. Follow starting procedures in Attachment 1: Genset Manuals.

NOTICE: • If the batteries are dead, then the batteries should be charged. Do not jump start the engine.

12. After the genset engine is running and warmed up, turn on the generator. This enables all switches on the Control Panel.

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

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M-300DH Operator’s Manual

Operations

Operating the M-300DH Preparing the Drilling Fluid Prior to starting drilling operations, fill the tanks with clean water and mix in bentonite to prepare the drilling fluid. Follow procedures in “Starting the M-300DH” section beginning on page 51 and have the genset running.

Filling Tanks 1. Connect a hose to a hydrant or water truck or place the pit pump in a water source such as a lake or river and connect a hose to it.

2. Connect the opposite end of the hose to one of the inlet ports (see drawing below).

3. Cap the unused side of the inlet port piping.

4. Turn the Shaker control on the Main Control Panel to the START position. Release when start is confirmed.

5. Turn on your pit pump or start the flow of water from the hydrant or water truck. Water will be pumped into the inlet port and routed over the shaker, through the screens and into the tank. Alternatively, if you are sure the water supply is clean, you may run a hose directly into the tank.

Valve Must be Open

Shaker

32MC1001A-Figure 2

Water Inlet Port

Mud Inlet Port Water Inlet Port

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M-300DH Operator’s Manual

Operations

Operating the M-300DH Adding Bentonite and Agitation Open valves 1, 3 and 4 (see drawing below). Valve 2 may be opened or closed, depending on the desired results. Opening Valve 2 allows some fluid from the clean tank to be pumped back to the first cut tank. This will improve dirty tank agitation, but could result in some unyielded bentonite being lost over the shaker (if the cone supply pump is also running).

Start the Mix/Agitation pump by turning the Mix/Agit Start control 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.

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 the drilling fluid continuously so the bentonite does not settle out. Ideal viscosity varies according to drilling conditions. Test kits and additional information are available from your drilling fluid supplier.

30mc5225A-mixbentonite Mix Hopper

1 2 3

4

Clean Tank

First Cut Tank

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

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M-300DH Operator’s Manual

Operations

Operating the M-300DH Ongoing Drilling Fluid Supply Adjust the manual jack screw AWD on the front of the shaker 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.

• Rotate the manual jack screw to raise or lower the shaker angle.

Manual Jack Screw

After you have established a return flow of used drilling fluid from the rig through the returns pit, use the M-300DH to clean the spent drilling fluid and provide a “clean” fluid supply. Periodically you will need to add more bentonite and clean water as needed for your drilling conditions.

Check the sand content using a sand kit. Maintain sand content as low as possible. Do not exceed 1/2% sand.

If the sand content is 1/2% or higher, check the screens on the Derrick shaker and replace or repair if necessary. Allow the clean tank to overflow over the top of the divider into the first cut tank and run the drilling fluid through the desilting cones again. Consider using finer mesh screens.

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M-300DH Operator’s Manual

Operations

Operating the M-300DH Pumping Fluid to a Directional Drill or Mud Pump Connect the directional drill or mud pump to one of the offload ports. Close the unused side of the offload port piping. Open all other valves in the drawing below.

Start the Offload/Agit pump by turning the Offload/Agit Start control on the Control Panel to “Start” and release when start is confirmed.

30mc5225A-offload Valves Offload Ports

Clean Tank

First Cut Tank

Fluid Pumping Checklist Review the following checklist before pumping fluid to the directional drill: • Have a full tank of drilling fluid with appropriate viscosity for your application agitating in the clean tank.

• Check that the connections on each section of mud hose running from the offload port on the M300DH to the directional drill are tightened securely.

• Check the oil and coolant levels in the genset engine. The fuel tank should be full before starting work each day.

• Run a hose from the returns pit to the M-300DH 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.

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

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M-300DH Operator’s Manual

Operations

Operating the M-300DH 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 M-300DH to clean and recycle the material.

1. Be sure the genset engine is running and the generator is ON. 2. The pit pump should be suspended in the returns pit. The hose should be securely connected from the pit pump to the inlet port. Open valve for the inlet port, if present.

3. On the Control Panel, ensure the AC Controls Stop button is not engaged.

4. Turn the Shaker control to Start. Release when start is confirmed.

5. Turn on your Pit Pump.

• This will begin a return flow of drilling fluid to the drilling fluid cleaning system. It is typically 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.

6. Open the butterfly valve on the cone supply pump. Turn the Cones control to Start. Release when start is confirmed. This starts the pump which brings drilling fluid from the First Cut Tank.

• The suction port of the centrifugal pump picks up the fluid and pumps it to the shaker topped by the cone manifold. The fluid is pumped into the cone and cleaned to 15 to 25 micron. The solids fall down out of the narrow end of the cone onto the shaker screens. The screens are typically 100 mesh or finer. Cleaned fluid is forced upward into the manifold and routed to the Clean Tank.

• Solids shaken off the shaker screens fall on to the chute and either to the ground or into a container or bin. They should be properly disposed of per local regulations.

• The clean tank also has a series of agitation jets to keep the solids from settling out of the fluid. The fluid is ready to be pumped to the mix hopper where bentonite is added. This prepared drilling fluid is held in the clean tank.

Fluid Passes Through Shaker Screen 30MC5222A-drw-5226

First Cut Tank

Solids Fall to Shaker Screen Fluid Passes Through Cones

Cleaned Fluid to Clean Tank Mud Inlet Ports

First Cut Tank

Clean Tank

30MC5222A-drw-5224

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M-300DH Operator’s Manual

Operations

Operating the M-300DH Stopping the Genset Engine NOTICE: Do not use an Engine Stop Button for normal shutdown. The Engine Stop Button bypasses the engine cool down and may cause engine damage.

Follow instructions in Attachment 1: Genset Manual for normal shutdown procedures. If you do not have the manufacturer’s procedures, follow the instructions below to ensure proper engine cool down before turning power off3.

1. Turn off all shakers, centrifugal pumps, pit pump, and any auxiliary electrical tools that are running off the genset. All these operations can be done at the Control Console.

2. Go to the genset. Disconnect power to the machine. Turn off breaker.

3. If not equipped with a Cool Down Timer, then run the engine for at least 2 minutes to cool down.

4. Turn the ignition switch to the OFF position.

5. If required to disconnect the battery, wait at least 25 minutes after engine stop before turning battery switch off.

3. Some newer engines stay running for up to 5 minutes after the key is turned to the OFF position before they turn off. This enforced cool down is normal.

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

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M-300DH Operator’s Manual

Operations

End of Job Dismantling the M-300DH

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 NOTICE: Tanks must be empty before moving or lifting the machine. Drilling fluid is heavy. Damage 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 M-300DH. The mud tanks filled with drilling fluid could add as much as 36,000 pounds (16,329 kg) to the weight of the machine. This could make the tractor trailer overweight.

2. Turn off the genset and genset engine.

3. Disconnect the pit pump from the plug under the Control Panel (if you have been using). Place the pit pump in the storage location (shown on page 19). For proper lifting procedures, refer to Attachment 4: Manual for the Pit Pump. Secure the pit pump with the retainer pin and chain.

4. Switch Battery Switch to Off and perform a Lockout / Tagout before entering the tank.

5. Clean residual drilling mud out of the tanks. Enter the tanks through the cleanout ports on the side of the unit.

6. Disconnect and clean out hoses.

7. Dispose of drilling mud following local regulations.

8. Secure the shaker chute.

9. Lower and secure work light post. DO NOT drive with the work light post extended.

10. Raise the discharge end walkway. Secure in place with pins.

11. Remove the bolt on stair extension, if using. Store and secure for transport.

12. Rotate the side ladder into transport position. Secure in place with pins.

13. Remove ground stake.

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M-300DH Operator’s 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 Attachment 1: Genset Manuals for operating the genset 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 Attachment 1: Genset Manuals.

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 genset 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 fluid should be thoroughly warmed before operating the mud system.

• Thoroughly clean the system and drain water and drilling fluid out of the pumps. If desired, after draining, the pumps can be filled with antifreeze when cold temperatures are expected.

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

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Notes

M-300DH Operator’s Manual Notes

NOTES:

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M-300DH Operator’s Manual

Storage and Transportation

Machine Storage and Transport

Storage and Transportation Minimum Storage Space Required Consult the “Specifications” on page 77 for the dimensions and weight of the M-300DH to establish storage space requirements. The surface must be firm enough to support the weight of the machine and prevent sinking.

Preparations for Storage For short-term storage, i.e., periods less than 30 days: 1. Clean mud and other foreign materials off the machine.

2. Drain water or bentonite slurry out of the centrifugal pumps and hoses. Thoroughly flush the machine.

Make sure there is no water or drilling fluid in the drilling fluid course. If you expect freezing temperatures, pump antifreeze through the system.

3. Clean the machine as described in “Cleaning” on page 65.

4. Eliminate sediment and water from the diesel fuel tank.

5. Fill the fuel tank to prevent condensation and rust.

6. Position the machine on a level surface.

7. Follow procedures to turn off the genset and its engine.

8. Remove all ignition keys and store in a safe place.

9. Turn the battery switch to the OFF position.

10. Turn off service lights. The lighting circuit is powered as all times. If service lights are left on, they will drain the battery.

11. Lubricate grease points on the machine.

For periods longer than 30 days, follow the procedures for short-term storage plus these additional steps: • Place the machine in a covered and dry site.

• Follow the instructions for storing the genset engine.

• Disconnect batteries and store them where the temperature will remain between 32°F and 105°F (0°C to 41°C).

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Page 61

Storage and Transportation

M-300DH Operator’s Manual Machine Storage and Transport

Winterizing Any time freezing temperatures are expected, the machine must be winterized to prevent damage to the pumps. Close all valves in the pump area of the machine (3 inlet valves (4 inch) and 5 control valves (3 inch)). Pull the drain plug from each pump and allow fluid to drain out of the pumps.

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M-300DH Operator’s Manual

Storage and Transportation

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.

Tanks may qualify as confined spaces. Workers could encounter hazardous conditions resulting in serious injury or death. Follow appropriate confined space entry regulations.

NOTICE: 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.

1. Clean the machine. Pump all drilling fluid and clean water out of the tanks. All tanks must be empty before transporting the machine. The mud tanks filled with drilling fluid could add as much as 36,000 pounds (16,329 kg) to the weight of the trailer. This means the rig will be overweight. Damage to the trailer and rear axle areas could result.

2. Turn off the genset and genset engine.

3. Lockout / Tagout generator set before entering the tanks. Clean residual drilling mud out of the tanks.

You may enter the tanks through the cleanout ports on the side of the unit.

4. Disconnect and clean out hoses.

5. Dispose of drilling mud following local regulations. Secure the shaker chute.

6. Lower work light post. DO NOT drive with the work light post extended.

7. Disconnect the pit pump from the plug under the Control Panel (if you have been using). Place the pit pump in the storage location (shown on page 19). For proper lifting procedures, refer to Attachment 4: Manual for the Pit Pump. Secure the pit pump with the retainer pin and chain.

8. Switch battery switch to OFF. 9. Raise the discharge end walkway. Secure in place with pins.

10. Remove the bolt on stair extension, if using. Store and secure for transport.

11. Rotate the side ladder into transport position. Secure in place with pins.

12. Remove the ground stake.

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.

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

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M-300DH Operator’s Manual

Storage and Transportation

Machine Storage and Transport 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.

• Ensure load is stable before lifting.

• All personnel must remain a safe distance away while the machine is being lifted.

The fork pockets can be used to lift the machine with a fork lift.

Fork Pockets

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M-300DH Operator’s Manual

Maintenance

General Maintenance

Maintenance If personal protective equipment is not used, serious injury or death of personnel can occur. Always wear protective eye wear. During maintenance all personnel on the jobsite should use proper protective equipment according to their duties.

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. Use proper lockout and tagout procedures before working on the machine.

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 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 NOTICE: Water can damage sensitive electronic components. Do not spray water against electronic components and control panels.

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

Page 65

M-300DH Operator’s Manual

Maintenance

General Maintenance General Cleaning Clean all the marking plates as well as all lighting devices. Do not use acid or abrasive solutions. Before pressure washing the M-300DH, ensure all components on the machine have cooled down. Do not direct the water spray towards the following components: • Muffler • Air filter • Batteries • Electric components, connectors and control panels • Hydraulic filters, hydraulic vents or breathers • Caps and open tanks

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.

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M-300DH Operator’s Manual

Maintenance

General Maintenance Welding NOTICE: BEFORE WELDING • Turn off the engine • Disconnect both the positive and negative battery cables from the battery.

• Disconnect all electrical control unit connectors.

• Clamp the ground cable for the welder as close as possible (no more than 2 feet (0.61 meters)) to the part being welded.

• Do not connect the ground clamp of the welder to any of the sensors, wiring harnesses, electrical control units or the components.

• Do not attempt direct welding of any electrical components. Remove or protect electrical wiring and components from welding debris, splatter and heat.

• Do not weld near flammable liquids or the fuel, hydraulic and other tanks.

• 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.

Tier 4 Diesel Engine Tier 4 diesel engines are designed to meet current regulations by minimizing gaseous and particulate (soot) emissions. Attachment 1: Genset Manuals and other information from your engine or genset manufacturer supersede the information below. Be aware of these and other requirements. Tier 4 final engines: • Use ULSD (ultra low sulfur diesel) fuel. Note that the use of other fuels may damage the engine and may void the manufacturer’s warranty.

• Require specific engine oil, refer to Attachment 1: Genset Manuals.

• Contain a Selective Catalyst Reduction (SCR) system which reduces NOx into nitrogen and water. The SCR system requires Diesel Exhaust Fluid (DEF) and periodic exhaust system cleaning.

The operator can monitor the status of the aftertreatment system using the display screen on the appropriate engine control panel. Indicator lamps illuminate to show system status and alert the operator when action is needed.

IMPORTANT: • This Tier 4 Final engine does not contain a Diesel Particulate Filter (DPF).

• To maintain the health of the engine’s aftertreatment system, keep the DEF tank filled with high quality DEF.

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

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M-300DH Operator’s Manual

Maintenance

General Maintenance Engine and Genset Maintenance Engine and genset maintenance items are outside the scope of this manual. Consult Attachment 1: Genset Manuals for recommended fluids (fuel, 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 contact the factory for advice on the compatibility of a new fluid with the one in service. See “Fluid Capacities” on page 78.

Approved Replacement Fluids (Ambient temperature 0°F to 110°F [-18°C to 44°C])

Grease

Gadus S3 V460D 2

AA Specification 301

Shaker Electric Motors

Kluber Staburags NBU 8 EP

AA Specification 305

Centrifugal Pump Bearings

Gadus S2 V220 2

AA Specification 306

Engine Oil

Rotella T 15W-40 CK-4 Triple Protection

AA Specification 401

Antifreeze

Rotella Extended Life Coolant (ELC)

AA Specification 604

Centrifugal Pump Motors

Gadus S3 T100 2

AA Specification 307

Water Course Antifreeze

Pitt-Penn RV Antifreeze

AA Specification 603

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M-300DH Operator’s Manual

Maintenance

Scheduled Maintenance Maintenance Schedule

M-300DH Maintenance Schedule Function

Per specs

Cycle Engine Stop Buttons Genset: Check Fuel Level Genset: Check Radiator Coolant Level Genset: Check Engine Oil Level Genset: Check DEF Level Genset: Check Air Filter Service Indicator Check Valves, Hoses and Fittings Inspect Shaker Screens Lubricate Angle Adjustment Jacks (Shakers)

10* hours X X,E X,E X,E X,E X,E X X X

50* hours

250* hours

500* hours

2600* hours

X

Inspect Shaker Vibration Isolators

X

Check Battery Water Level

X

Inspect Motor Couplers on Pumps

X

Lubricate Shaker Electric Motors

X

Lubricate Centrifugal Pump Bearings Lubricate Centrifugal Pump Electric Motors

Yearly

X

NOTES: E, See Attachment 1: Genset Manuals for methods and materials. * Do not exceed the indicated number of hours without performing the required maintenance

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M-300DH Operator’s Manual

Maintenance

Scheduled Maintenance 10 Hour Inspection and Maintenance Perform the 10 hour inspection and maintenance items in the Maintenance Schedule.

Cycle Engine Stop (Disable) Buttons Verify that all Engine Stop buttons are working properly. Perform an operating check of all controls.

Make necessary repairs before starting operations.

Engine: Check Fuel Level Explosion hazard. Ultra low sulfur diesel fuel poses a static ignition hazard. Death or serious injury from fire or explosion could result.

Ensure your fuel delivery system is properly bonded and grounded.

Fill the fuel tank at the end of each shift. 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 Manuals.

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.

NOTICE: 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 NOTICE: • Before changing engine crankcase lube oil, wait for the engine to cool.

• Refer to Attachment 1: Genset Manuals 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 Manuals.

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M-300DH Operator’s Manual

Maintenance

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 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.

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

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M-300DH Operator’s Manual

Maintenance

Scheduled Maintenance Lubricate Grease Fittings NOTICE: Grease fittings should be kept clean so that contamination is not forced inside. Replace damaged fittings.

Grease points must be lubricated per the maintenance schedule. 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.

Shaker Angle Adjustment Bolts Lubricate the shaker angle adjustment bolts before any angle adjustment is performed.

Grease Point

Grease Point

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M-300DH Operator’s Manual

Maintenance

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.

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

Page 73

M-300DH Operator’s Manual

Maintenance

Scheduled Maintenance 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.

NOTICE: • 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.

NOTICE: • If the batteries are dead, then the batteries should be charged. Do not jump start the engine.

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.

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M-300DH Operator’s 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 Perform 10 hour, 50 hour,250 hour and 500 hour inspection and maintenance items, plus: Lubricate shaker electric motors.

Per Specifications Lubricate Centrifugal Pump Electric Motors Follow maintenance schedule on the motor nameplate.

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Page 75

Notes

M-300DH Operator’s Manual Notes

NOTES:

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M-300DH Operator’s Manual

Specifications

Specifications

Specifications Machine Dimensions / Weight Length Width Height Estimated Weight*

Without Trailer 20.3 feet (6.2 m) 8 feet (2.44 m) 10.2 feet (3.1 m) 22,000 pounds (9,980 kg)

With Trailer 28.3 feet (8.6 m) 8.5 feet (2.59 m) 13 feet (3.96 m) 28,600 pounds (12,973 kg)

* Weights shown include the American Augers’ supplied genset.

Generator Set Generator (60Hz): or Generator (50Hz): Fuel Capacity: Fuel Consumption:

Stateline Tier 4 Final / 75 kW Prime Power / 480 V / 60 Hz Stateline Tier 4 Final / 58 kW Prime Power / 400 V / 50 Hz 88 U.S. Gallons (333 liters) 5 U.S. Gallons (19 L) /hour @ 75% load

Generator specifications shown for American Augers’ supplied genset.

Controls Remote Controls: Remote Controls:

Pendant for Offload (Supercharge) Pump Start/Stop Pendant for Pit Pump Start/Stop

Pump, Mixing/Agitation Pump Design: Estimated Output

Centrifugal, 30 Hp (22.4 kw) electric motor 600 gpm at 38 psi (2271 Lpm at 2.6 bar)

Pump, Cone Supply Pump Design: Estimated Output

Centrifugal, 30 Hp (22.4 kw) electric motor 600 gpm at 38 psi (2271 Lpm at 2.6 bar)

Pump, Offload/Agitation Pump Design: Estimated Output

Centrifugal, 25 Hp (18.6 kw) electric motor 500 gpm at 38 psi (1890 Lpm at 2.6 bar)

Accessories Two, 50 foot (15.5 m) hoses with cam and groove fittings Four, DC LED work lights 120 Volt AC courtesy outlet on genset, if equipped

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

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Specifications

M-300DH Operator’s Manual Specifications

Fluid Capacities When adding or replacing fluids, use the fluid shown in “Approved Replacement Fluids” on page 68.

Engine Oil: 9 quarts (8.5 liters) Antifreeze: 18 quarts (17.0 liters)

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Refer to the Safety Awareness Program in this manual before attempting to operate this machine

M-300DH Operator’s Manual

Appendix

Appendix

Appendix The appendix contains information that the operator of the M-300DH will find useful to have available for reference during operation of the M-300DH. 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.

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

Page 79

Notes

M-300DH Operator’s Manual Notes

NOTES:

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Refer to the Safety Awareness Program in this manual before attempting to operate this machine

M-300DH Operator’s Manual

Appendix A

Appendix A: (List of Attachments)

Appendix A Attachment 1: Genset Manuals Attachment 2: Manual for MCM 250 Series Pumps Attachment 3: Manual for Derrick Shakers Attachment 4: Manual for Pit Pump Attachment 5: Manual for the trailer (if option is installed)

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

Page 81

Notes

M-300DH Operator’s Manual Notes

NOTES:

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Refer to the Safety Awareness Program in this manual before attempting to operate this machine

M-300DH Operator’s Manual

Declaration of Conformity

Sample Declaration of Conformity

Refer to the Safety Awareness Program in this manual before attempting to operate this machine

Page 83

American Augers, Inc. 135 US Route 42 P.O. Box 814 West Salem, Ohio 44287 www.americanaugers.com TEL: 419-869-7107 • 800-324-4930 (USA) FAX: 419-869-7425

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 32MC10200 Released January 2020 Revision 00