catalogue equipment

8/2/2019 Catalogue Equipment

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WARNING

Unsafe use of this equipment could result in serious injury or death. This manual con-tains important instructions for the safe operation and recommended maintenance of

your P-750/G2 mud pump. All who operate this mud pump must carefully read andunderstand this manual before starting the machine. In particular read the safety infor-mation. Keep this manual available both as a reminder for your experienced operatorand as a training aid for your new staff. Replacement manuals are available by calling

American Augers.

P-750/G2 OPERATION &

SAFETY INSTRUCTION

MANUAL


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Forward P-750/G2 Operators Manual

Page 2 Refer to the Safety Awareness Program in this manual before attempting to operate this machine.

Forward

Introduction

INTRODUCTION

Since 1970, American Augers has been adevoted manufacturer of trenchless technologyequipment; customers worldwide will recognize theP-750/G2, as the premier piece of drill fluid pumpingequipment that maintains rugged, unsurpassedpower, and industry leading designs. AmericanAugers always provides its equipment with worldwidetechnical support/parts service, and AmericanAugers encourages customers to contact the factorywith any operational or assistance needs.

Every effort has been made to adequatelycover the operation of the P-750/G2. Specifications

are subject to change without notice or obligation.American Augers will continue to update itsproduct manuals with current operationalinformation, but some units maybe retrofittedindependently by the customer or by themanufacturer per a customer request at thefactory, or while in service, and the informationherein may not reflect those changes.The materials may not be reproduced in whole orin part without the express written permission ofAmerican Augers Inc.

Part Number: 75MP10000

Released April 2008 Revision 00


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Refer to the Safety Awareness Program in this manual before attempting to operate this machine. Page 3

P-750/G2 Operators Manual Forward

Location of Machine Serial Number Plate

Machine Serial Number

___________________________________

Machine Serial Number Locations


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Refer to the Safety Awareness Program in this manual before attempting to operate this machine.Page 4

Location of Engine Serial Number Plate

Engine Serial Number

___________________________________

Engine Serial Number Location


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Location of Pump Serial Number Plate

Pump Serial Number

___________________________________

Pump Serial Number Location


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Eaton Transmission Serial Number

______________________

Eaton Transmission Serial Number Location

Location of Eaton Transmission Serial Number Plate


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Revision Record

Revision Number Description of Change Date00 Initial Release Serial Numbers P750010308 through P750020308 4/28/2008

Revision to Manual


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Revision Record

Revision Number Description of Change Date

Revision to Manual, Continued


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NOTICE

Before using this manual, familiarize yourself with the

Description Of Components (page 15).

NOTICE

Mud Pumps have a number of hazards unique

to their operation. A series of safety alert

decals, developed in conjunction with other

manufacturers, are provided on American

Augers mud pumps to alert the operator to

hazards of the machines. The Safety Section

explains the hazard alert signs.

American Augers encourages use

of the One-Call system.

PERFORMANCE

Actual machine, accessory, and component performance, capacity, and results can be ad-

versely 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 previouly listed.


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P-750/G2 Operators Manual Table of Contents

Contents

Forward............................................................................................2

Introduction ............................................................................................................. 2

Machine Serial Number Locations ........................................................................... 3

Engine Serial Number Location ............................................................................... 4

Pump Serial Number Location ................................................................................ 5

Eaton Transmission Serial Number Location ...........................................................6

Revision Record ..................................................................................................... 7

To The Owner .......................................................................................................... 9

Overview .........................................................................................15

P-750/G2 Mud Pump Components ....................................................................... 15

General Information ......................................................................16

Operation and Maintenance Manual ...................................................................... 16

Operator ............................................................................................................... 16

Ownership of Information ....................................................................................... 16

Manufacturer Identification Data ............................................................................ 16

Machine Identification Data ................................................................................... 16

Qualification of Personnel ..................................................................................... 16

Declaration of EC Conformity ................................................................................ 17

Use of Personal Protective Equipment ..................................................................17

Legal Disclaimer ................................................................................................... 17

Purpose of Machine .............................................................................................. 17

Ground Leveling .................................................................................................... 17

Ambient Conditions .............................................................................................. 17

Features of Transport ............................................................................................ 17

Machine Handling Procedures .............................................................................. 18

Warranty ............................................................................................................... 18

Request for Service/Support ................................................................................. 18

Warranty and Service for Diesel Engine ................................................................18

Instruction Manual.................................................................................................. 18

Safety Information .........................................................................19

Jobsite Safety ....................................................................................................... 19

Safety Plan and Checklist ..................................................................................... 19


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Table of Contents P-750/G2 Operators Manual


Responsible Personnel ......................................................................................... 20

Competent Person ................................................................................................ 20

Operators ............................................................................................................. 20

Support ................................................................................................................. 20Hazards ................................................................................................................ 20

Underground ......................................................................................................... 21

Surface ................................................................................................................. 21

Overhead .............................................................................................................. 22

Verify Utility Locates .............................................................................................. 22

Traffic Control (Pedestrian and Vehicle) ................................................................ 22

Safety Practices, Safety Equipment ...................................................................... 22

Drilling Precautions ............................................................................................... 23

Reaming and Installation Precautions .................................................................... 23

Response to Events .............................................................................................. 23

Electrical Strike ..................................................................................................... 24

Gas Strike ............................................................................................................. 24

Fiber Optic Strike .................................................................................................. 24

Communications Line Strike ................................................................................. 24

Sanitary/Storm Sewer and Water Strike ................................................................. 24

Conclusion ............................................................................................................ 24

References ........................................................................................................... 25OperatorGeneral Precautions ............................................................................ 25

Starting and Stopping Precautions ........................................................................ 25

Operating Precautions .......................................................................................... 25

Maintenance Precautions ...................................................................................... 26

Fuel Handling Precautions .................................................................................... 26

Safety Awareness Program ................................................................................... 26

Understand Signal Words ..................................................................................... 26

Safety Alerts....................................................................................28Safety Alerts .......................................................................................................... 28


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Table of Contents P-750/G2 Operators Manual


Maintenance...................................................................................51

Maintenance ......................................................................................................... 51

Preventative Maintenance ..................................................................................... 51

Qualification of the Technican ................................................................................ 51

Frequency of Inspections ....................................................................................... 51

Maintenance Schedule of the P-750/G2 Mud Pump ...............................................52

10 Hour Inspection and Maintenance...........................................53

10 Hour Inspection and Maintenance ..................................................................... 53

50 Hour Inspection and Maintenance ...........................................57

50 Hour Inspection and Maintenance ..................................................................... 57

500 Hour Inspection and Maintenance.........................................58

500 Hour Inspection and Maintenance ................................................................... 58

1000 Hour Inspection and Maintenance.......................................59

1000 Hour Inspection and Maintenance ................................................................. 59

Specifications .................................................................................61

Machine Dimensions / Weight ............................................................................... 61Power Train .......................................................................................................... 61

Pump .................................................................................................................... 61

Controls ................................................................................................................ 61

Accessories.......................................................................................................... 61

Limited Warranty............................................................................63


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P-750/G2 Operators Manual Overview

OverviewOverview

1. Skid Assembly2. Fuel Tank3. Engine / Transmission Assembly4. Mud Pump Assembly5. Overpressure Exhaust

6. Main Junction Box, Hidden in this view7. Cable Holder8. Operators Station9. Chainbox10. Discharge Dampener11. Suction Dampener12. Suction Piping13. Battery Box14. Discharge Connection

P-750/G2 Mud Pump Components


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Overview P-750/G2 Operators Manual


General Information

Operation and Maintenance Manual

TITLE: Operation & Safety Instruction Manual, P-750/G2 Mud PumpEDITION: 2008

Part number: 75MP10000

Operator

The operator must read and follow the manual.

Ownership of Information

American Augers, Inc. reserves all rights to the information in this manual.The manual cannot be reproduced or photocopied in part or in whole without previous written authorization

from American Augers, Inc. The use of the manual is restricted to the customer who received it and only for

purposes of installation, use and maintenance of the relevant machine. American Augers declares that theinformation contained in this manual fits the technical and safety specifications of the machine. AmericanAugers disclaims responsibility for direct or indirect damages to persons or property caused when the manualor the machine are used in violation of the information contained herein.

The information contained in the manual refers only to the machine mentioned in Paragraph, MACHINEIDENTIFICATION DATA. American Augers reserves the right to modify or improve the manual and the ma-chines without notice.

Manufacturer Identification Data

AMERICAN AUGERS, INC.135 U.S. Rt. 42, P.O. Box 814

West Salem, Ohio 44287 USATel. 419-869-7107 Fax 419-869-7425

Web Site: www.americanaugers.com

Machine Identification Data

Type: Mud PumpModel: P-750/G2Serial number: Found on identification plateYear of manufacture: Incorporated as part of the serial number.

Location of identification plates: See illustrations on pages 3 through 6.

Qualification of Personnel

If skilled personnel operate the machine according to the advice and instructions supplied in the manual,the machine will operate safely. All the operations of transport, use and maintenance must be carried out onlyby skilled and authorized personnel, after studying and understanding the instructions supplied by the manu-al.
http://www.americanaugers.com/


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P-750/G2 Operators Manual Overview


General Information

Declaration of EC Conformity

If required, the declaration of EC conformity is issued at consignment of the machine together with themanual. EC conformity is not required in North America.

NOTICE

American Augers disclaims any responsibility for damages to persons or property caused by

the operation of the machine by untrained personnel.

Use of Personal Protective Equipment

WARNING

If personal protective equipment is not used, serious injury or death of personnel can occur.

The operator and all other personnel on the worksite should use proper protective equipment according totheir duties.

Legal Disclaimer

NOTICE

American Augers disclaims any responsibility for damages to persons or property caused by

the operation of the machine in violation of the instructions contained in this manual.

Purpose of Machine

The machine was designed for the purpose of pumping drilling fluid to directional drills.

Ground Leveling

With the P-750/G2, it is very important to make the pad the unit is to set on as level as possible. Prefer-ablly with a dozer, scrape an area 10 foot wide (3 m) by 26 foot long (8m) to a level grade.

Ambient Conditions

Temperature limits: 5F and 105F [-15C and +40C] (with oils and coolants recommended). For temper-ature lower than 32F [0C] Refer to: OPERATION UNDER AMBIENT TEMPERATURES BETWEEN -40FAND +5F [-40C AND -15C]. For temperatures not included in this range, contact American Augers.

Relative humidity : 100%Maximum altitude: 6500 ft [2000 m] above sea levelAtmospheric conditions should allow adequate visibility within the operating area.The machine should not be operated when lightning is likely.

Features of Transport

The machine should be transported by a truck tractor, in accordance with local transportation laws.


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Overview P-750/G2 Operators Manual


Machine Handling ProceduresUse

For safety reasons, it is recommended only one person operates the controls. Other trained personnel

may work near the pump if they are wearing personal protective equipment.

Maintenance

During maintenance, with the machine running, be especially cautious to ensure the safety of all person-ell.

WarrantyGeneral Conditions

Warranty is subject to the conditions specified in the warranty certificate. The warranty certificate is on

the inside of the last page of this manual.

Limitations of Warranty

The warranty for all the components purchased and not produced by American Augers directly are subjectto the original warranty of suppliers/manufacturers and therefore defects in materials or workmanship are con-sidered valid only if they are recognized by the same suppliers/manufacturers. In particular the warranty onthe diesel engine is supplied by the diesel engine dealer in the area where the drill is sold.

Request for Service/Support

For service support in or out of the warranty period, contact American Augers.Provide model number, serial number of the machine, and working hours. The number of working hours isshown on the hour meter of the Catepillar engine control panel.

Warranty and Service for Diesel Engine

The local diesel engine dealer services the diesel engine. The diesel engine warranty is valid worldwide.Only diesel engine dealers are authorized to perform repairs under warranty and supply service and spareparts.

Instruction Manual

This manual is part of the safety system of the equipment. Use it during training of all personnel who willpariticipate in the operation of the equipment. Ensure that a copy is always available on the jobsite and thatthe operators have read it and have access to it. Carefully follow the instructions, advice, and procedurescontained in this manual.

General Information


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P-750/G2 Operators Manual Safety

Safety

Jobsite Safety

The following is only an outline of good safety practices. It is the responsibility of each person working

with mud cleaning and pumping systems to learn and follow all local, state and federal safety regulations. Alloperators must read and understand the Operation and Safety Instruction Manual before starting the mudpump. The meaning of the safety alert signs is explained in the Operation and Safety Instruction Manual.

Safety Plan and Checklist

Each company should have a safety manual that includes the following:

Operations and maintenance procedures that comply with applicable regulations; Emergency procedures for utility strikes; Emergency procedures for other high risk activities; Detailed emergency evacuation plan;

Employee training program; Records of incidents, accidents and training.

As with any operation, it is important to work safely and have procedures and contingency plans in placeto handle emergencies. Safety and communication procedures should be well established and all personnelon site should be instructed on protocol. The following is a list of issues that should be addressed when de-signing a safety program and contingency plans:

Safety starts at the top; Identify the chain of command; Clearly outline corporate safety philosophy and develop safe work procedures; Require participation by all salary and wage personnel; State the Personal Protective Equipment policy;

Every employee has the right and obligation to refuse dangerous work; Orientation of new employees is essential; A Competent Person and trained first aid personnel are required on every site; First aid equipment and fire extinguishers must be available at an identified location in every commer-

cial vehicle and on site; Provide location and access to local emergency facilities;

Communicate effectively.

The following is a list of issues that should be addressed when developing safety procedures for specificactivities:

Identify and define the activity; Identify related safety hazards;

Develop written step-by-step procedure for performing the activity; Eliminate, isolate or control the identified hazards with procedures; Continuously monitor for changing hazards; Review and revise procedures when an incident or accident occurs; Closely supervise new, inexperienced employees.

Safety Information


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Safety P-750/G2 Operators Manual


The following is a list of issues that should be addressed before starting work at a new location. Theseissues should be reviewed with everyone present at the beginning of each shift:

Discuss specific hazards and procedures; Discuss location of emergency facilities;

Discuss evacuation plan and emergency procedures Brief all personnel, sub contractors and visitors as they arrive; Record discussions and attendees.

It is imperative that site-specific hazards are identified and appropriate safety procedures are discussed,as every site has unique safety issues that need to be addressed. Crews should be aware of specific safetyand emergency procedures.

Responsible PersonnelCompetent Person

The Competent Person is responsible for ensuring that a safety briefing is provided for all authorized job-site personnel prior to beginning operations and periodically during the project, and to assign duties to suit-ably qualified personnel. The Competent Person is also responsible for ensuring that generally accepted con-struction safety practices and suitable procedures are understood and followed by all personnel.

Operators

Operators of mud pumping equipment must be deemed competent by the Competent Person, or super-vised by a qualified operator. Operators must have continuous 2-way radio contact with the drill locator andproduct side personnel to coordinate the drilling operation. Backup radios or spare batteries should be avail-able.

Support

Support personnel should be briefed by the Competent Person upon arrival, and must follow and maintainall safety procedures throughout the job. Support personnel and visitors must be informed of hazards, theirresponsibilities, and any restrictions of activities.

Hazards

Prior to commencement of any boring activity, a hazard analysis should be performed to identify all per-ceived hazards. Procedures should then be created to remove, isolate or otherwise control the identified haz-ards. As with any construction operation, compliance with all OSHA, State and Local Regulations is re-quired, regarding general safety practices for activities including:

Vehicle operation Trench Shoring and Sloping Mobile equipment operation Confined-space Entry Noise Hand tools Traffic control Power tools Verification of utilities Fall protection Security of jobsite and isolation of hazards

Safety Information


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Material handling Manual lifting

Activities that are specific to HDD must also be addressed including:

Rig operation Drilling fluid system operation Pilot bore tracking Working on product side Utility clearances Communications Electrical strike protection Handling loose drill pipe Rotating drill pipe Making/breaking tool joints

Underground

Underground hazards to consider include:

Electrical power cables, which can cause serious injury or electrocution if connected Fluid and gas pipes, which may transport asphyxiating, toxic, flammable, and or explosive gases or

liquids Fiber optic cables carry laser light signals, which can cause eye damage Low-pressure sewage and storm water lines. These pose a unique hazard potential if an HDD gas or

electric line installation has been installed that has intercepted the sewage line without detection. Subse-quent maintenance or repair activity could cause a gas leak, explosion, or electrocution.

Surface

The job site surface should be thoroughly evaluated for indications of possible underground hazards.

Transformer boxes should be checked by a qualified utility worker to determine the number and orien-tation of lines entering the box. Ground grids should also be checked

Manholes within the drill area should be opened and inspected, without entry, to determine the under-ground utility it services. The direction of flow in a sewer should be checked to determine the approximategrade. This information can be used to project depth of the utility where the bore is being made

Wire attached to poles should be assumed to be live Water and gas shutoff depths should be confirmed to provide initial confirmation of the depth of the

pipe and facilitate the potholing process. A minimum of 6" to 8" (150 to 200mm) should be added to depths forvalves going to house services. Additional clearance may be required for large valves. This information canbe used to facilitate potholing, and is not by itself a safe method of verifying the depth or location of the utility

before construction. Out buildings (i.e. storage sheds) should be checked to determine if they have electrical wires or oth-

er utility services that may not be marked on any plans Gas barbeque grills, outdoor lighting, etc. should be identified and services confirmed Ditch line depressions in the landscape or obvious changes in vegetation may reveal previous excava-

tion and should be investigated Road repairs may indicate the presence of recently installed or repaired utilities Marker signs or casing vents at or near property lines indicated underground hazards Private utilities and utilities that do not subscribe to the one-call system are not marked by One Call

operators. The Contractor should check State and local regulations and Contract Documents to determineresponsibility for verifying locations of unmarked utilities.

Safety Information


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Overhead

Overhead lines must be avoided. Overhead lines are of particular concern during mobilization/demobili-zation, while handling drill pipe, or loading and unloading heavy equipment. If the voltage is unknown, always

maintain at least 20ft. (6m) of separation between equipment and power lines. If the voltage is known, OSHAregulations outline the required minimum separation. If necessary, place highly visible markers on either sideof the overhead hazard or designate an individual to notify equipment operators as they approach.

Verify Utility Locates

The location of all identified utilities must be verified using non-destructive methods of excavation. Thebore profile must be designed to maintain acceptable clearances between underground utilities and struc-tures, and the final reamed hole. Possible migration of the back reamer from the pilot bore toward the utility,due to excessive steering or a tight radius must be carefully considered when establish clearances. As ease-ments become increasingly congested, it may be necessary to increase the easement widths to accommo-date demand for new utilities.

If there is any risk to the utility from the drilling activity, a window must be excavated at or near the utilityto visually monitor the potentially hazardous situation. A vacuum unit is required to remove the drilling fluidduring the process, and high pressure drilling fluid hazards must be addressed. If the bore passes closelyby a utility,it may be necessary to continuously monitor the separation after the drill head or reamer passesthe window, as the drill string or product pipe may subsequently contact the utility during the completion ofthe installation.

Communication is a critical ingredient of any successful horizontal directional drilling project. It is imper-ative that the drill locator and the drill rig operator have an understanding of the job prior to commencement ofthe work. They should walk the planned bore path with the tracking equipment to evaluate any potentialfields of electromagnetic (active) interference and look for signs of reinforced concrete or other possible pas-sive interference that may hinder the operation, the discuss the identified hazards.

During the actual boring process, if abnormal readings are found with the tracking equipment, the contrac-tor should stop, back up, and verify previous readings prior to commencing the bore. This is critical; as devia-tion from the planned bore profile could result in underground utility strike. Care must also be taken duringthe pullback to ensure that utilities are not damaged due to the upsizing by the enlarged back reamer andpossible straightening of the bore during back reaming and product installation.

Traffic Control (Pedestrian and Vehicle)

Necessary traffic control must be maintained throughout the project. Typically, mobilization, demobiliza-tion, material handling, and intermittent movement of mobile equipment require traffic control if the activityconflicts with vehicle or pedestrian traffic. Traffic control includes permits, planning, notification, flag persons,warning signs and barricades. The work area, particularly around the drill rig and entrance/exit pits, mustalso be secured to prevent unauthorized entry. Emergency vehicles and buses must have access during

construction.

Safety Practices, Safety Equipment

Safe practices must include identification of hazards, as well as isolation, control or removal of hazards.Personal protective equipment that is required on an HDD job-site is similar to that required on other con-struction job-site. Examples include:

Safety Information


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Hard hat meeting OSHA criteria Safety glasses, goggles or face shields meeting OSHA criteria Hearing protection Highly visible reflective clothing Work boots

Work gloves Any other safety equipment mandated by other rules or required by the Owner or regulatory agency Dielectric boots and gloves Suitable communication devices Remote break out wrenches for working on the drill string

If the drilling unit equipped with an Electrical Strike Sensing System, its use should follow manufacturersrecommendations. The system may include audible and visual warning alarms, grounding mats, and person-al protective equipment. Electrical sensing stakes must be driven into the ground and the strike alert systemtested prior to operation.

Drilling Precautions

The following precautions should be observed during the drilling operation: If a hazardous situation is suspected, work should be stopped until an evaluation is made and appro-

priate corrective action taken. Potential pinch points on the drill rig and support equipment must be identified and avoided Safe clearances (at least 3ft. (900mm) or as specified by regulatory authorities) must be maintained

between the bore and all utilities. The minimum clearance must take into consideration the final reamed di-ameter and the bend radius of the pilot bore

Workers must stay clear of the rotating drill string The drill must not be operated when personnel are working on or near the drill string The drill must not be operated without positive communication with the drill locator or exit side per-

sonnel The manufacturers specified maximum torque and thrust/pullback capacity of the drill pipe must not

be exceeded Remote breakout wrenches must be used safely. Drilling machine torque or backhoes with wrench-

es should never be used to make or break tool joints.

Reaming and Installation Precautions

The following precautions should be observed during reaming and product installation:

Two-way radio communication must be maintained at all times between the entry and exit sides The drill pipe must not be rotated until all personnel have been notified and acknowledgement has

been made by all personnel Workers must never step over rotating drill pipe and must maintain a safe distance when working

near rotating drill pipes When crossing existing underground utilities, the utility must be exposed at the crossing location

and monitored during the crossing.

Response to Events

If an existing utility is struck during the boring operation, emergency procedures must be initiated to re-duce the likelihood of human injury. Procedures to follow in the even of utility strikes are summarized belowby type of utility.

Safety Information


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Electrical Strike

If an electrical strike occurs, workers should not move. The voltage difference between the equipmentand the ground, or between a persons feet may be sufficient to cause injury or death. Do not touch the ma-

chine, drill pipe, water system, mud-mixing system, or anything connected to the drill as these items may behighly charged. The drill operator should remain calm and reverse the direction of advance in an attempt tobreak contact with the electrical line. The electrical utility company must be contacted immediately. Thedrill operator should follow the manufacturers procedure to determine if the drill is electrically charged beforeattempting to dismount the drill.

Gas Strike

If a gas line strike occurs, evacuate the area immediately. The drill operator should shut down all en-gines and under no circumstance should the operator attempt to reverse the bore to break contact as furthermovement may cause a spark. Emergency services and the gas utility company should be contacted imme-diately.

Fiber Optic Strike

If a fiber-optic strike occurs, workers must not look into the cut ends of the cable, which can cause se-vere eye damage. Drilling must stop immediately and the utility owner must be contacted.

Communications Line Strike

If a communications line strike occurs, drilling must stop immediately and the utility company should becontacted.

Sanitary/Storm Sewer and Water Strike

If a water or sewer line strike occurs, drill should be stopped immediately and all bystanders should bewarned that a strike has occurred and that they should stay away. Medical attention should be obtained forpersonnel who have come into contact with sewage. As with any strike, the utility owner should be contact-ed immediately.

Conclusion

Hazards that are specific to HDD include the rotating drill string, making up and breaking out of tooljoints, and unknown utility strike potential. However, the most common incidents and accidents on an HDDsite are those that are common to other construction activities including slips, trips, and falls, excavationcave-ins, pinched fingers and toes, vehicle accidents, and back injuries. The common hazards and hazardsspecific to HDD equipment and operation must be identified and isolated or removed to avoid incidents andaccidents.

The investment of time and money in training or hiring an experienced crew is minimal when compared tothe cost of injuries or damaged utilities. Safety procedures must be followed throughout the job to reduce thelikelihood of incidents or accidents. For more information on safety consideration in HDD, safety videos andwritten procedures developed by drill rig manufacturers and the Equipment Manufacturers Institute should bereviewed.

Safety Information


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References

Directional Crossing Contractors Association (DCCA), 2000. Horizontal Drilling Safe Operations Guide-lines.

Equipment Manufacturers Institute (EMI), 2000. Safety Manual: Directional Drilling Tracking Equipment,and Safety Video: Safe Operations of Directional Boring Equipment, EMI, 10 S. Riverside Plaza, Chicago,IL. Both the manual and video are available from Hubbard Publishing (Ph: (800) 369-2310)

OperatorGeneral Precautions

It is the responsibility of the operator to read and understand the Operators Manual and other informationprovided and use the correct operating procedure. Machines should be operated only by qualified operatorsand trained helpers.

Make sure that all protective guards, doors, etc. are in place and secure.Remove all loose objects stored in or on the machine. Remove all objects which do not belong in or on

the machine and its equipment.It is the operators responsibility to point out each of the safety signs on the machine and ensure the

crew understands the importance of adhering to each of the safety signs.It is the operators responsibility to know that all underground utilities have been located before the well is

started, and to avoid them by using proper drilling techniques.In some instances venting of exhaust may be required. It is the operators responsibility to be sure that

the exhaust fumes have been properly vented.Know and obey all federal, state, and local codes and regulations.Make sure all personnel know and stay in their prescribed areas to ensure a safe operation.

Starting and Stopping Precautions

Do not start machine until all personnel are clearly away from any rotating or moving parts.Check operation of all machine controls before using the machine.Make sure all servicing as prescribed in the Operators Manual has been completed.Start and operate the machine only from the operators station.Make sure all fluid lines are securely connected before starting the machine.When shutting down machine, follow manufacturers recommended procedure.Procedure for shut down. Shut power source down, relieve system pressure, and remove the starter key

(if so equipped).

Operating Precautions

Make sure all operating personnel observe and use safe operating practices, including adhering to all

safety signs.Watch that all personnel and objects are clearly away from any rotating or moving parts.Never leave operator station while machine is in operation.Do not operate machine un less protective guards, doors, etc. are in place.

Shut down machine at first sign of malfunction or hazardous condition.

Safety Information


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CAUTION

indicates a potential hazard or unsafe practice which, if not avoided, may result in minor

personal injury, product, or property damage.

Safety Information


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Safety Alerts

Safety Alerts


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Safety Alerts

(7) Precautions about machine being electrical

ly charged.

(10) Precautions about not running pump dry(9) Precautions about diesel exhaust

(8) Precautions about underground utilities

(1) Precautions about electrocution hazard (2) Precautions about bonding frame to ground

rod

(3) Precautions about grounding machine before

drilling

(5) Precautions about rotating part


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Safety Alerts


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Safety Alerts

(1) Precautions about electrocution hazard (2) Precautions about bonding frame to ground

rod

(3) Precautions about grounding machine before

drilling

(5) Precautions about rotating part

(7) Precautions about machine being electrical

ly charged.

(10) Precautions about not running pump dry(9) Precautions about diesel exhaust

(8) Precautions about underground utilities


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Operations P-750/G2 Operators Manual


Operations

Operations

The Operation Section presents the P-750/G2 Site Preparation, Controls and Instruments, Set Up andPumping Operation.

Site Preparation

When initially arriving at the work site, inspect for a level place on which to position the P-750/G2 relativeto the directional drill it is to support. From the entry point of the drill, the attachment point for the mud hosesto the directional drill can be determined. The P-750/G2 should be positioned 50 to 75 feet ( 15.2 m to 23 m)from the point where the mud hoses attach to the directional drill.

With the P-750/G2, it is very important to make the pad the unit is to set on as level as possible. Prefer-ablly with a dozer, scrape an area 10 foot wide (3 m) by 26 foot long (8m) to a level grade.


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P-750/G2 Operators Manual Operations

Detailed Controls

Safety Switches

There are four (1) Emergency Stop push buttons on the P-750/G2 Mud Pump controls.

P-750/G2 Operators Station

P-750/G2 Main Junction Box


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Detailed Controls

P-750/G2 Mud Pump Control

Catepillar Engine Control Panel


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Detailed Controls

Battery Disconnect Switch

The battery disconnect switch is located on the side of the battery box as shown in the following illustra-tion. This switch connects and disconnects the batteries from the electrical system. Rotate to the right to

connect and rotate left to disconnect.


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Detailed Controls

P-750/G2 Main Junction Box

(1) The Mud Pump Stop push button stops the engine from this location. Push in to stop the engine.(2) A 20 Amp fuse to protect the electrical system.


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Detailed Controls

Catepillar Engine Control Panel

(1) Engine Emergency Stop push button. Push in to stop engine. Must be pulled out to be able to startthe engine.

(2) Key Ignition Switch with three positions. Straight up is the Stop Position. Rotate 45 degrees right forthe run position. 90 degrees right is the start position.

(3) Engine Hours meter. Displays the number of accumlated hours on the Catepillar engine.(4) The throttle. Push up to increase engine speed and pull down to decrease engine speed.(5) Yellow diagnostic warning light. If this light illuminates contact your Catepillar technican.(6) Red warning light. If this light illuminates contact your Catepillar technican.(7) 15 amp circuit breakers.

Caterpillar Messenger

This display is intended to allow the operator to monitor the engine information while the engine is beingoperated. A complete explanation of how to access and use the display is found in the attachment about theCaterpillar Messenger.


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Detailed Controls

Lights Switch

The switch for the work lights is located on the end of the battery box as shown in the following illustra-tion.

Serial Number P500041007 Location


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Set Up

Hose Connectons

WARNING

Liquid contents of these hoses is under high pressure. Only work on hoses when pump is off.

Connect the suction hose (12) of the P-750/G2 mud pump to the outlet (discharge) of the mud cleaningsystem. Make sure the connection is properly made and secure.

Connect the P-750/G2 discharge (14) to the drilling fluid intake on the directional drill. Make sure theconnection is properly made and secure.

Try to route the hoses with a minimum number of bends. Sharp bends in the hose reduce the flow to thedirectional drill.


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Starting the P-750/G2 Mud Pump

Make sure the gear shift lever on the mud pump transmission is in neutral. A neutral switch is in thetransmission which allows starting only in neutral.

On the engine panel in front of the gear shift, turn the ignition key (2) to the right to start the engine.When the engine s tarts, release the key.

At this point, the mud pump engine should be running. Allow the engine to run at least ten minutes forengine warm-up and to build pressure in the air circuit.

COLD WEATHER NOTE: The block heater on the engine should be set at 85F (30C) if it is an adjust-

able thermostat type. Newer models are preset at the factory and have no adjustment. These block heatersare 240 volt models and require a similar power source. Plug in the block heater at the end of the days shift.The heater will keep the water jacket coolant warm to 85F (30C) and the engine will start with greater easethan if a block heater is not used.


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Pumping Drilling Fluid to a Directional Drill

Have all safety devices in place and in good working order, including ground stake, hard hats, approvedboots, safety chains, and gloves. Have emergency phone numbers available for hospital, doctor and ambu-

lance.

Check the oil and coolant level in the engine on the P-750/G2. Fuel level should be started out each dayat full.

Attach the high pressure mud hose (12) from the P-750/G2 to the mud cleaning system and the direction-al drill (14). The discharge hose connection (14) is of the hammer union type and must be tightened securelyby hitting the ears of the each collar with a hand sledge hammer. The mud cleaning system should supplydrilling fluid at 25-30 PSI (975 GPM), minimum, to the inlet of the P--750/G2 pump.

Make sure any valves in the mud piping are in the proper position so as not to damage the system whenthe mud pump is started.

Start the engine on the mud pump as stated in the Paragraph, Starting the Mud Pump Engine.Pumping drilling fluid with a sand content greater than 1/2% can cause excessive to the fluid pumping

system.



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Select the proper transmission gear to get the desired mud pump flow rate.

The amount of drilling fluid flowing through the system can be controlled by adjusting the engine throttle(4).



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End of Pumping Operations

Stopping the Mud Pump Engine

Throttle (4) the mud pump engine down to an idle (900 RPM).

Pull out one of the Clutch buttons (3) to disengage the clutch.

Shift the transmission to neutral.

Push in one of the Clutch buttons (3) again to engage the clutch, taking pressure off of the throw-outbearing.

Run the engine at idle speed for 5 to 10 minutes to cool down the engine.

If possible, flush the pump with clear water, and add antifreeze to the pump, turning the pump over 3 or 4revolutions afterwards if temperature falls below freezing.


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End of Pumping Operations

Turn the ignition key (2) to OFF to shut down the engine.

Turn the Battery Disconnect Switch to Off.


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P-750/G2 Operators Manual Storage and Transport

Machine Storage and Transport


Minimum Storage Space Required

Level 312 x 96 inches, height 120 inches [8 x 2.5 m, height 3.12 m].

Storage

Clean all mud and other foreign materials off the machine. Position the machine on a level surface. Switch off electric system by turning the battery switch at the battery box. Lubricate the entire machine according to the daily schedule.

For periods longer then 30 days: Place the machine in a covered and dry site, and follow the instructions of storage for Caterpillar en-

gine. Disconnect batteries and store them at temperatures above 32F (0C). Eliminate sediment and water from the tanks (diesel fuel and oil), top off all the gear boxes.

Protect the machine from salty or acid environments, solvents, gas and flammable liquids and explo-sives.

REFER TO: Attachment 1, Caterpillar Diesel Engines.

Drain or Protect the Fluid Course

Drain water or bentonite slurry out of the mud pump and hoses. Alternatively, pump antifreeze throughthe system.

Transport

WARNING

Transport of the machine must be carried out by trained and authorized personnel only, after

learning the information supplied in the manual.

Preliminary Operations for Loading the Machine for Transportation

Clean the machine.

CAUTION

Dont direct water spray inside the muffler, or the air filter, against electric components or

control panels.


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Storage and Transport P-750/G2 Operators Manual


WARNING

Before loading the machine on a trailer, follow the instructions supplied in this manual.

Transportation Responsibility

The transporter is responsible for using the proper method of transport in conformity with local regula-tions.

Detailed information on the machine features are found in the Overview and General Information Sections

WARNING

Make sure that all personnel keep a safe distance while loading the machine for transportation.

Lifting the Machine

1. If the machine must be lifted (example: to load on a ship).2. Use spreader bars to ensure that the lifting lines do not come in contact with the machine.



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P-750/G2 Operators Manual Maintenance

Maintenance

Maintenance

Maintenance

WARNING

Perform maintenance when the machine is off. Before operating, clean the machine and lock

movable parts. For maintenance to be carried out with running machine, follow instructions in

Operations.

Hydraulic oil, gearboxes oil, diesel engine oil, pins and bearings grease, diesel engine cooling liquid, bat-teries liquid, fuel: handle with care.

Engines, muffler, gearboxes and hydraulic system can reach very high temperature. Do not attempt main-tenance immediately after stopping the work until after the parts are cool.

WARNING

Do not perform welding near the tanks and flammable liquids.

DANGER

Make sure personnel keep a safe distance during maintenance and control operations.

Preventative Maintenance

This section includes all the necessary operations for maintenance by the drill operator (example: greas-ing, adding oil, etc.). More detailed procedures will be provided in a service manual.

Qualification of the Technican

The technician in charge must be trained to know the operation and handling of the machine, to verify thatthere are no functioning faults, to carry out maintenance with suitable equipment and protection, and to informthe responsible qualified personnel about special repairs that cannot be made by himself (example: adjust-ment of diesel engine, welding, etc.).

Frequency of Inspections

Periodical inspections give the operator a simple identification and solution of the problems.


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Maintenance P-750/G2 Operators Manual


Maintenance Schedule

Maintenance Schedule of the P-750/G2 Mud Pump


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10 Hour Inspection and Maintenance

WARNING

Do not attempt any repairs while the pump is running

Check the chainbox oil level using the transparent gauge mounted on the chainbox. The oil level is to bemaintained up to the halfway point of the gauge. Add oil as necessary. The level must be checked when thepump is not operating. If contaminated or milky, flush and change immediately.


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Perform 10 hour and 50 hour inspection and maintenance items, plus:

WARNING

Before checking or changing engine crankcase lube oil wait for the engine to cool.

Change the engine oil and filters. See Attachment 1, Engine Specifications for methods and materials.

WARNING

Wait for engine to cool

Clean or replace air filters. See Attachment 1, Engine Specifications for methods and materials.



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P-750/G2 Operators Manual Maintenance



Perform 10 hour, 50 hour and 500 hour inspection and maintenance items, plus:

Change pump crankcase oil. Using diesel fuel or solvent, flush and clean the entire crankcase area. Ifcontaminants are observed during inspection, determine the cause and repair before using the pump. UseShell Spirax EW 75W-90 oil. The fill port is shown in the right hand photo. Use the procedures indicated inAttachment 2, Pump Specifications.

WARNING

Before checking or changing engine fuel filters wait for the engine to cool.

Change engine fuel filters. See Attachment 1, Caterpillar Diesel Engines for methods and materials.Tighten drive shaft fasteners.

Change pump chainbox oil.

Oil can be added using either the access panels or the vent port shown in the above photo. If the ventport is used then caution must be exercised not block the vent holes when the vent cap is replaced.



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Change transmission fluid. The drain port is located on the right side of transmission when facing therear of the engine. See illustration below.

Drain and refill engine coolant. See Attachment 1, Engine Specifications for methods and materials.



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P-750/G2 Operators Manual Specifications

Specifications

Specifications

Machine Dimensions / Weight

Length: 25 feet 6 inches (7.8 m)Width: 8 feet (2.49 m)Height: 10 feet 3 inches (3.12 m)Estimated Weight: 39,000 lbs (17,690 kg)

Power Train

Engine: CaterpillarC-18 Tier III, Diesel

Rating: 600 HP (447 kW)FuelCapacity: 300 Gallon (1,136 L)Transmission: Eaton-RTLO-22918B 10 SpeedBattery: Two, Deka 908DMF, 12 vo lt, 1450 CCA

Pump

Pump Design: Quintiplex, piston and linerRated Capacity: *750 U.S. Gallons (2,839 L) /minuteBore X Stroke; 5.5 X 7.87 inches (139.7 X 200 mm)Maximum Pressure: 1500 psi (103 bar)(* Note: Pump capacity will vary depending on the overall mud weight, drilling fluid mixture/content, and

the working elevation)

Controls

Remote Controls: Mud Pump Throttle, Mud Pump Start/Stop, Clutch Actuator, Horn

RemoteInstruments: Digital Mud Flow Meter (gallons per minute / li ter per minute)

Accessories

Pulsation Dampers on inlet and dischargeTwo, 25 foot (7.6 m) suction hoses with 6 inch (152 mm) Kamlok fittings

33 U.S. Gallons (125 L) / per minute Liner Wash System with supply tank

24 volt, Dual Work Lights


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Notes P-750/G2 Operators Manual


Notes


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P-750/G2 Operators Manual Limited Warranty

Limited Warranty


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American Augers, Inc.

135 US Route 42

P.O. Box 814

West Salem, Ohio 44287

www.americanaugers.com

Always include machine serial number when ordering parts.

Due to our continuing product improvement, machine specifications are subject to change without notice
http://www.americanaugers.com/