Boring Machine Operation & Safety Instruction Manual (2009)

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Boring Machine Operators Manual

Introduction

Forward

INTRODUCTION

American Augers was established in 1970 to

tion of all models of American Augers Boring

provide a full line of modern equipment for the

Machines.

trenchless excavation construction industry. The

Boring machine specifications are subject to

company is organized in three product divisions

change without notice or obligation to retrofit

to serve the full range of trenchless technology.

units already in the field. This manual will be

American Augers is the division producing the

constantly updated to remain current with new

leading line of Horizontal Earth Boring

operations. Please call if there are areas requir-

Machines. We are proud of our equipment and

ing further explanation or instruction.

the job it can do. We encourage you to call us

The materials may not be reproduced in

for any and all your boring needs. Every effort

whole or in part without the express written per-

has been made to adequately cover the opera-

mission of American Augers Inc.

Manual Part Number BMNG10000

Released July 2009 Revision 06

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

Page 2

Boring Machine Operators Manual

Forward

Revision Record

Revision to Manual

Revision Number

Description of Change

Date

Total rewrite and update. Includes old style and "NG" models

8/2/2007

Updated and reformatted.

9/30/2008

Added text about different methods of banding and updated

11/7/2008

specifications

Revised text about Preventing Machine Upset, Page 27

2/4/2009

Revised Detail Controls for 36/42-600NG and 48/54-900NG Boring

2/11/2009

Machines in accordance with ECN's

Updated Thrust Charts in the Appendix in accordance with ECN

4/24/2009

Added instructions about setting gear backlash

7/8/2009

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

Page 7

Boring Machine Operators Manual

Forward

To The Owner

Thank you for your purchase of the American Augers Auger Boring Machine.

This manual contains important information that will help you and your crew set up and safely operate

the Auger Boring Machine. DO NOT operate or permit anyone to operate or service this machine until you

have read this Manual. Use only trained operators who have demonstrated the ability to operate and service

this machine correctly and safely.

DO NOT use this machine for any application or purpose other than those described in this Manual.

Consult the American Augers factory for changes, additions, or modifications that may be required for this

machine to comply with various safety requirements. Unauthorized modifications could cause serious injury

or death. Anyone making such unauthorized modifications is responsible for the consequences.

Make sure this Manual is complete and in good condition. Contact the American Augers factory to

obtain additional manuals and for further information about/or assistance with your machine. Your American

Augers factory has approved service parts and technicians with special training that know the best methods

of repair and maintenance for your machine.

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

Page 9

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Boring Machine Operators Manual

NOTICE

Before using this manual, familiarize yourself with

the Description Of Components (page 15) and the

Glossary of Terms.

American Augers encourages use

of the One-Call system.

NOTICE

Horizontal earth boring machines have a num-

ber of hazards unique to their operation. A

series of safety alert decals are provided on

American Augers’ horizontal earth boring

machines to alert the operator to hazards of the

machines. The Safety Section explains the haz-

ard alert signs.

PERFORMANCE

Actual machine, accessory, and component performance, capacity, and results can be adversely

affected by or vary with such factors, as environmental conditions, weather, failing to exercise

proper maintenance, machine functionality not being utilized within suggested operating

levels, mechanical or component substitutions that may alter factory standards, operator

experience, or other unforeseen limitations not previously listed.

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

Page 10

Operators Manual

Table of Contents

Forward

Introduction

Machine Serial Number Locations

Revision Record

To The Owner

Overview

Boring Machine Components

Location of Components, NG Models

General Information

Operation and Maintenance Manual

Ownership of Information

Manufacturer Identification Data

Machine Identification Data

Qualification of Personnel

EC-Declaration of Conformity

Use of Personal Protective Equipment

Legal Disclaimer

Purpose of Machine

Pit Preparation

Ambient Conditions

Features of Transport

Machine Handling Procedures

Warranty

Request for Service/Support

Warranty and Service for Diesel Engine

Instruction Manual

Safety Information

Safety Awareness Program

Basic Safety Guidelines

Safety Alerts

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

Page 11

Table of Contents

Operators Manual

Site Preparation

Guidelines For Use Of Boring Machines

Setting and Aligning the Track

Detailed Controls

Safety Switches and Tethered Deadman Switch

24/30-150 Boring Machine Controls

36/42-440NG Boring Machine Controls

36/42-600NG Boring Machine Controls prior to S/N NG3660002841208

36/42-600NG Boring Machine Controls, S/N NG3660002841208 and higher

42-600NG Boring Machine Controls

48/54-900NG Boring Machine Controls prior to S/N NG48549002281208

48/54-900NG Boring Machine Controls S/N NG48549002281208 and higher

60-1200NG Boring Machine Controls

72-1200NG Boring Machine Controls

Installing the Boring Machine

Assembly of Split-Design Machines

Before Operating The Engine

Quik Tran

Preparation of Casing

Constructing the Steering Head

Installing the Lead Casing and Auger in the Pit

Case Boring Procedure

Collaring

Preparing the Exit Pit

Removing the Auger at the Completion of the Bore

Storage and Transportation

Minimum Storage Space Required

Storage

Transport

Preliminary Operations for Transportation of the Machine

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Page 12

Operator’s Manual

Table of Contents

Lifting the Boring Machine

Boring Machine Weights

General Maintenance

The Value of a Preventive Maintenance Program

Qualification of the Technician

Welding

Cleaning

Scheduled Maintenance

Maintenance Schedule

10 Hour Inspection and Maintenance

50 Hour Inspection and Maintenance

500 Hour Inspection and Maintenance

1000 Hour Inspection and Maintenance

After Each Use

Specifications

24/30-150 Specifications

36/42-440 Specifications

36-600 Specifications

42-600 Specifications

100

48-900 Specifications

101

48/54-900 Specifications

102

60-1200 Specifications

103

72-1200 Specifications

104

Appendix

105

Appendix A: Boring Machine Force Charts

107

Appendix B: Entrance Pit

111

Appendix C: Ground Conditions Chart

112

Appendix D: Cutting Heads

113

Appendix E: Auger Weight Charts

114

Appendix F: Casing Weight Charts

116

Appendix G: Boring Machine Glossary of Terms

118

Limited Warranty

123

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

Page 13

Boring Machine Operators Manual

Overview

Boring Machine Components

Current Design, NG Models

1) Pit Face

2) Cutting Head

3) Steering Head

4) Steering Knuckle

5) Auger

6) Casing

7) Casing Adapter

8) Casing Pusher

9) Boring Machine

10) Push Bar

11) Backstop

12) Saddle Adapter

13) Master Saddle

14) Extension Track

15) Drive Chuck (Front Drive)

16) Spoil Ejector

17) Master Track

18) Quik-Tran Drive

19) Male Hex Shank (Auger Shank)

20) Auger Tube

21) Auger Flite

22) Female Hex Bushing (Auger Bushing)

23) Spoil Ejector Door

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

Page 15

Overview

Boring Machine Operators Manual

Overview

Boring Machine Components (continued)

Pre NG Design

1) Pit Face

2) Cutting Head

3) Steering Head

4) Steering Knuckle

5) Auger

6) Casing

7) Casing Adapter

8) Casing Pusher

9) Boring Machine

10) Push Bar

11) Backstop

12) Saddle Adapter

13) Master Saddle

14) Extension Track

15) Drive Chuck (Front Drive)

16) Spoil Ejector

17) Master Track

18) Hook Rollers

19) Male Hex Shank (Auger Shank)

20) Auger Tube

21) Auger Flite

22) Female Hex Bushing (Auger Bushing)

23) Spoil Ejector Door

24) Brake

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

Page 16

Boring Machine Operators Manual

Overview

Location of Components, NG Models

Illustration does not reflect actual hardware only the location of hardware on assembly.

1) Power Package - This portion of the machine contains the engine, clutch, transmission, and coupling

half. It also includes the fuel tank, hydraulic oil tank, filters, hydraulic pumps and operating controls

2) Indicates lift points for the power package only, using the sling provided by American Augers

3) Indicates lift points for the base unit.

4) The sling provided by American Augers.

5) Master Casing Pusher - Contains the spoil chamber, spoil door, and casing adapter, as needed for

smaller diameter casings.

6) Base Push Unit - Included in this section are the base frame unit, header wall, gearbox, final drive,

spoil paddles, chuck, thrust cylinders, push bar, operators station.

7) Master Track - This section of track is furnished with the machine, and is always used as the rear most

track section. It has a thrust plate bolted to the end of the track.

8) Extension Track - These are additional sections of track to be bolted to the master track and to each

other to allow installation of longer casing sections. Two sections of extension track along with the master

track are furnished with each machine.

9) Saddle - Rests on the track in front of the boring machine to carry casing and auger.

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

Page 17

Boring Machine Operators Manual

Overview

General Information

Operation and Maintenance Manual

TITLE:

Boring Machines Operation & Safety Instruction Manual

EDITION:

2008

Part number:

BMNG10000

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 authoriza-

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

for purposes of installation, use and maintenance of the relevant machine. American Augers declares that

the information contained in this manual fits the technical and safety specifications of the machine. American

Augers disclaims responsibility for direct or indirect damages to persons or property caused when the man-

ual or the machine are used in violation of the information contained herein.

The information contained in the manual refers only to the machine mentioned in Paragraph, MACHINE

IDENTIFICATION DATA. American Augers reserves the right to modify or improve the manual and the

machines without notice.

Manufacturer Identification Data

AMERICAN AUGERS, INC.

135 U.S. Rt. 42, P.O. Box 814

West Salem, Ohio 44287 USA

Tel. 419-869-7107 • Fax 419-869-7425

Web Site: www.americanaugers.com

Machine Identification Data

Type:

Auger Boring Machine

Model:

Various

Serial number:

All

Year of manufacture:

All

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

only by skilled and authorized personnel, after studying and understanding the instructions supplied by the

manual.

NOTICE

American Augers disclaims any responsibility for damages to persons or property

caused by the operation of the machine by untrained personnel.

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

Page 19

Overview

Boring Machine Operators Manual

General Information

EC-Declaration of Conformity

If required, the declaration of EC conformity is issued at consignment of the machine together with the

manual and the CE mark will be applied. EC conformity is not required in North America.

Use of Personal Protective Equipment

WARNING

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

can occur.

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

to their duties.

Legal Disclaimer

NOTICE

American Augers disclaims any responsibility for damages to persons or property

caused by the operation of the machine in violation of the instructions contained in

this manual.

Purpose of Machine

The machine was designed for the purpose of horizontal boring through the earth.

Pit Preparation

See the appendix for the pit preparation requirements.

Ambient Conditions

Temperature limits: 5°F and 105°F [-15°C and +40°C] (with oils and coolants recommended). For tem-

perature lower than 32°F [0°C] contact American Augers. For temperatures not included in the range 40°F

AND +5°F [-40°C AND -15°C] contact American Augers.

Relative humidity : 100%

Maximum altitude: 6500 ft [2000 m] above sea level

Atmospheric conditions should allow adequate visibility within the operating area.

The machine should not be operated when lightning is likely.

Features of Transport

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

Machine Handling Procedures

Use

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

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

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

Page 20

Boring Machine Operators Manual

Overview

General Information

Maintenance

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

ell.

Warranty

General Conditions

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

Limitations of Warranty

The warranty for all the components purchased and not produced by American Augers directly are sub-

ject to the original warranty of suppliers/manufacturers and therefore defects in materials or workmanship

are considered valid only if they are recognized by the same suppliers/manufacturers. In particular the war-

ranty on the diesel engine is supplied by the diesel engine dealer in the area where the drill is sold.

Warranty Certificate

The warranty certificate is on the inside of the last page of this manual.

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 working hours can be

read from the hour meter display set into the tachometer. Or, where a Caterpillar engine is used, from the

hour meter in the Caterpillar engine display.

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 spare

parts.

Instruction Manual

This manual is part of the safety system of the equipment. Use it during training of all personnel who will

pariticipate in the operation of the equipment. Ensure that a copy is always available on the jobsite and that

the operators have read it and have access to it. Carefully follow the instructions, advice, and procedures

contained in this manual.

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

Page 21

Boring Machine Operators Manual

Safety

Safety Information

Safety

Safety Awareness Program

Understanding Operation Safety

All references throughout this manual are to current models of American Augers Boring Machines. Oper-

ating guidelines will generally apply to most models in each group. Please call American Augers if you

encounter problems not addressed in this manual.

BE AWARE OF SAFETY INFORMATION.

This is the safety alert symbol. This symbol is placed in the manual to alert you to the potential

for bodily injury or death.

UNDERSTAND SIGNAL WORDS

Signal words are used to identify safety information within the text of this manual, and are used on the

hazard alert signs used on the machine.

DANGER

indicates an imminently hazardous situation which, if not avoided, will result in

death or serious personal injury.

WARNING

indicates a potential hazard or unsafe situation which, if not avoided, could result in

death or serious personal injury.

CAUTION

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

minor personal injury or product or property damage.

If you are the owner, operator, or the helper using an American Augers Earth Boring Machine, it is

important that you recognize that your boring machine is a powerful piece of construction equipment. (IT

MUST BE OPERATED WITH RESPECT AND CAUTION.)

All operators or trainees must carefully read and thoroughly understand this Operation Manual

before starting or using this machine. Thorough training of both operators and helpers is essential for the

safe operation of this equipment. Never allow inexperienced personnel to operate or work near the machine

unless they are carefully supervised during training. In the United States, workplace safety is regulated by

the Occupational Health and Safety Administration (OSHA). OSHA regulations are found in the Code Of

Federal Regulations., Chapter 29. This is known as 29CFR1910. Information can be obtained from your

Regional U.S. Department of Labor Office.

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

Page 23

Safety

Boring Machine Operators Manual

Basic Safety Guidelines

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

with boring machines to learn and follow all local, state and federal safety regulations. All operators must

read and understand the Operation & Safety Instruction Manual before starting the machine. The meaning

of the hazard alert signs is explained in the Operation & Safety Instruction Manual.

Good safety practice dictates the following rules for each job:

1. Post the location and phone number of the nearest aid station or hospital.

2. Have at least one of your workers trained in first aid.

3. Have a complete first aid kit on site.

4. Keep a fire extinguisher on site.

5. Always wear proper personal safety equipment including hard hat, steel toe boots or shoes, and eye

protection.

Thorough training of the operator is essential for the safe operation of any boring machine. American

Augers recommends a SAFETY AWARENESS PROGRAM to aid in the training of your operator.

Regular safety meetings with your crew will reduce confusion and make your job site a safer place to

work. Any employee that ignores or refuses to follow your safety rules should not be allowed on the job site.

If an accident occurs, first take care of the victim. Then write down your own observations. Include a

drawing of the site, showing the location of all equipment at the time of the accident. Have all other wit-

nesses write down their observations as soon as possible, and keep a copy. Record as many details, includ-

ing time, weather conditions, and any unusual events, that you can recall. This record and the field log will

greatly aid you in preventing another similar occurrence.

Safety Suggestions for Earth Boring Equipment

1. Each employer shall protect employees from falling into the entrance or exit pit by the placement of a

guardrail or fence at ground level around the pits.

2. No crew shall consist of less than two persons.

3. No work shall be done on any part of the auger while the power source is running.

4. Disengage rotation of the auger during spoil removal from entrance pit.

5. All engine exhaust must be vented to the open atmosphere.

6. Always turn the engine off before leaving the operator’s station for any reason.

7. It is recommended that the exit pit be excavated at the beginning of the boring process. If this is not

possible then the boring procedure should be stopped short of the exit pit location to allow the exit pit to be

excavated and then the boring completed. This will minimize the risk to personnel and equipment.

8. Always remove machine from tracks before lifting, then lift machine and tracks separately. Before

transporting, always secure machine to tracks with dogs engaged.

WARNING

Before doing any service on the machine, push the Emergency Stop button and remove the

ignition key.

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

Page 24

Boring Machine Operators Manual

Safety

Basic Safety Guidelines

SAE Recommended Practice AA2305 AUG06

Operating Precautions for Horizontal Earth Boring Machines

1. Scope

These general operator precautions apply to horizontal earth boring machines as defined in SAE J2022.

These should not be considered as all inclusive for all specific uses and unique features of each particular

type of machine. Other more specific operator precautions not mentioned herein should be covered by users

of this SAE Recommended Practice for each particular machine application.

1.1 Purpose-This SAE Recommended Practice is intended to be used as a guide for manufac

turers and users of Horizontal Earth Boring Machines to improve the degree of personal safety for oper-

ators and others during normal operation and servicing. Avoidance of accidents also depends upon the care

exercised by such persons. Inclusion of this practice in state, federal, or any laws or regulations where flexi-

bility of revision is lacking is discouraged.

2. References

2.1 Applicable Documents-The following publication forms a part of this specification to the extent

specified herein. The latest issue of SAE publications shall apply.

2.1.1 SAE PUBLICATION-Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-

0001.

SAE J2022-Classification, Nomenclature, and Specification Definitions for Horizontal Earthboring

Machines

3. Personnel Precautions

3.1 Avoid loose fitting clothing, loose or uncovered jewelry.

3.2 Know and use the recommended protective equipment that is to be worn when operating this

machine. Hard hats, protective glasses, protective shoes, gloves, reflector type vests, respirators and ear

protection are examples of types of equipment that may be required.

3.3 Be sure all personnel know and follow safe operating procedures, including a complete understand-

ing of all safety signs and avoidance procedures.

3.4 Know and use the hand signals required for particular jobs and know who has the responsibility for

signaling.

4. Operator-General Precautions

4.1 It is the responsibility of the operator to read and understand the Operator’s Manual and other infor-

mation provided and use the correct operating procedure. Machines should be operated only by qualified

operators and trained helpers.

4.2 Make sure that all protective guards, doors, etc. are in place and secure.

4.3 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.

4.4 It is the operator’s responsibility to point out each of the safety signs on the machine and insure the

crew understands the importance of adhering to each of the safety signs.

4.5 It is the operator’s responsibility to know that all underground utilities have been located before the

bore is started, and to avoid them by using proper boring techniques.

4.6 In some instances venting of exhaust may be required. It is the operator’s responsibility to be sure

that the exhaust fumes have been properly vented.

4.7 Know and obey all federal, state, and local codes and regulations.

4.8 Make sure all personnel know and stay in their prescribed areas to insure a safe operation.

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

Page 25

Safety

Boring Machine Operators Manual

Basic Safety Guidelines

5. Starting and Stopping Precautions

5.1 Do not start machine until all personnel are clearly away from any rotating or moving parts.

5.2 Check operation of all machine controls before using the machine.

5.3 Make sure all servicing as prescribed in the Operator’s Manual has been completed.

5.4 Start and operate the machine only from the operator’s station.

5.5 Make sure all fluid lines are securely connected before starting the machine.

5.6 When shutting down machine, follow manufacturer’s recommended procedure.

5.7 Procedure for shut down. Shut power source down, relieve system pressure, and remove the starter

key (if so equipped).

6. Operating Precautions

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

all safety signs.

6.2 Watch that all personnel and objects are clearly away from any rotating or moving parts.

6.3 Never leave operator station while machine is in operation.

6.4 Do not operate machine unless protective guards, doors, etc. are in place.

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

7. Maintenance Precautions

7.1 Shut down power source and relieve system pressures before doing any maintenance.

7.2 Observe manufacturer’s recommended maintenance procedures.

7.3 Maintenance should be done by trained personnel.

7.4 Do not modify the machine in any way.

7.5 Repair or replace damaged or missing protective guards, doors, etc.

7.6 Replace all missing, illegible, or damaged safety signs. Keep all safety signs clean.

7.7 Use a piece of cardboard or wood to check for pressurized leaks to prevent fluid penetrating the

skin.

Hydraulic fluid escaping under pressure can have sufficient force to enter a person’s body by penetrat-

ing the skin and cause serious injury and possibly death if proper medical treatment by a physician familiar

with this injury is not received immediately.

8. Fuel Handling Precautions

8.1 Do not smoke or permit open flames (which includes welding) while fueling or near fueling opera-

tions.

8.2 Do not refuel while engine is running, or while the engine is hot.

8.3 Do not refuel to tank capacity. Allow room for fuel expansion.

8.4 Tighten the fuel tank cap securely. If cap is lost, replace it with only the original manufacturer’s

approved cap.

8.5 Always use the correct grade of fuel.

8.6 Prevent fuel spillage by maintaining control of the fuel filler nozzle when filling the tank.

8.7 Clean up spilled fuel immediately.

8.8 Never use fuel for cleaning purposes.

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

Page 26

Boring Machine Operators Manual

Safety

Basic Safety Guidelines

Preventing Machine Upset

Machines designed to cut into the earth or to bore rock can cause injury if used incorrectly. Designers

always face the problem of making the machine safe to use without making it useless.

Auger boring machines present two major risks. One is the rotation of the auger. The other is machine

upset. Both present serious danger because operators are in a pit with the boring machine. Machine upset

occurs when the auger or cutting head gets caught and is unable to rotate. When the machine does upset, it

can do so in the blink of an eye, and there is very little chance to jump out of the way. Since escape is

unlikely, the operator must concentrate on prevention.

Boring machines “torque” as a normal reaction of the machine to resistance encountered by the rotating

drill string. When operating in tough conditions, certain combinations of factors can cause a severe, high-

torque machine reaction which can cause a boring machine to upset. These factors include: 1) Operating a

machine at full power in a low gear or reverse; 2) auger or cutting head catching on an obstruction; 3)

advancing into the face rapidly or erratically.

First, the operator must keep the boring machine firmly attached to the track. All American Augers NG

Boring Machines which have rack and pinion with Quik Tran are inherently captured into the track. Earlier

gneration machines require the deployment of hook rollers. The track is usually much wider than the boring

machine, which provides stability. Note that we don’t recommend staking the track to the ground, since some

movement is necessary to keep the track tight against the backstop.

Casing Pusher

Casing Adapter

Casing

Torque Plate

(both sides)

Spoil Ejector

Bolt, Washer, Nut

The casing must always be firmly attached to the boring machine during boring. This is done by welding

“torque plates” to the casing. These “torque plates” are bolted to the master pusher or casing adapter. It pre-

vents the casing from rotating, and in addition, the friction between the casing and the bank soil makes the

boring machine less able to turn over. The casing and torque plates are part of the safety system. Never

operate the rotation without being attached to the casing.

HTD Head

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

Page 27

Safety

Boring Machine Operators Manual

Basic Safety Guidelines

The operator must use care when operating a cutting head with wing cutters. These are designed to

open in front of the casing and make a bore slightly larger than the casing itself. The ideal situation is to

remove the cutting head in the exit pit before removing the auger sections. Otherwise, the auger is rotated

backwards so the wing cutters can retract and the head can be pulled back into the casing. If the operator

tries to operate the auger in the forward rotation with the head inside the casing, the wing cutters can snag

on the inside of the casing.

If the cutting head becomes locked and cannot turn, the operator should move the joystick to neutral and

continue to hold it with the clutch button pushed in, and then push the emergency stop button. Releasing the

clutch can cause damage and injury.

Free-boring (boring without casing) exposes personnel to high-risk hazards of unprotected drill string

and increased possibility of machine upset. All American Augers Boring Machines are designed and sold for

cased bores only. When removing auger from the casing after a bore, keep all personnel away from the

exposed rotating auger.

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

Page 28

Boring Machine Operators Manual

Safety

Safety Alerts

Please note the limited warranty included in this manual. If you have questions on the warranty or

about any part of the machine operation, please contact American Augers.

Safety Alerts

Danger-Rotating Auger and Cutting Head

Rotating auger and cutting head present many shear points where the operator’s limbs could be caught

and injured. They are part of the drill string which is the combination of all rotating components that is

attached to the final drive of the machine. It includes the spoil paddles, auger sections, and the cutting head.

The machine must be turned off whenever work is being done on the auger string, such as installing and pin-

ning auger, removing and unpinning auger, and installing, adjusting, or removing the cutting head. This is

especially important when pinning or unpinning auger sections inside the spoil chamber.

Danger-Rotating Blades

The spoil chamber encloses the rotating blades of the spoil paddles that push the spoil out of the cham-

ber. The close tolerances of the paddles and chamber walls present a hazard. American Augers equips its

Boring Machines with gravity activated spoil doors for a dual purpose. The spoil door shields the exit open-

ing against accidental entry of tools or workers into the spoil chamber, while also protecting nearby person-

nel from flying rock chips. Keep the door closed whenever the machine is operating. Do not stand in front of

the door while the machine is operating. The door is to be opened only with the machine shut down in order

to provide access during the pinning and unpinning of auger sections.

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

Page 29

Safety

Boring Machine Operators Manual

Safety Alerts

Danger-Machine Upset

Boring machines “torque” as a normal reaction of the machine to resistance encountered by the rotating

drill string. When operating in tough conditions, certain combinations of factors can cause a severe, high-

torque machine reaction which can cause a boring machine to upset. These factors include: 1) Operating a

machine at full power in a low gear or reverse; 2) auger or cutting head catching on an obstruction; 3)

advancing into the face rapidly or erratically. It is important to always securely attach the casing to the mas-

ter casing pusher. The weight of the casing and the ground resistance add to the stability of the machine,

deterring machine upset. For spoil removal from the master pusher area, shut off the machine and always

station the worker beside the casing, not the machine. Never allow unnecessary personnel forward of the

operator when the machine is operating.

Caution-Pinch Points

During normal operation of the machine the operator must advance the push bar. The operator must be

aware of the position of the push bar since it moves slowly into position. Always operate the machine from

the platform provided. When using a side-operated machine, the operator must keep personnel away from

the push bar area at the rear of the machine.

Danger-Free Boring

Free-boring exposes personnel to high-risk hazards of unprotected drill string and increased possibility

of machine upset. All American Augers Boring Machines are designed and sold for cased bores only. When

removing auger from the casing after a bore, keep all personnel away from the exposed rotating auger.

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

Page 30

Boring Machine Operators Manual

Safety

Safety Alerts

Warning-”Billboard”

A number of instructions for safe operation are listed on a “billboard” for the operator. Read and under-

stand them before using the machine:

To Avoid Death or Serious Injury

- Read and understand operator’s manual and safety signs (decals) before starting the machine.

- Be sure all personnel know and follow safe operating procedures.

- Engine must be turned off before:

- Opening spoil ejector door

- Working in casing

- Working in exit pit

- Doing any maintenance.

- Properly vent exhaust fumes.

- Always secure auger in casing before lifting.

- Do not modify this machine.

- Always bore with at least a trained operator and a helper.

- Machine may move without warning while in operation.

- Relieve pressure in hydraulic system before servicing.

- Do not operate with guards removed.

- Know and obey all codes and regulations.

Danger-Fire Hazard

Never fuel your machine when the engine is hot or running. Fuel can be ignited by a hot muffler, a spark

or an electrical short and can cause serious injury. Always use an approved container to store fuel.

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

Page 31

Safety

Boring Machine Operators Manual

Safety Alerts

Warning-Keep Hands Clear

Rotating gears present many shear points where an operator's hands and fingers could be caught and

injured. The gears are part of the Quik Tran system that moves the boring machine up and down the track.

The machine must be turned off when servicing the Quik Tran system to prevent accidental rotation of the

gears.

Warning-Pinch Point

When lowering the boring machine into the track, care must be taken to keep hands and feet clear of the

gap between the cam followers on the machine and the top of the track. If a lifting device should fail and the

machine should fall, hands and feet could be crushed between the cam follower and the top of the track.

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

Page 32

Boring Machine Operators Manual

Operations

Site Preparation

Operations

Guidelines For Use Of Boring Machines

The following pages outline the basic procedures for making a cased bore. The recommendations and

suggestions offered throughout this manual are based upon years of field experience. They may not be valid

for every job and every situation. The user employs them at his own risk. American Augers encourages you

to contact the factory for technical assistance whenever there is a question about technique or the applica-

tion of a particular machine on the job.

Designing the Job and Preparation of the Entrance Pit

When the job is in the planning stage, provide enough room for safe loading and unloading of equip-

ment, and for spoil removal. Accidents are less likely to occur at sites that are open and kept clear of debris.

In most instances, an entrance pit will be required at the approach side of the bore. The dimensions of

the pit floor, required to install 20 feet (6.1 meter) sections of casing, are found in the Entrance Pit Chart,

Appendix B. These dimensions will provide the most convenient and safest working conditions.

It is the responsibility of the owner to make a safe pit that is in accordance with the rules set forth in the

(OSHA) Code of Federal Regulations 29. There are specific requirements for pit construction, protection,

barricades, traffic control, installation and type of ladders used in the pit and personal safety equipment.

American Augers strongly recommends that the owner become familiar with the requirements of

29CFR1910. Information can be obtained from your Regional Department of Labor Office.

The floor of the pit must be aligned with the proposed casing grade. It must also be solid enough to sup-

port the equipment being used without settling. We recommend the use of a concrete base with base of

crushed stone to aid in removal of water. Contractors sometimes choose to place the track on planking on a

crushed stone base. This technique is effective on short, non-critical bores.

The boring operation requires that a square, secure backstop be provided for the track push plate. The

thrust for the entire bore is transferred through the track to the backstop. Should the backstop fail during the

bore campaign, valuable time will be lost in rebuilding. The backstop should be designed to withstand two

times the maximum thrust of the boring machine being used. American Augers, Inc. strongly recommends

using the services of a competent engineer to assist in the pit base and backstop design.

On all bores, it is recommended that a steel plate be used between the track push plate and the back-

stop. For larger diameter and longer bores, driven sheeting, and/or a poured concrete pad should be con-

sidered. Experience and soil conditions will dictate the best method. A GOOD BASE AND A SECURE

BACKSTOP ARE ESSENTIAL FOR ALL BORES. Refer to the Ground Conditions Chart in Appendix C for

base and backstop recommendations.

The possibility of flooding always exists during the boring operation. The location of a pit sump for

pumping should be considered during the design of the pit. The sump is placed on the right front or right rear,

depending on the slope of the pit floor. This placement will move water away from ejected spoil on the left

side of the machine.

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

Page 41

Operations

Boring Machine Operators Manual

Setting and Aligning the Track

The most critical part of the bore is the setting of the machine track on line and grade. If the alignment is

not right when you start, it is not likely to improve.

NOTICE

The machine and the track sections are designed to be placed seperately.

Always use balanced lift points.

Instructions for the assembly and breakdown of split machines are contained in this manual. Note that

there are two sets of lifting eyes on split machines. The upper set (1), located on the rack, is used to lift the

power package out of the push package. It is NEVER used to lift the entire machine. A second set (2) is

located on the push package and can be used to lift either the entire machine (without track) or the push

package alone.

Lift and place the master track in the pit with the push plate against the backstop. Install the extension

tracks by aligning the tops of the joints and bolting together using Grade 5 bolts in ALL holes. Note that the

track sections are numbered at each end. Extension tracks are installed so that adjoining ends have the

same number. Use a string and plumb bob to align the track sections with the line of the proposed bore,

before setting the machine.

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

Page 42

Boring Machine Operators Manual

Operations

Detailed Controls

Safety Switches and Tethered Deadman Switch

Emergency Stop Push Buttons

This is a red PUSH-to-STOP control, located at the operator’s station. The control must be pulled up/out

(PULL-to-RUN) before the engine will start. The purpose of the control is to provide a rapid means of shut-

ting down the entire machine in the event of an emergency. The location of this control varies from machine

to machine and will be shown when the control station for each machine is discussed.

Tethered Deadman Switch

This is a flexible cord with a clip that attaches to the operator's uniform. If the operator leaves his station,

the cord pulls a switch that stops the engine.

WARNING

Do not attempt to bypass the deadman control. Operation of the machine with the

deadman control disabled can result in injury or death.

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

Page 43

Operations

Boring Machine Operators Manual

Detailed Controls

24/30-150 Boring Machine Controls

(1) Emergency Stop -- This is a red PUSH-to-STOP control, located at the operator’s station. The con-

trol must be pulled up/out (PULL-to-RUN) before the engine will start. The purpose of the control is to pro-

vide a rapid means of shutting down the entire machine in the event of an emergency.

(2) Ignition Switch -- Starts the engine.

(3) Tachometer -- A tachometer shows engine speed. Also includes the hour meter display if not a

Caterpillar engine.

(4) Gearshift --The boring machine is equipped with a 4 forward speed gearbox with reverse mechanical

transmission. The shifting pattern is shown on a label in the operator’s view. Operation in forward gears will

cause the auger to rotate FORWARD or clockwise as viewed from the rear of the machine. Reverse gear

will cause the auger to rotate in REVERSE, or counterclockwise as viewed from the rear of the machine.

Drive torque is determined by the gear selected. The highest machine torque is in first and reverse gears.

(5) Clutch -- The clutch is a mechanical automotive type that is disengaged by pulling the clutch lever

toward the operator. The clutch lever must be held by the operator while shifting gears. Releasing the lever

engages the clutch.

(6) Brake Lever

(7) Pushbar Dogs Foot Pedal -- This pedal extends or retracts the pushbar dogs. On the 24/30-150

machines it is spring loaded "out".

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

Page 44

Boring Machine Operators Manual

Operations

Detailed Controls

(8) Throttle -- Pull the throttle to increase the engine speed (RPMs). Most models have a positive throt-

tle, which requires a center button to be depressed before the throttle can be pulled out (accelerate) or

pushed in (decelerate). The throttle position (engine speed) and the gear selected control the auger rotation

speed.

(9) Engine Oil Pressure indicator light.

(10) Engine Oil Temperature indicator light

(11) Alternator operation indicator light.

(12) Thrust Pressure Gauge -- The thrust pressure gauge is matched to the pump system pressure

specified for each machine. Check the pressure rating decal on your machine and be aware of it throughout

your operation. The forward thrust of the machine can be judged in relation to the thrust pressure gauge and

the pressure rating decal. The pressure rating decals for the machines are shown in Appendix A.

(13) Thrust Pressure Adjust -- This control is found on the instrument panel. It allows the operator to limit

the thrust of the boring machine to match its output to job conditions.

(14) Thrust Control -- Push forward on the handle to advace the boring machine and pull back on the

handle to retract the boring machine.

(25) Tethered Deadman Switch -- This is a flexible cord with a clip that attaches to the operator's uni-

form. If the operator leaves his station, the cord pulls a switch that stops the engine.

WARNING

Do not attempt to bypass the deadman control. Operation of the machine with the

deadman control disabled can result in injury or death.

Each boring machine has a fuel gauge on the fuel tank and a sight gauge on the hydraulic tank.

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

Page 45

Operations

Boring Machine Operators Manual

Detailed Controls

36/42-440NG Boring Machine Controls

17b

17a

17c

(1) Emergency Stop -- This is a red PUSH-to-STOP control, located at the operator’s station. The con-

trol must be pulled up/out (PULL-to-RUN) before the engine will start. The purpose of the control is to pro-

vide a rapid means of shutting down the entire machine in the event of an emergency.

(2) Ignition Switch -- Starts the engine.

(3) Tachometer -- A tachometer shows engine speed. Also includes the hour meter display if not a

Caterpillar engine.

(4) Gearshift --The boring machine is equipped with a 4, 5 or 6 forward speed gearbox with reverse

mechanical transmission. The shifting pattern is shown on a label in the operator’s view. Operation in for-

ward gears will cause the auger to rotate FORWARD or clockwise as viewed from the rear of the machine.

Reverse gear will cause the auger to rotate in REVERSE, or counterclockwise as viewed from the rear of the

machine. Drive torque is determined by the gear selected. The highest machine torque is in first and

reverse gears.

(5) Electric/Hydraulic Clutch-- The clutch is power assisted. The trigger on the joystick engages the

clutch. If the operator releases trigger, the clutch will automatically disengage.

(8) Throttle -- Pull the throttle to increase the engine speed (RPMs). Most models have a positive throt-

tle, which requires a center button to be depressed before the throttle can be pulled out (accelerate) or

pushed in (decelerate). The throttle position (engine speed) and the gear selected control the auger rotation

speed.

(9) Engine Oil Pressure indicator light.

(10) Engine Oil Temperature indicator light

(11) Battery indicator light.

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

Page 46

Boring Machine Operators Manual

Operations

Detailed Controls

(12) Thrust Pressure Gauge -- The thrust pressure gauge is matched to the pump system pressure

specified for each machine. Check the pressure rating decal on your machine and be aware of it throughout

your operation. The forward thrust of the machine can be judged in relation to the thrust pressure gauge and

the pressure rating decal. The pressure rating decals for the machines are shown in Appendix A.

(13) Thrust Pressure Adjust -- This control is found on the instrument panel. It allows the operator to limit

the thrust of the boring machine to match its output to job conditions.

(15) Quik Tran Control -- Some early production models of NG boring machines used a winch and cable

to retract the boring machine to its starting position on the master track. Recent production machines use the

Quik-Tran system to retract to the starting position.

(16) Pushbar Control -- This lever controls a hydraulic circuit that extends or retracts the pushbar dogs.

On the 36/42-440NG boring machine the pushbar dogs are retracted with this valve. The pushbar dogs are

normally spring loaded “out”.

(17) Joystick -- Depending on the model, the joystick contains one or two push buttons and a trigger

switch. Movement of the joystick toward or away from the operator controls the movement of the boring

machine toward or away from the pit face.

(17a) ROTATE ENABLE push button switch, which enables the clutch circuit. Each push button is the

“maintain contact” type. Once the button is pushed, the circuit stays energized even if the engine is stopped.

The operator must push the button a second time to de-energize the circuit.

(17b) ROTATE ENABLE light.

(17c) ROTATE trigger switch that controls the electric clutch. The operator must hold the trigger to keep

the clutch engaged.

(18) Dogs Latched Indicator -- Indicates that the Pushbar Dogs are latched.

Each boring machine has a fuel gauge on the fuel tank and a sight gauge on the hydraulic tank.

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

Page 47

Operations

Boring Machine Operators Manual

Detailed Controls

36/42-600NG Boring Machine Controls prior to S/N NG3660002841208

17a

17b

17c

(1) Emergency Stop -- This is a red PUSH-to-STOP control, located at the operator’s station. The con-

trol must be pulled up/out (PULL-to-RUN) before the engine will start. The purpose of the control is to pro-

vide a rapid means of shutting down the entire machine in the event of an emergency.

(2) Ignition Switch -- Starts the engine.

(3) Tachometer -- A tachometer shows engine speed. Also includes the hour meter display if not a

Caterpillar engine.

(4) Gearshift --The boring machine is equipped with a 4, 5 or 6 forward speed gearbox with reverse

mechanical transmission. The shifting pattern is shown on a label in the operator’s view. Operation in for-

ward gears will cause the auger to rotate FORWARD or clockwise as viewed from the rear of the machine.

Reverse gear will cause the auger to rotate in REVERSE, or counterclockwise as viewed from the rear of the

machine. Drive torque is determined by the gear selected. The highest machine torque is in first and

reverse gears.

(5) Electric/Hydraulic Clutch-- The clutch is power assisted. The trigger on the joystick engages the

clutch. If the operator releases trigger, the clutch will automatically disengage.

(8) Throttle -- Pull the throttle to increase the engine speed (RPMs). Most models have a positive throt-

tle, which requires a center button to be depressed before the throttle can be pulled out (accelerate) or

pushed in (decelerate). The throttle position (engine speed) and the gear selected control the auger rotation

speed.

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

Page 48