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Safety and Operations Manual OTS Control Station and Steering Head

Manual Part No. E851102

Table of Contents Page Forward 3 Hazard Alert Decals 4 Hazard Decal Placement 8 Specifications and Maintenance 9 Pre-Operational Check List 10 Starting the Bore 19 Completing the Bore 23 Troubleshooting 25 Warranty and Return Goods Policy 26 ©2014 McLaughlin Group Revised: 11/30/2016

All rights reserved. No part of this manual may be reproduced in any form or by any means without prior written permission from McLaughlin Group, Inc.

2006 Perimeter Rd. Greenville, SC 29605 Toll Free: 800-435-9340 – Phone: 864-277-5870

Fax: 864-235-9661 – www.mightymole.com Email: mmole@mightymole.com

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WARNING

Battery post, terminals and related accessories contain lead and lead

compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

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Forward This manual contains important safety information and operational instructions for your McLaughlin system. Read and understand this manual before operating this equipment. Failure to do so may result in serious personal injury or equipment damage. Keep the manual with the equipment at all times for future reference. If you sell the equipment, be sure to give this manual to the new owner. A replacement copy of this manual is available through your local McLaughlin dealer or by contacting McLaughlin Group, Inc. directly at:

McLaughlin Group, Inc. 2006 Perimeter Road Greenville, SC 29605

800-435-9340 - Toll Free 864-277-5870 - World Wide

864-235-9661 - Fax mmole@mightymole.com - Email

www.mclaughlinunderground.com

The illustrations, instructions and specification in this manual are subject to change. McLaughlin Group, Inc. reserves the right to make product changes at any time. Contact your McLaughlin Group, Inc. dealer for the latest information on McLaughlin equipment.

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Hazard Alert Decals BE AWARE OF SAFETY INFORMATION

This is the safety-alert sign. This symbol is placed in the manual and on your machine to alert you to potential bodily injury or death.

SIGNAL WORDS The safety-alert icon is used with the following signal word: DANGER, WARNING AND CAUTION. When you see these words in the manual or on decals on your machine, carefully read and follow all instructions. Watch for these words and learn their meanings DANGER Imminent hazard which, if not avoided, will result in

death or serious injury. WARNING Potentially hazardous situation which, if not

avoided, could result in death or injury. CAUTION Potentially hazardous situation which, if not

avoided, may result in minor personal injury or property damage.

READ YOU OPERATOR’S MANUAL Read and understand the operator’s manual for your machine. Do not operate your machine unless you have read and understand the warnings and instructions contained in it. Contact your McLaughlin dealer if your manual becomes damaged or lost. Keep hands, feet and clothing away from moving parts. Keep all shields and guards in place. Do not modify or remove guards Turn off the machine before servicing.

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Specific Hazard Alert Symbols READ MANUAL

Carefully read and understand all safety decals and proper operating techniques. The safety decals in this manual contain important information. Understanding these decals will help you operate your equipment properly. Replace missing or damaged decals. Allow only authorized personnel to operate equipment. Closely supervise inexperienced operators.

SERVICE AND MAINTENANCE Make sure the machine is always in good working condition. Safety devices must always be installed and functioning properly. Check machine daily before operating. Do not modify this machine. Use only McLaughlin repair parts. Follow all service and maintenance intervals.

PERSONNAL PROTECTIVE EQUIPMENT Proper protective equipment is required for safe operation of this equipment. Protective Equipment:

1. Hard Hat 2. Safety Glasses 3. Safety Vest 4. Ear Protection 5. Gloves 6. Steel Toe Boots

Wear close fitting clothes. Avoid jewelry such as bracelets, necklaces and watches. Restrain long hair.

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LOCATE UNDERGROUND UTILITY LINES

Before starting work, make sure all underground utilities have been properly located. Inadvertent contact with buried utilities may cause death or serious injury. Contact with electric lines can cause electrocution. Contact with gas lines can cause explosion or fire.

MOVING PARTS Keep hands, feet and clothing away from moving parts. Keep all shields and guards in place. Do not modify or remove guards. Turn off machine before servicing.

HIGH PRESSURE FLUIDS This machine may use water, air and hydraulic fluid at high pressures. High pressure hydraulic fluid and water can cause serious injury. Wear protective clothing. Relieve system pressure before servicing.

FLAMMABLE LIQUID

Fumes and/or fuel can explode or catch fire. Shut off engine before refueling. Keep engine and machine free from fuel. Wipe up any spilled fuel immediately.

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WARNING: FAILURE TO FOLLOW ANY OR ALL OF THE SAFETY INSTRUCTIONS IN THIS MANUAL, COULD RESUT IN DEATH OR SERIOUS INJURY. DO NOT USE THIS MACHINE IN A MANNER THAT IS INCONSISTENT WITH ITS INTENDED DESIGN.

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HAZARD ALERT DECAL PLACMENT Hazard alert decals on your machine contain important information that will help you operate your equipment safely. Decal Maintenance: 1. Keep decals clean. Clean with soap and water. Do not use harsh chemicals or spray decals directly with high pressure water. 2. Replace decals when they become damaged or hard to read. Clean the surface of dirt, grease and oil before applying. 3. When replacing a machine component with a decal, replace the decal also. 4. See our local dealer or contact McLaughlin for replacement decals 5. Part numbers for each decal appear on the decal as well as in the manual.

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Specification and Maintenance Dimensions: Length: 96” 243 cm Width: 32” 82 cm Height: 68” 173 cm Weight: 2800 lbs. 1270 kg Power Requirements: 110 V, 60 Hz, 20 Amp. Consult Factory Single Phase Hydraulic Pressure (max): 6,500 psi. 448 bar Water Pressure (max): 60 psi Consult Factory Hyd. Pump ½ hp. Consult Factory Reservoir capacity: 1.6 Gallon Water Pump Capacity (max): 3.1 gpm and 9.5 Amp Consult Factory Water Tank Capacity 50 Gallon 190 liters Battery: Interstate MT-34 or Equivalent Battery Tender: 110 Volt - 12Volt & 5 Amp Max Fluids: Hydraulic Fluid: Mobil EAL224H – Biodegradable hydraulic oil Use only biodegradable hydraulic oil. Antifreeze: Use only biodegradable antifreeze. Always relieve system pressure before performing any service or maintenance. Maintenance: Check hydraulic reservoir at startup and weekly when in continual use. Check hydraulic hoses and manifolds daily for leaks when in constant use. Grease bearings on reels monthly. Keep all hoses capped when not in use.

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Pre-Operational Check List o Connect to power source 120V in North America, (240V most other counties),

test Ground Fault Interrupter-GFI.

Figure 1 o Use a voltmeter to check battery voltage. If it is below 12V, the battery must

be charged. For best results, let the battery charge for 10-12 hrs. o Check fuses, replace if necessary. o Make sure hoses are not crossed from shipping, plug and pressure them up

to 5000psi (350 bars), hold. Test red water hose along side chart tube. o Check hydraulic oil level in pump reservoir. It should be approximately 1”

below the fill cap. Use only biodegradable hydraulic oil. (Mobil EAL224H or equivalent)

o Fill water tank to full line with clean clear water, or biodegradable antifreeze. Do not use dirty or discolored water.

Inspect the Steering Head o Check the LEDs: bulbs, lenses, flasher, wiring and all connections. o Tighten all hinge bolts. Do not reuse hinge bolts. o Check under all 4 flaps. Make sure they are clean, no mud or dirt. o Check all hoses and the inspection cover. o Check auger, cutting head and wing cutters. Replace any worn teeth, replace

worn wing cutter bolts. Do not reuse wing cutter hardware.

Place auger in head and check bit placement o Hard Soil: When boring in hard soil conditions, keep the cutting head close

the front end of the steering head. Boring with the auger even with rear of

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Steering Head, should be a good starting point, depending on drive of your machine. Make sure the wing cutter will clear the front of the Steering Head. Make a note of the clearance between the cutter and the front of Steering Head. The following casing sections can not deviate (get longer) more than that clearance, if necessary cut a few inches off of the rear casing section.

o Check to see if the full size cutters will close sufficient enough to allow removal of auger and bit thru the center tube. The auger must be tight, no more than 1⁄4 in (10mm clearance), when running full size cutter, build up auger as needed. NOTE: If auger is loose in the steering head, the wing cutters will cut to the right and the bottom, forcing the operator to constantly steer to make up for the overcut.

Figure 2 o The amount of overcut, may need to be adjusted for your type of soil. Do not

assume factory settings are correct for your type soil. With new auger or bit slide auger and bit from rear of head towards the front.

o Good Soil: Place cutting head - 1” (25mm) in front of cutting edge of Steering Head, No wing cutters are necessary. Adjust your first casing length, depending on drive of your machine.

o Soft/Unstable Soil: Position cutting head inside the Steering Head - 6” (150mm). If soil is running, place cutting head back inside, behind cone, no wing cutters are necessary. Adjust the first casing length, depending on the drive of your machine.

NOTE: Steering Head will not work properly if a top void is present. Running full size cutters in soft, unstable soil or augers too far forward, will cause top void.

Steering Head and first section of casing. The Steering Head has a straight cut on the rear; weld to bevel from first section of casing. The Steering Head must be parallel or straight with the first section of casing. This weld will bear most of the steering load, so it must be a strong, high quality weld. It is a good practice to weld the steering head and casing on both the outside and inside, whenever possible. Make sure the total length of casing is correct allowing for proper clearance on cutting head, push rings and adapters. NOTE: If the steering head is not welded strait, the operator will be forced to steer the entire bore.

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Placing Augers in the first casing sections and Steering Head. Place augers after welding. Use a 1”-8 (24mm) bolt and lock-nut to attach the first auger to the Steering head auger.

Place Control Station in the pit. – Place the Control Station at the rear of the pit, next to the machine and the Operator. Refer to Figure 3A. It is best to put the Control Station on the opposite side of the spoil. Put the Control Station on blocks, firm and level, if it settles elevation will change. Ground Control Station using the grounding stake supplied with the machine. Refer to Figure 3B. Drive ground stake completely into the ground. NOTE: Do not connect the Control Station to power until after the ground stake is installed. Figure 3A Figure 3B

Place the red water-level hose into the top of tank. Close the chart valve, turn water pump on and open inlet valve. Let run until ready to hook up hoses.

NOTE: Control Station needs to be placed so water level will accept the full change in grade. Example: If going down on .5% and the bore is 500 ft. (150m) long you need 2.5 ft. (.75m) of chart tube on water level, below the starting point (Top of casing). Additional chart tube can be added when going up.

Ground Stake

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o Readings are more accurate if there is a minimum of 2 ft. (600mm) of chart tube above your readings. Extend up if needed. Refer to Figure 4B.

Place the first section of casing and Steering Head in the pit. Steering Head may weigh as much as first section of casing and augers. Always use stable saddles. Make sure Steering Head flaps are not sitting on the saddles or spacers.

a. Place the Steering Head and first section of casing in pusher and saddle, double check length of casing by visually seeing the location of bit after attaching to drive chuck on machine. b. Using a level, turned sideways on cutting block, confirm the Steering Head is level. Reference Figure 5.

Figure 5

Figure 4B Figure 4A

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c. Check grade and alignment of the first section of casing. The first section of casing and steering head should match the tracks. d. If you are going to use a sonde, now is the time to place it into the sonde housing. Use 3X - 1/8” O-rings around sonde, and make sure sonde is grounded.

Attach the Steering Head to the Control Station. o Check all hoses; ensure there are no kinks or tangles in the hoses

on the reels. The hoses should be lying relaxed on the reels. Transportation can cause tangled and crossed up hoses.

o Attach hydraulic hoses, by first using wrenches. T to T, B to B, L to L and R to R. Make sure hose connections are all tight.

o Attach the water level hose to sensing head, using wrenches or hose clamp. If using bentonite or water injection, attach those hoses accordingly. Place hoses in the pattern shown in Figure 6. Always have red hoses and wires in the center of the hydraulic hoses.

Figure 6

o Attach wire to rear of the sonde, attach ground wire to sonde, and Steering Head. Carefully place lid over sonde and tighten bolts. NOTE: Roll of wire lengths for many sondes cannot exceed 200 feet, anything longer will build a magnetic field. Always consult sonde manufacturer for proper operating parameters.

NOTE: This pattern in Figure 6, must stay the same through out the crossing. If hoses cross, it is VERY difficult to remove them after the crossing is done. If “T”(top) is far left, it must always be there. With crossed or tangled hoses it may be impossible to pull hoses out after completion.

Attach the LED wire by twisting the wires together and then using quality silicone filled wire nuts or soldering and heat shrink. Then tape and tuck into opening. If using sonde attach wire using wire nut and tape.

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Coil or tie-off wire around bar in inspection opening, to prevent it from being pulled part during the bore. Refer to Figure 7.

Figure 7

After all hoses and wires are connected, close inspection cover and tighten bolts.

Test o Connect Control Station to clean power source. Push reset on GFI. o Fill water tank with clean water, if not done so earlier. o Run water level until all air is out of the system. (if not done earlier). If

possible, run red (water) hose back into tank on Control Station and let it run for 15 minutes before hooking it up to sensing head in Steering Head. This process may save several minutes and 20 plus gallons (75l) of water. Do not start drilling until all the air is out of the line. Using antifreeze will slow down the waters movement.

Figure 8

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Water Level Operation, Reference Figure 8: To turn off all water: Chart Valve / Off Water Inlet Valve / Off

o To cycle water through system and back to water tank: Chart Valve / On Water Inlet Valve / On

o To send water to water reel and cutting head: Chart Valve / Off Water Inlet Valve / On

o To take a water level reading: Turn Water Inlet Valve to On

Turn Chart Valve to Off and let water flow to sensing head. Turn Chart Valve to On and let water build in chart tube

Once water has reached a minimum of 2 ft. above sensing head, turn the Water Inlet valve to Off. Water level in chart tube should even out with the sensing head height.

o NOTE: You must have three (3) consecutive readings that are the same

before continuing. You can use an instrument and check elevation at water block (drilling up hill it will be inside bottom of casing under water block) against chart tube reading. If there is air in red water hose, the readings will be high. If the chart tube is blocked, the readings will be low. If readings are both high and low, the chart tube is not high enough. If readings are not the same, let water run longer and recheck.

o Open each flap to check the hoses are correctly connected. Check for leaks.

o On larger Steering Heads, now is the time to top off reservoir for the hydraulic pump that controls the flaps. Located in the Control Station.

o Test sonde. o Test alignment lights.

4” or 5” or 6” Channel Installation o The size of channel depends on how many hoses are going to the front

and what size Steering head you are running. o Position hoses on top of casing in the same pattern as shown in Figure 6.

Start placing the channel on top of the casing. Channel should be flush with the rear of the inspection cover on the Steering Head, or lower. It is very important not to tangle up the hoses. Stop the channel 3 ft. (1m) in front of machine, on first section of casing. Refer to Figure 9.

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Figure 9

o Each additional channel should be same length as the casing section. o Place the channel in the top center of the casing. Butt channel up against

inspection cover on Steering Head. Using a level and tape, measure the distant from edge of channel to level, place the end of channel closest to the machine at the same measurement. Refer to Figure 10.

Figure 10

o Every 2 ft. (600mm) place a 2” (50mm) weld on each side of the channel. Channel should stop 3 ft. (1m) from the front of the boring machine; all other channels will be the same length as the casings. When connecting channels weld the corners of tops together. Keep weld away from red hoses and wires. Do not weld to inspection cover. A wooden/plastic wedge placed at end of channel near machine will help hoses from getting tangled.

o Using a chalk line, snap a line on top of channel. (Center of casing, may not be center of channel) See Figure 11.

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Figure 11

o Hoses cannot be positioned above the top of casing. Do not run hoses over top of casing pusher. Route hoses down the along the side of the machine and tie them off to keep them in proper position. Reference Figure 12.

Figure 12

Anti-roll stops. Place two anti-roll stops on casing at pusher on machine, one on each side. Do this for every section of casing. No exceptions! Not doing this will cause faulty alignment readings. Reference Figure 13.

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Figure 13

Using a tilting instrument or string-line, check alignment on the full length of casing, adjust if necessary. A parallel reading is Ok if it is close. If it is parallel but off 1” (25mm) or more there is another problem, find the problem and fix. Most of the time the Steering head has rolled.

Whenever possible, set tilting transit so you can see the exit point. This will eliminate most of the errors. When using string, check the plumb bobs before starting. If you use faulty alignment settings, the length of your crossing magnifies the error.

Double check cuts, alignment, grade, bit location, layout, etc.

Front of bore pit should be square to casing and bore path. NOTE: Steering Heads are designed to hold your grade and alignment, not to

make big changes. It is very important to start the first section correctly. The alignment is just as important as the grade.

Starting the Bore NOTE: Steering heads are designed to hold grade and alignment, not to make big changes. It is very important to start the first section correctly. The alignment is just as important as the grade.

Drill Steering Head into the ground, if falling or riding up, pull back and correct. Stop when at the weld joint between the steering head and casing. The sensing head should be just ahead of the steering head/casing weld joint.

o At this time lay out your crossing using blue painters tape along the chart tube on Control Station. Establish a starting point and then an elevation every casing section. Put additional marks at half way points. Very important!!! If you are running 20 ft (6m) sections of casing the first length of casing behind the water sensor will be 0’ to 16’ (0-5m)(depending on auger lengths) long. Allow for a short first section of casing when calculating elevation changes. For calculating the length of

Anti-roll stops

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first section of casing, it is distance from water level sensor to end of casing. This is a time consuming but critical step. Use two people for best results. Reference Figures 14 & 15.

Figure 14

Figure 15

The first section of casing must follow alignment from a tilting instrument or the string line, adjust accordingly. This is very important, it gives an idea of which way the casing may be pulling.

For the first section of casing, leave a 4’ level (1m level) on top of channel set to grade. This will indicate if the casing is rising or falling. Reference Figure 16.

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Figure 16

Casing alignment is very important. Each subsequent section of casing must be aligned to the previous section. Ensure the new casing section is aligned properly and weld the casing in place. Weld any gaps remaining after aligning the casing. Check readings from the sonde. Use the pitch from sonde only as a guide. Most of the time the alignment readings will be parallel to bore. Get three readings before making corrections.

Your grade should hold until more weight is in front of the saddle than behind it.

Make SMALL adjustments. It may take 2 machine cylinder strokes to see any change in direction. When checking line or grade, keep a log of the corrections you make, (when and how much) Reference Figure 15. If no corrections show up go big and drop pressures back down after change.

Check every 5ft. (1.5m). Once stabilized, check minimum every 10 ft. (3m).

On tight grade crossings, check every stroke for the entire crossing. The higher the accuracy, the more frequent grade checks need to be done.

If you make a hard (big) correction for grade, you need to check every stroke until steering is stabilized.

Check alignment after installing each section of casing, BEFORE welding the next section on. The same person should check alignment each time.

If line is not stabilized or a hard correction was made, check alignment at the half-way point of the section of casing as well.

If you loose control of your grade and have to make a hard correction to keep up, it may prevent you from seeing your alignment lights!

DO NOT leave oil pump running. Use it only when opening a flap.

DO NOT leave water pump running. Use it only when purging air out of system.

Keep a log of the corrections you make. (when and how much) A good place to keep track of you correction is on second piece of painters tape on other side of sight tube on Control Station. Reference Figure 14 & 15.

When crossing is complete record readings for reference later, if necessary.

Checking Grade

When checking grade, purge the system until water column is 2-4 ft. (600-1200mm) above reading and allow it to stabilize. Don’t let grade get off, but don’t over correct either. When extending a flap to steer, start with a 500 to

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1500 psi (35-100 bar), see what happens. Every soil will react differently. Seldom do you need to go higher than 3000 psi (200 bars), but don’t be afraid of going to 6500 psi (450 bar). After making changes it may take 2 strokes to show up. It takes less flap pressure when running outside cutters then when Steering head is doing the cutting. The more work a flap(s) is doing the higher your thrust pressure will be. Steering Procedure

When opening a flap, open (change) the valve that controls that flap. Close (lock) the other three hydraulic valves, turn on hydraulic pump. When gauge reads slightly above the desired pressure close the valve (lock) and turn off hydraulic pump. Slowly open the valve and to lower the pressure to the desired reading. When a flap is at desired pressure, open the other valves. During the drilling operation the valves should be open unless steering is in progress.

The hoses continually will get walked on or pulled. Purge the system every grade check. Make sure to allow enough time for the water to stabilize.

When using the sonde the top flap must be closed at least 5 ft. (1.5m) before taking reading for the pitch. Depth, roll and alignment can be checked at any time.

Keep a log of the corrections you make. (when and how much) You should have enough information so another person can steer if necessary.

Checking Alignment

Make sure to keep casing clean enough so as not to block the alignment lights. If not sure, disconnect and check to see if you can see the lights before moving machine all the way to rear of pit. Never put any part of body near or in the master pusher or around paddles without machine off and having possession of the keys.

After disconnecting and moving machine to the rear of the pit, two plumb bobs need to be set up on line. One at the end of the casing, the second should be placed 2’-3’ (1m) in front of the machine.

If using a tilting instrument, align the two plumb bobs. If you are hanging plumb bobs from a string line, set up the string line.

Attach ground wire to the casing, if equipped, then switch power on (12volts DC) to the wire going to lights in the Steering Head.

Align your eye with the two plumb bobs and the Steering Head lights. The amount you are off is the total amount the Steering Head is off. The lights are 6”(150mm) apart from center of the left light to the center of the right light. On most models the right LED will blink. Very helpful on long crossings. If both lights blink your battery is not charged enough.

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Figure 17

Don’t be afraid of running parallel. DO NOT over correct! If moving off course slowly, three readings will truly indicate path and future path. It may be a curve.

If a hard correction was required, stop half-way through the casing section and take an additional reading.

The goal for steering is to aim the Steering Head so no flaps are open. This will keep the push pressure down and provide a straight casing.

When using a sonde for alignment, it can be done anytime even during the drilling operation. Use some type of markers (paint, cones). Before making an adjustment obtain at least three readings.

Keep a log of the corrections you make, when and how much. It is best to put information on painters tape on the Control Station.

Completing the Bore

10 ft. (3m) before completing the bore, open all the valves and allow the flaps to close. If you have flaps open when you enter the receiving pit, it may cause the face of pit to cave in.

Take a picture of the bore information on painters tape and keep it for reference if necessary.

The exit shaft needs to be long enough to remove the Steering Head and attach a full size auger to the auger string, and wide enough to get around the Steering Head to cut it off.

Push the Steering Head into the exit shaft far enough so it can be cut off with a torch or saw.

After the Steering Head is in the receiving pit, open inspection cover. Disconnect wire and water hoses, then the four oil hoses. Cap all hoses.

After all lines are disconnected, move the Control Station to the center of the pit. Rewind the wire first, followed by the water hoses, then the oil hoses. Remove/rewind the hoses one at a time.

Hose can be returned to reels at the same time the Steering System is being cut off.

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Removing the Steering Head o Cut the casing 1” (25mm) or so behind the weld joint on the steering

head. Don’t try to do a good torch job now, just cut it off without damaging the hoses, wire or Steering Head. Cut top off last.

o Disconnect the Steering Head auger from auger string. After removing the Steering Head place a full size (clean out) auger in its place and attach it to the auger string. Using a communication device, guide the operator until the auger is in the casing. Boring machine must be off when removing Steering Head or attaching clean out auger.

o If using a sonde, remove before has a chance to get hot or damaged.

Readying the Control Station and Steering Head for the next bore Steering Head: - Refer to the Parts and Service Manual for all repair parts.

o Remove old casing from Steering Head. o Remove flaps and inspect for cracks, broken welds and etc. Repair as

necessary. Remove any dirt or debris. Check all hose connections. o Replace hinges and hinge bolts, after every bore. Use only high strength

– American made bolts with a minimum of 140,000 psi yield. Always use anti-seize on bolts. Do not reuse hinge bolts.

o Check light housing and lens. Replace if necessary. o Replace LED bulbs after every bore. o Check Hard Faced surfaces, resurface face if necessary. o Build up auger as needed so it is tight in the steering head, ¼”(10mm)

max clearance. Replace teeth as needed cutting head. Make sure wing cutters are working correctly. Replace worn wing cutter bolts. Note: Full size cutters, bit and auger will wear much faster than Steering Head.

Control Station: o Visually inspect hoses; if they look good, plug hoses and run up to 5,000

psi (350bars) and hold. Hold pressure for 2 hours or longer (best to over-night). Check for leaks.

o If hoses do not build pressure, then oil reservoir may be low. Fill with hydraulic oil and retest. (Use only Mobil EAL224H or equivalent).

o Check for internal damage of hoses. Run oil thru each hose (one at a time) with ends open (into a bucket). Pressure should not exceed one pound per foot of length. All four hoses should be the same. There should be a constant and equal amount of fluid flowing through each hose.

o Run water pump looking for damage in red water hose, repair if necessary.

Hold (or tie strap) red water hose next to chart tube and purge water system (after getting air out), the two should come to the

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same level, and stay the same. A pinhole caused by welding can give inconsistent readings.

o Using an ohm meter, test the wire for shorts, test against the frame. Test voltage at the battery and at end of wires, should be very close. If more than 10% difference, check all connections, including collector ring on reel. Recharge the battery.

o Check water in tank. Replace if dirty.

Safety Guidelines: o Never put any part of body near or in the master pusher or around

paddles without making sure the machine is turned off and having possession of the keys.

o Control Station must be grounded at all times. o Never work in a bore pit or a receiving that does not meet current codes. o Always use a communication device when working on exit pit. o Never put any body parts including hands or fingers under opened flaps. o Remove flaps if maintenance is required. o Always relieve system pressure before servicing the Control Station or

Steering head. Disconnect and plug hydraulic lines before removing Steering head.

o Never stand between the steering head and the front face of the bore pit during operation.

o The boring machine must be turned off and the key must be with the operator in the exit pit, when removing the Steering Head or attaching a clean out auger.

o Consult and follow all local safety inspector guidelines. o Use standard welding and safety guidelines when welding

o Always use proper slings and lifting devices when lifting or moving the Steering Head and Control Station.

o Keep body clear of rotating reels on control station. o Always follow drilling machine guidelines, instruction and safety

guidelines.

Troubleshooting: If water level not reading consistently:

Air in red hose, purge. Colum of water is not high enough above readings, raise chart

tube. Low spot trapping water in chart tube retuning to tank, eliminate

low spot. Dirty water in tank, clean tank and replace water, purge red hose. Control station settling not stable, block control station.

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Pinhole in water hose, replace hose. Lights not working:

o Poor connection at Steering Head, redo connection. o Battery not charged or bad, charge overnight or replace. o If both LEDs flash, low battery. o Broken/burnt out LEDs, replace.

Flaps will not open:

o Hydraulic pump not powered on, power up. Check GFI o Low hydraulic oil, add oil to reservoir. o Empty hydraulic hoses, run until full. o High pressure reading on one flap without load, crushed hose,

replace.

General Returns of Merchandise 1. All returns must be pre-authorized A. Please call our Service department for an RGA number B. RGA number must be on the outside of box. C. Include any required paperwork or special instructions D. Items returned without an RGA number will not be accepted 2. All returns are subject to a 20% restock charge. 3. Special items are non-returnable A. Non-stock parts B. Custom parts

C. If you are unsure about a parts status when ordering, ask your McLaughlin representative if the item fits the above conditions.

4. Items must be returned within thirty days of original order date. 5. Items not returned within 30 days from the date of RGA is issued, will not be accepted. 6. The Item(s) must be in new condition. Used Item(s) are not returnable.

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Limited Warranty The Manufacturer warrants its products to be free from defects in material and workmanship for a period of twelve months from the date of shipment from the factory. The Manufacturer shall not be responsible for any damage resulting to or caused by its products by reason of installation, improper storage, unauthorized service, or alteration of the products, neglect or abuse, or use of the product in a manner inconsistent with its design. This warranty does not extend to any component parts not manufactured by Manufacturer; however, Manufacturer’s warranty herein shall not limit any warranties made by manufacturers of component parts which extend to Buyer Claims for defects in material and workmanship shall be made in writing to Manufacturer within ten days of discovery of defect. Manufacturer may either send a service representative or have the product returned to its factory at Buyer’s expense for inspection. Upon notification of defect, Manufacturer will issue a return goods authorization number to Buyer. The return goods authorization number must accompany the product returned. If judged by the Manufacturer to be defective in material or workmanship, the product will be replaced or repaired at the option of the manufacturer, free from all charges except authorized transportation. Buyer shall be responsible for all maintenance services consisting of lubrication and cleaning of equipment, replacing expandable parts, making minor adjustments, and performing operating checks, all in accordance with procedures outlined in Manufacturer’s maintenance literature. THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES AND NO REPRESENTATIONS, GUARANTEES, OR WARRANTIES, EXPRESS OR IMPLIED, (INCLUDING BUT NOT LIMITED TO A WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE), ARE MADE BY THE MANUFACTURER IN CONNECTION WITH THE MANUFACTURE OR SALE OF ITS PRODUCTS. NO EMPLOYEE, DISTRIBUTOR, OR REPRESENTATIVE IS AUTHORIZED TO CHANGE THIS WARRANTY ON BEHALF OF MANUFACTURER THE REMEDIES OF BUYER SET FORTH HEREIN ARE EXCLUSIVE AND ARE IN LIEU OF ALL OTHER REMEDIES. THE LIABILITY OF MANUFACTURER WHETHER IN CONTRACT, TORT, UNDER ANY WARRANTY, OR OTHERWISE SHALL NOT EXTEND BEYOND ITS OBLIGATION TO REPAIR OR REPLACE, AT ITS OPTION ANY PRODUCT OR PART FOUND BY MANUFACTURER TO BE DEFECTIVE IN MATERIAL OR WORKMANSHIP. MANUFACTURER SHALL NOT BE LIABLE FOR COST OF INSTALLATION AND/OR REMOVAL OR BE RESPONSIBLE FOR DIRECT, INDIRECT, SPECIAL OR CONSEQUENTIAL DAMAGES OF ANY NATURE.