Professional Documents
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LS250 - OM - Oct2 English (12934)
LS250 - OM - Oct2 English (12934)
LS250 - OM - Oct2 English (12934)
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Copyright © 2015 Boart Longyear. All rights reserved. ISSUE No. 20150301
Boart Longyear is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
DO NOT START or OPERATE THE MACHINE until you have READ
this manual and UNDERSTAND the contents.
Hazard signal words are used throughout this manual. They appear
in the narrow left-hand column of several pages and, with their
additional text description, are intended to alert the reader to the
existence and relative degree of hazard.
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Copyright © 2014 Boart Longyear. All rights reserved. ISSUE No. 06112014
Boart Longyear is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
Figure 1–1: General view 1 ................................................................................. 7
Figure 1–2: General view 2 ................................................................................. 8
Figure 1–3: Assembly Drawing ......................................................................... 11
Figure 1–4: Lifting Points Elevation .................................................................. 15
Figure 1–5: Lifting Points Plan View ................................................................. 15
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Copyright © 2014 Boart Longyear. All rights reserved. ISSUE No. 06112014
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2.1.1 Safety Labels .................................................................................. 23
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4.1.1 Equipment Description and Identification ....................................... 67
4.1.2 Safeguards .................................................................................... 67
4.1.3 Routine Checks .............................................................................. 68
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5.1.1 Operational Requirements .............................................................. 89
5.1.2 Safety Requirements ...................................................................... 89
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Figure 5–2: Metric Bolt Torques and Safe Loads ............................................. 93
Figure 5–3: Imperial Bolt Torques and Safe Loads .......................................... 93
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Figure 1–1: General view 1 ................................................................................. 7
Figure 1–2: General view 2 ................................................................................. 8
Figure 1–3: Assembly Drawing ......................................................................... 11
Figure 1–4: Lifting Points Elevation .................................................................. 15
Figure 1–5: Lifting Points Plan View ................................................................. 15
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Copyright © 2015 Boart Longyear. All rights reserved. ISSUE No. 20150301
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• This manual is a general description of the operation and maintenance
requirements of the LS250 Minisonic Drill Rig.
• Pictures, descriptions and technical data may therefore not match your
drill rig in every aspect.
• You are the one who is responsible for your personal safety when
• operating the LS250 rig.
• This manual is only a general guide to essential operating procedures,
safety precautions, etc.
• The procedures described in this manual do not relieve you of your
responsibility to exercise caution and common sense.
• You must comply with all safe working procedures and instructions
• relevant to your drill site at all times!.
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a. Consumables. Boart Longyear warrants for a period of one
(1) year after the date of shipment of the consumable products
manufactured by it, or the performance of related services, under
the Contract, that such consumable products are free from defects
in materials and workmanship and such services are performed in a
professional and workmanlike manner; provided, however, with respect
to consumable products purchased through an authorized Boart
Longyear distributor, the warranty period shall commence on the date of
purchase by the end-user.
(i) contact Boart Longyear and request authorization to return any goods
claimed to be defective promptly upon Purchaser’s discovery of the
alleged defect,
(viii) accessories of any kind used by the Purchaser which are not
manufactured by or approved by Boart Longyear.
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Copyright © 2015 Boart Longyear. All rights reserved. ISSUE No. 20150301
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Copyright © 2015 Boart Longyear. All rights reserved. ISSUE No. 20150301
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This manual describes the BOART LONGYEAR LS250 series
Minisonic Drill Rig and outlines its operational and maintenance
procedures . It also includes a number of procedural hints.
The manual must be retained in its storage box on the rig, so that it is
always available.
The Manual set includes a spare parts catalogue depicting and
describing the individual components of the rig.
In the interests of technical development, Boart Longyear reserves
the right to modify the drill rig and the data in this manual without
prior notification.
The LS250 Minisonic Rig is a self contained, drill rig especially designed
to work in areas otherwise inaccessible by standard drill rigs.
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Rod
Presenter
The drill mast carries a Minisonic drill head, together with the entire
drill string. The drill mast is attached to the mast carrier by means of
adjustable trappings. Holding and thread breaking clamps allow for rapid
rod changes.
All control and monitoring elements of the fully hydraulic drill are
conveniently positioned. Self-explanatory graphic symbols are used to
indicate control functions. The LS250 Minisonic drill is Crawler mounted,
all tramming is controlled from a Radio Remote control.
The drilling control panel is mounted on the front right hand side of the
machine and swings across the front for tramming. The set-up control
panel is mounted halfway down on the right side.
Emergency STOP buttons are fitted on the Driller control panel and on
the Radio Remote control. The operator is protected from the rotating
drilling elements by a wire mesh guard with interlocked door that
reduces rotation speed and power when opened. Activating any of these
switches immediately stops all drilling and tracking functions.
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The diesel engine is fitted with a soundproof cover for operating in areas
with stringent noise regulations.
Features
Mast with feed cylinder and extension to enable 3 m (10 ft) rod pull.
Rod holding and thread break-out clamps with variable clamping
force.
Minisonic head rotate.
Surface drilling operations of large diameter (3” to 12”) holes.
Provides highly representative, continuous core samples in difficult
ground.
New generation diesel engine power supply.
Hydraulic mast raising with mast shift compensates for uneven drill
site conditions.
Three hydraulic independent Stabiliser Jacks
Enhanced Safety - Interlocked safety cage rotation barrier - head
rotation slows when open for enhanced safety.
Compact Footprint - Fits in shipping container and makes the LS250
MiniSonic perfect for smaller drill pads.
Enhanced Safety - Rod presenter allows the casing to be loaded
horizontally.
Easy Operation and Maintenance - Pilot operated hydraulic system is
easy to operate and maintain.
Increased Precision - Eliminate time consuming moves with the
articulated mast and wiggle tail which allows the mast to shift from left
to right and front to back enabling the mast to be positioned precisely
over the hole. The articulated mast allows for drilling from 90 to 45
degrees.
High Efficiency Rotation and Oscillation Unit - Patented airbag
system isolates the vibration from the rig and transfers it down the
hole for more efficient drilling.
Increased Accessibility - Wide track mounted and low ground
pressure (.28 bar/4 psi) - perfect for increased accessibility in the
most sensitive terrains.
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4.75 in (121 mm ) 78 m 255 ft
6 in (152 mm ) 61 m 200 ft
7 in (178 mm ) 52 m 170 ft
8 in (203 mm ) 45 m 150 ft
9.25 in (235 mm ) 39 m 130 ft
10.5 in (267 mm ) 34 m 110 ft
12 in (305 mm ) 30 m 100 ft
*Depths based on normal drilling conditions. Varying ground conditions
and drilling styles may give varying results.
Sonic Head
Drill Head Type - MiniSonic
Vibration Motors - Fixed displacement piston motors
Frequency Range - 0-75 Hz
Output Force @ 150 Hz - 182 kN 41,000 lbs
Maximum Torque - 2,400 Nm 1,700 ft.lb
Rotation Speed - 0-80 RPM
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CRAWLER CHASSIS
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PRIME MOVER
Engine -
Maximum pressures: Crawler max: 410 (6000 psi) Sonic 275 bar(4000
psi)
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Foot Clamp/Breakout System
Voltage: 120 v
Frequency: 60 Hz
Power: 4000 W 5.36 hp
Current: 200 Amps
Voltage: 12-30 V DC
Duty Cycle: 68%
WELDER GENERATOR - European Version - Hydraulic driven Dynaset
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SPT (Standard Penetration Test) Auto Hammer
Type - Hydraulic motor/chain driven automatic release Hammer.
Motor type: Gerotor - low speed high torque
Chain type: Roller chain A60 3/4”Pitch
Maximum pressure: 124 bar (1800 psi)
Maximum flow: 60 l/min (15.9 US gpm)
Impact rate: 1 to 30 Blows/min.
Hammer size: 63.5 kg 140 lbs
Hammer fall height: 762 mm 30 inch
All up weight: 226 kg 498 lbs
Certified Hammer efficiency: 64% to 72%
!
Offloading.
Transport Dimensions.
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The picture shows a typical rig equipped with an automatic, hydraulically
operated SPT (Standard Penetration Tester) Auto-Hammer. The weight
of the drop hammer is 63Kg, and the free fall height is 75 cm.
Auto-Hammer (SPT)
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2.1.1 Safety Labels .................................................................................. 23
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Maintenance note - To ensure that all personnel are continually aware
of the dangers of the rig, examine all signs during routine maintenance
and replace as required.
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Become familiar with machine safety labels and locations. The following
illustrations show safety label locations on the machine.
Contact with overhead electrical power lines will cause serious injury or
death.
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DO NOT operate this machine without head guard in place. Operator
may be drawn into rotating parts.
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A name plate listing the model number, serial number, machine weight
and power. Please record the information so that it will be available
should the name plate become lost or damaged.
The removal of the type plate is strictly forbidden, and will invalidate any
warranty claims.
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PPE - Personal Protective Equipment
3. Wear gloves
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Always use Lockout /Tagout procedures before working on the electrical
system when servicing the rig.
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Stop and observe surrounding warning decals
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Indicates to refer to the manual before proceeding with any activity.
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Surfaces adjacent to this warning can be too hot to touch.
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Diesel fuel connection site.
Wear protective gloves and eye protection during all operations on the
battery.
Do not tilt battery, acid may leak from the degassing openings.
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Fire fighting and further measures:
Prevent burning people from running away and extinguish fire by means
of fire-extinguishing cover or powder fire extinguisher.
Fight fire together with other people if possible in order to minimise your
own endangerment.
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Extinguish at the flame root from front to back
After extinguishing the fire, do not leave the fire location, maintain
observation on the fire location in case of flash-backs.
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This is a safety cage (guard) that covers the Mast and Drillhead in the
area within reach of the operator. The Cage Gate has a switch that
when opened reduces the drillhead rotation speed and torque to a safe
level. Other interlock configurations are available.
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.
Do not attempt to operate the drill rig unless you are fully familiar with
all rig controls, gauges, functions and operational sequences.
Failure to comply with the detailed instructions contained in the
Operating Manual could result in physical injury or even death.
Always wear an approved helmet, safety shoes or boots, safety
glasses,nose mask, and hearing protection when near an operating
drill rig.
Keep hands, arms, legs and clothing away from all moving parts of
the drill and its accessories. Failure to comply could result in physical
injury or even death.
Do not touch rotary heads, drifters, shank adapters,couplings, drill
steels, casing, bits, and crowns with your bare hands during drilling.
These parts usually get hot and a severe burn may result. Be sure to
wear work gloves when you are handling any of these components.
Dry Nitrogen is the only gas used to charge accumulators on drifters
and rotary heads. Never use Oxygen to charge accumulators
because a mixture of Oxygen and Oil may ignite to produce an
explosion.
Make sure that accumulators are always in perfect condition. Inspect
regularly and thoroughly to ensure that accumulator components
have no cracks or signs of excessive wear.
When pressurised, damaged accumulators could burst, scattering
metal fragments throughout the area, and severely injuring
personnel.
Be sure to bleed the accumulator before attempting to disassemble
it, and only replace with accumulators that have been tested and
approved.
Always operate the rig from the operator position.
Make sure all other persons are clear of the rig before moving or
starting any operation.
Tram only with the jacks fully retracted, the mast fully retracted and
resting on its support bracket. The drill head should be centred in the
middle of the mast.
Use extreme caution when tramming or setting up on uneven ground.
Always ensure that the stability of the rig is not impaired.
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Drills have many moving components. Keep yourself and all other
persons clear of moving drill heads, feed mechanisms, drill strings,
and moving tools.
Know where you are drilling! Make sure you do not drill into any
utilities, such as buried electric cables, gas, or water mains.
Use only purpose-made craneage lugs and/or lifting holders when
lifting the rig.
Do not remove or disable protective guards and safety devices under
any circumstances.
Pay particular attention to the accident prevention devices and
ensure that they are always fully functional. Defective devices
may delay stopping rig functions, and may therefore cause severe
personal injury or even death.
Exhaust fumes from internal combustion engines are deadly. Be
sure to only operate the drill rig in well ventilated areas.
If you must operate the rig in a confined area, consult your
occupational health and safety representative to ensure safe drill
operations at all times.
Noise and Vibration levels -
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Keep the casing section firmly secured to prevent it from sliding
down and squashing fingers during this process. Care must be taken
when flushing with compressed air because pressurised air can drive
cuttings with extreme force and great velocity.
Ensure that all persons are at a safe distance before opening air to
the drill string.
Always relieve pressure on the flushing medium in the drill string
durings steel changes (i.e. extending the drill string and tripping-out
the hole).
When using DHD drill tubes (API, etc.) always ensure that clamps are
placed directly alongside couplings (joints).
DHD tubing is manufactured using relatively thin-walled tubes, which
may deform or be damaged by hydraulic pressure.
Never stand beneath drill bits when inspecting for wear and removing
plugs when flushing holes. Plugs may be forced out by flushing
pressure, or the bit may drop out causing severe injury.
Use a mirror for inspection if the bit cannot be removed for checking.
Do not hit drill bits with a hammer when cleaning strings of concrete
residue. Carbide inserts may break and cause severe injury.
Remember that some cleaning solvents used for removal of oil and
grease develop dangerous fumes when they vapourise. Be sure to
use solvents only in well-ventilated areas.
The rig must be secured against inadvertent and unauthorised
movement prior to each operational interval.
To avoid inadvertent or unauthorised start up once the engine is
stopped, ensure the starter key is taken out of the ignition lock and all
covers, doors and lids are locked and secured.
If the vehicle is parked on a slope or incline, the crawler tracks must
be secured using wedges, in addition to engaging the hydraulic
brakes.
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Always use original Boart Longyear parts to replace worn
components. For safety reasons this specific requirement must be
complied with. It applies to:
- hydraulic hoses and other components.
The safety devices on the drill rig must only be changed by or with
the permission of Boart longyear approved personnel.
Boart Longyear drill rigs must be used only as directed and described
in the Operating Manual. The drill rig must not be used for :- Towing
other machines, lifting parts other than for the the drilling duties,
carrying passengers or materials other than drilling tools, or for
clearing debris from the drill site.
The rig functions must be activated only from the control panel.
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Be sure that no one is within the Danger Zone of the vehicle.
This is the area around the rig, within which persons may be
endangered by slewing the rig or moving any of its operational
components.
The operator can work the rig only if no-one is within the Danger
Zone. If someone enters the Danger Zone the operator must
immediately give appropriate warning signals. These are usually
made with hooters, but pre-determined hand signals can be used to
warn other people if on-site noise is liable to drown audible signals.
The operator must immediately terminate all operations if other
people do not leave the Danger Zone, despite having been warned.
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- Can be expected to perform responsibly and are designated for
the job by the contractor.
- High Winds
- Unsecured ground
- Longitudinal 10 Degrees
The operator is responsible at all times for the operation of the rig
and must modify procedures to allow for any likely instability and
ensure a safe work area.
To avoid the danger of falling and crashing, the crawler rig must
always keep a safe distance from ledges, pits and slopes.
It is the contractor’s responsibility to assess the ground bearing
capacity and state a safety distance for the rig.
Check the bearing capacity of bridges, floors and any structures prior
to moving the rig onto them.
SIGNALLING
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The contractor is responsible to determine if utility lines are buried on
the drill site, and the site owner is obliged to supply this information.
If utility lines are present their location must be clearly marked. Plans
clearly detailing the location (run and depth) of utility lines must be
kept for reference on the working site.
The operator must stop working immediately and inform the site
manager if a utility line or its protective cover is detected.
Uncovered utility lines must be secured against swaying or slipping.
The operator must park the drill rig on bearing and level ground, and
secure against inadvertent or unauthorised movement, prior to each
operational break and at the end of each working day.
The drill rig must be parked on a slope or incline, the crawler tracks
must be secured with wedges in addition to the hydraulics brakes.
Drill rigs should be parked only where they do not impede public or
site traffic.
If necessary it must be secured with warning triangle signalling lines
or warning lights.
During working breaks and at the end of each working day the
operator must rest drill mast and drill string on the ground, and
secure them against inadvertent or unauthorised movement.
The operator must not leave site if drill rig and tools are not secured.
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The operator must set all operating levers in
“o” position prior to leaving the control console.
The operator must stop the drill rig engine and secure it against
inadvertent or unauthorised start-up, prior to leaving the drill rig.
Inadvertent or unauthorised start-up is avoided, if the engine is
stopped , the starter key taken out of the ignition lock, and covers
doors and lids are locked.
Markings:
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Defective and faulty lines must be exchanged immediately.
Due to its status Din EN 982 can be considered as the legal base
for a judicial decision, this should be considered for compensation
claims.
Din EN 982 also specifies: Hose assemblies must be connected to
hydraulic systems as follows:
They must have the necessary length to avoid mechanical stresses
caused by movements during operation.
Hose assemblies shall not be twisted, i.e. by defective rotary
fittings.
Hose assemblies must be protected from excessive abrasion of the
cover.
They must be adequately fixed to avoid stresses caused by their
own weight.
Fittings must be adequately fixed to avoid a whipping of the hose in
case of accidents.
Hose assemblies must be properly shielded if streaming oil
leakages are likely to cause personal injuries.’
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3.6.1 General rules for Feed chains: ....................................................... 54
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Rod Handler. Safety Cage Sonic
Drillhead
Engine Panel Rig Set-up Panel Driller Control Hold Clamp and
Panel Breakout Clamp
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Engine Exhaust Mast in Raised
position
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Air and Water Driller Panel Rod Handler
control valves swung out Ready for use
ready for use
Driller Panel
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Read all instructions prior to tramming the rig.
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Top Winch
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The Drill Mast assembly carries the Sonic drill head, and is capable
of drilling from 45° off horizontal to 90° vertical down. The travel of the
sonic head is infinitely variable in forward drilling mode and features fine
and fast feed and return. The drillhead vibration and rotational speed
are manually adjustable; being infinitely variable.
The hydraulically controlled feed system allows full control of the drilling
speed and bit weight. The drill mast has a facility to move sideways and
fore and aft for positioning adjustment over the drill string.
Mast
Minisonic head
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The SONIC Head provides the vibration and rotation to the drill string.
The head comprises of a single motor driven Rotation system, a tub
Lube system, and an oscillator system - all controlled from the control
panel. Air cushions isolate the vibrations to the head and drill string. The
whole Head has Side Shift and Side Tilt
The Side Shift allows for unobstructed winch use down the drill hole.
The Side Tilt facilitates extraction of the samples.
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Feed Chains should be tightened to give a 6 mm to 12 mm(1/4”-1/2”)
deflection (approximately 5 to 10 kg(10-20lbs) of force applied by
hand), both sides must be equal and the deflection is measured 600
mm(2ft) from the cradle. If there is excessive deflection in the feed
chain, tighten the chains at the anchors. The feed chains will also need
to be adjusted if the drill cradle is not running parallel with the mast as
shown below.
Feed chains should not be allowed to run dry. A good quality chain
lubricant is recommended. Do not use old motor oil to lubricate the feed
chains.
Feed chains have to be checked daily for cracks and fissures. Pins and
links with wear marks and grooves or mechanical deformations must be
replaced. Feed chains have to be checked weekly for elongation.
Fix the total length of 17 double-links of a new chain within the pitch
distance (roller to roller / link to link) The test procedure compares the
total length of the new chain and the used chain and if the used chain
shows increased lengths of 161/2 double-link gauge, the chain must be
replaced.
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A special valve in the hydraulic system automatically balances the load
applied to the up and down movement of drill head.
Chain Adjuster
Leaf Chain
Sonic Head
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Mast horizontal with
Grippers released
The Mast is raised to vertical by two Lift cylinders which are complete
with over centre counter balance valves to lock the cylinders in the
event of hose failure. There are two automatically applied Grippers that
maintain the mast in the vertical position during long working cycles.
The Grippers automatically release under hydraulic pressure when the
Mast is lowered.
Mast stiff legs are required for all mast operating angles except vertical
if the maximum pullback force 6710kg (14,800lbs) is applied. Mast stiff
legs are to be used at all mast angles other than vertical. If the mast
is supported by a rigid and strong soil condition, the stiff legs are not
required in the vertical configuration
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This device is for holding, making up and breaking out the drill pipes,
core barrels and casing tubes. It includes:-
1. Holding Clamp - for holding the drill string during thread making
or breaking.
2. Breakout device - with a clamp for gripping the upper drill pipe
then a breakout cylinder for breaking the thread by rotating up
to 19 degrees.
Standard clamps have a capacity of up to 305mm(12”) Dia.
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The rig is equipped with a Rod Positioner for the safe loading and
un-loading of rods when extension drilling
Rod Positioner
Stowed and
Guarded
Rod Positioner In
Pick-up Position
Rod Positioner
moving to Loading
position
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Mounted to the top of the Mast assembly the winch is used for lifting
core barrels and drill pipes, also for setting up the SPT tester. The winch
is hydraulically driven by a planetary motor controlled from the driller
control panel.
Main Winch
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The rig is equipped with a hydraulically powered Crawler Tracks. These
comprise of a Left and Right hand pair. See crawler Instructions section
at the back of this manual
Crawler Tracks
The Bredel Grout Hose type Pump is a direct hydraulic motor operated
pump. The outlet is connected into the drilled hole. The flow from the
grout pump is variable up to approximately 160 l/min (42 gpm) at 16
bar(232 psi)
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FMC E04 Water/Mud pump shown. (BLY will also offer an FMC E09
water pump as an option).
Relief Valve
Pump Inlet
FMC Pump
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Battery
Battery Switch
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Most of the operating controls are on the main control panel. Please
refer to the Operation section 4 for a full description of the control panel
and the location of the valves,gauges and lights.
There are three stabilisers used to level and stabilise the drill rig, two at
the rear near the Drilling mast and one at the centre of the front of the
rig.
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The pumps are mounted directly on the diesel engine The hydraulic
system on the LS250 drill rig consists of a combination of open and
closed loop hydraulics. The track drives of the carrier and the drill head
oscillator and rotation utilize piston pumps in a closed loop system and
all the other hydraulics use piston pumps in an open loop system.
Oil level and temperature sensor which shuts down the system if the
temperature exceeds 80C(180F).
Oil filter with a visual signal device. When this shows red the
filter cartridge must be replaced. The filter grade is 10 micron.
Recommended oil 17/15/13 class (ISO 4406).
A filling tap with breather and pre-filter.
A ball-valve to close the oil circuit in case of a shutdown or repair,
avoiding the loss of oil.
One heat exchanger is incorporated in the return circuit and is driven
by hydraulic motor.
All the control and monitoring elements of the drill are assembled in the
control panels.
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4.1.1 Equipment Description and Identification ....................................... 67
4.1.2 Safeguards .................................................................................... 67
4.1.3 Routine Checks .............................................................................. 68
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THIS PAGE INTENTIONALLY LEFT BLANK
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The LS250 Sonic drill rigs are designed to operate fully independently,
and are therefore suited to all types of drilling applications, in a variety of
ground conditions.
The pictures on the following pages locate the main components of the
LS250.
Note: The hydraulic reservoir can be filled with a wide range of oils. See
the Oil Selection Chart in section 5 to determine the oil most suited to
your conditions.
All operators must be familiar with the equipment and its proper care. If
adjustments or repairs are necessary, or if any damage is known, the
operator must report the details promptly to an appointed person and
must notify the next operator upon changing shifts.
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During tramming operations it is essential that the Mast is laid down and
all items are securely anchored. A slow practical tramming speed must
be applied at all times.
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The following is a checklist for a visual inspection of the LS250. Ensure
that the inspection is performed by an individual with knowledge of
all operational procedures. Each section has a pass or fail choice. If
there is a problem, it should be noted and corrected immediately. Make
copies of this checklist and file away for future reference. The list is not
exhaustive and the inspection may take into account aspects of the rig
that are not listed.
1 Mast Assembly:
Condition:
Frame: Damaged Cracked Welds OK
Cylinders Bad OK
Pulleys Warped OK
Grooves Worn OK
Chains Bad OK
Spacers or Seals Bad OK
Comments: Rusty Needs Repair
Needs Painting Other:
3 Stabilisers:
A. Front Left
Condition:
Bow Slight Bad OK
Pin Connection Bad OK
Pin Hole Bad Cracked Welds OK
B. Front Right
Condition:
Bow Slight Bad OK
Pin Connection Bad OK
Pin Hole Bad Cracked Welds OK
C. Rear Centre
Condition:
Bow Slight Bad OK
Pin Connection Bad OK
Pin Hole Bad Cracked Welds OK
Comments: Need Repairs Other:
4 Driller Panel
Condition:
Frame & Pivots: Damaged Cracked Welds OK
Valve Levers Damaged OK
Valve Knobs Missing Damaged OK
Nameplates Missing Damaged OK
Comments on Cabinet Rusty Needs Repair
Needs Painting Other:
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5 Rig Setup Panel
Condition:
Frame Damaged Cracked Welds OK
Valve Levers Damaged OK
Valve Knobs Missing Damaged OK
Nameplates Missing Damaged OK
Comments on Cabinet Rusty Needs Repair
Needs Painting Other:
6 Engine Panel
Condition:
Frame & Pivots: Damaged Cracked Welds OK
Valve Levers Damaged OK
Valve Knobs Missing Damaged OK
Nameplates Missing Damaged OK
Display screen Damaged OK
Lights Damaged OK
Comments on Cabinet Rusty Needs Repair
Needs Painting Other:
8 Bolt Connections
All bolted connections are to be inspected, tightened, and missing
parts replaced or visibly marked as missing or damaged and in
need of repair.
9 Summary of Inspection
Appearance: Good Fair Poor
Repairs Needed: None Minor Major
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Minisonic SPT Test Rig Rear Gauge Hinged Safety Safety
Drillhead Control Panel Gate Guard
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!
The following is a full description of the control panels and the location
of the valves,gauges and lights.
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Engine Engine Engine Emergency
Diagnostic Warning Light Warning Stop Button
Screen Light
Pre-heat
Glow Plug
Light
Reset
Button
Engine
Start/Stop
Switch
Fine Feed Fast Feed Wrench Rotate Top Clamp Bottom Clamp
Working Clockwise
Light / Counter
Switch clockwise
Spare Pressure
Switches Selector
Rod Switch
Presenter Head
Clamp Rotation
Rod
Presenter Head
Swing Vibration
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Feed Feed Feed Counter clockwise Clockwise
Speed Pressure Balancing Rotation Pressure Rotation Pressure
Control Control Control Control Control
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Water Pressure Dump/ Washer Inlet Valve from Outlet to Sonic
Pressure Return to Tank Valve Water Pump Head
Gauge
Pre-heat
Glow Plug
Light
Reset
Temperature
Button
Warning
Light
Engine
Fast/Slow Start/Stop
Speed Selector Switch
Switch
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Front Left Right Mast Side Mast Front / Mast Mast
Jack Rear Rear Slide Rear Slide Dump Raise
Jack Jack
Radio
Remote
Battery
Charger
Top Clamp
Pressure
Gauge
Bottom Clamp
Pressure Top Air Bag
Gauge Pressure
Top Air Bag Control
Pressure
Gauge Bottom Air
Bag Pressure
Bottom Air Control
Bag Pressure
Gauge
Head Lube
Control
Head Lube
Pressure
Gauge
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There are three stabilizers used to level and stabilize the drill rig, two at
the rear near the Drilling mast and one at the front of the Cab.
Front Rear
Stabilizer Stabilizer
Jack Jacks
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When travelling up hills or slopes, always travel directly up the slope.
Set the travel speed to a low range and operate slowly.
Do not suddenly change speed on a slope. There is a danger that the
direction of the machine may suddenly change and the machine may
slip.
When travelling down a slope set the speed range to low, run the
engine at low idling, and operate the travel lever to a position less
than 1/2 of the full stroke. If the machine travels too fast there is a
danger that the engine will overrun and the machine may slip.
If a dangerous state occurs by any possibility, and when it becomes
necessary to stop the machine urgently, press the parking brake
switch to set it to STOP position or turn the enine starting switch to
the OFF position to stop the engine.
Power Unit
- Check that the main pump has been primed. If not, prime by
removing the case drain hose and adding Hydraulic oil until case is
full. Refit hose.
Check that the diesel engine levels of coolant, engine oil and diesel
fuel are correct.
Coolant
Type of coolant:
Freezing point
Oil
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Check that the crawler track planetary gear boxes have been
primed.
Type of oil:
Viscosity:
Check that the tension of the crawler tracks is set correctly
See manual
Hydraulic Circuit
The pumps are mounted directly on the diesel engine. In the complete
version of the drilling rig there are two closed loop pumps and one load
sense pump. The number 1 closed loop pump powers the helper side
crawler track, and head oscillation. The number 2 axial piston pump
powers the driller side Crawler track, and head rotation
The load sense pumps power all other drilling and setup functions.
Two gear pumps are fixed to the engine one controls head lube and
the other runs the fan on the hydraulic cooler. All pumps are protected
against excessive pressure by safety valves mounted before the
distribution valves. The fixed pressure rating must not be changed.
Oil level and temperature sensor which turns a warning light on if the
temperature exceeds 80 degrees C (176 degrees F)
Be sure to check that all control elements (levers) are in the neutral
“O” position.
The Emergency STOP switches must not be activated.
Release any activated switches by rotating them slightly
All stopcocks for pump suction lines must be open.
Hydraulic hoses and lines must be securely connected and tightened.
Check for oil leaks.
Check oil levels in the engine, gearboxes, and hydraulic oil tank.
Check the diesel fuel level in the fuel tank. For further information see
the Engine Manual.
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Prevent possible injury. Components can be hot. always wear the
proper personal protective equipment when working in and around oil
coolers.
Read the manual and become familiar with all the rig instructions prior
to starting or tramming the rig. Before operating any controls, know how
each control functions. Check that there are no persons or obstacles in
the surrounding area, sound the horn then start the engine.
Before starting the engine be sure to set the parking brake switch to
the ON (stop) position - the engine will not start without setting the
parking brake to this ON(stop) position. Selection of Drive on the
Drill/Drive selector automatically applies the brake.
Ensure the Battery is switched ON position (situated near the front of
the rig inside the door by the engine).
Set the selector near the top of the Electrical Box to the proper
location for starting the rig (Electric Box or Control Panel)
Set the accelerator control to slow position.
Turn on the starter key
Press the blue re-set button.
Start the rig
The oil pressure warning lamp and battery control (ignition) lamp
must light up.
After the engine starts release the key (the key will automatically
return to the ON position)
The oil-pressure warning lamp and battery control (ignition) lamp
must switch off.
Turn the Remote Controlon.
Switch to Drive (Constant Horn should sound).
Release the Brake, right hand button on thr Remote Control (Horn
should sound intermittently).
Low Temperature starting:
Set the engine speed to maximum and set the high speed position.
Turn the starter key to the PRE-HEAT position and hold until the
preheating lamp on the control panel box lights up - appox. 8
seconds. When the key is released it will return automatically to OFF.
When the resister on the instrument panel glows red, turn the key to
START the engine.
After the engine starts release the key.
Check for leaks, and rectify before proceeding.
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After starting (warm-up operation.
Set the speed control to low speed and run for approx 5 minutes
under no load.
Set the speed control to mid range speed, and run for approx 5 mins
under no load.
Check that the instrument panel gauges, monitor, charge lamps.
Check that there is no abnormality in the exhaust gas colour, engine
noise or vibration.
Consult the operating manual for further instructions regarding driving
and steering the rig.
Run the engine under light load until the coolant temperature is within
the green range. Do not suddenly accelerate the engine
Not Used
Slow Speed Driving
Max: 0,6 m/s
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The Tracks are operated with the two large Joysticks. The left Joystick
steers the left chain, the right steers the right chain. Pushing the
Joysticks drives the rig forwards, and pulling drives in reverse. Push or
pull the joysticks together for in-line driving and in opposite direction for
steering
Sounding Horn
Activation Button
Cable Connection
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Hints for Optimum Drilling
!
Monitoring the pressure in the rotation circuit indicates how much
torque is being applied to the drill string.
If you notice that the pressure is reaching the set limit, you may be
getting stuck. Stop advancing and retract the drill string slightly. Shut
off the oscillation (if mounted) and allow the drill string to rotate with
the flushing flowing until the torque pressure drops back down. Then
proceed further.
Also watch the feed pressure gauge, as this will help to establish an
idea of how much force is on the bit.
Pay close attention to flushing pressure. A rise in pressure indicates
that either the bit is getting clogged or the annulus is collaring.
Take corrective action before it is completely clogged or collared.
Also, make sure that everyone is clear of the rig, as sometimes the
plug opens with considerable force and cuttings come up the annulus
at great speed.
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Under some deep hole applications the Feed Balancing pressure and
Feed pressure tend to reach a balance point due to the weight of the
drill string. Decreasing Feed Pressure will slow down the penetration
rate and will overcome this balance point. Beyond this balance point
it will become necessary to increase the Feed Balancing pressure to
counter the increase in weight of the drill string.
Our aim is to ensure your rig is operating efficiently to help you achieve
maximum productivity with minimum of downtime, we offer the following
guide to reduce lost time during start up.
REMEMBER:
The tooling does the actual drilling, the drill rig only powers the
drill head, which in turn only rotates/vibrates and guides the drill
string into the ground.
Should you have any queries or doubts about a particular
application, you can refer to the the selection of Boartlongyear
tooling brochures which are readily available from your
BL representative, or look up our web site
(www.boartlongyear.com).
If you need further assistance contact your Boart technical
representative.
Once you have decided which system and method will work best
on your particular site, it is very important to ensure that all
components required are actually on site.
The safety cage is in place to protect the operator from moving parts
of the drill string. If the safety cage is open then the drilling work can
only be performed in either Restricted Operating Mode or, under certain
conditions, in Rod Handling Mode.
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Different Restricted Modes :
ROM - useful for when the operator needs to work directly on the drill
string, in this case the safety cage is open and not in a ‘rod handling
enable’ position. To activate the ROM mode set the drilling/driving
selector to drilling, normal/rod handling/ROM selector to ROM and
press START/RESET pushbutton. The fine feed handle is not active
in this operating mode and the rotation is only engaged (at speed
reduced to 30 rpm max.) with a ‘dead-man’ pushbutton de-pressed.
Fast feed speed is reduced to 15 m/min. max. This would apply when
core barrel handling.
Rod Handling Mode – when the safety cage is open and set in a
‘rod handling enable’ position, to allow for rod handling by means
a Rod Loader or Rod Presenter, the Rod Handling Mode can be
activated. In order for this, set the drilling/driving selector to drilling,
normal/rod handling/ROM selector to Rod Handling and press the
START/RESET pushbutton. The fine feed handle is not active in this
operating mode and the rotation is only engaged (at speed reduced
to 30 rpm max.) with a ‘dead-man’ pushbutton de-pressed. Fast feed
speed is not reduced.
Safety Process with Restricted Mode :
With the safety cage closed the drill rig works in normal drilling
operation: set the drilling/driving selector to drilling, normal/rod
handling/ROM selector to normal and press the START/RESET
pushbutton to activate,
When the operator opens the doors of the safety cage. The Rotation
and Feed stop directly and the failure indicator light on the control
panel will flash,
The operator must then switch to the ROM (or RH-Mode) and then
press the START/RESET push button on the operator’s control
panel. Please note that the indicator for ROM (or RH- Mode) will
illuminate in the colour mode shown below,
The operator can then start operation again, with reduced speeds of
rotation (by the simultaneous pressing of the dead-man button on top
of the rotation handle) and feed (only in the ROM).
If the operator closes the safety cage, then the operation Stops.
Normal drilling mode is resumed by switching back to Normal Drilling
Mode and pressing the START/RESET push-button. The indicator for
drilling mode will illuminate.
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5.1.1 Operational Requirements .............................................................. 89
5.1.2 Safety Requirements ...................................................................... 89
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Cost consciousness and the call for greater efficiencies have led to an
ever-increasing use of machinery in the construction industry. This has
enabled contractors to dispense with expensive manpower, while at the
same time reducing time spent on-site.
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Individual stipulations require checks:
For the purpose of care and maintenance instructions this means that:
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Regardless of which system or method is used, make sure that the
following tools and equipment are available on-site.
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Shovel - to remove
cuttings from the area
Hammer - sometimes
necessary to strike the
casing to loosen thread
connections
Grease Gun
with Pressure
gauge for
Crawler Track
tensioning
Chain Wrench
Rod Lifter
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For replacement of irreparable or worn parts
consult the Parts List supplied with this Operating Manual for part
numbers and ordering. Consult the Manufacturers Manuals at the end of
this manual for in-depth explanations of maintenance of the proprietary
items of the rig. All maintenance aspects of these items are shown in
these manuals.
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Mast Tilt Cylinder Mast Slide Cylinder Mast Slide Grease
Pins - Grease Points Pins - Grease Points Points - 2 each end
Mast Dump
Slides
Grease
Points
Weekly - Clean and lubricate the all slides and pivots; also clean and
lubricate the Dump and Tilt cylinder clevises .
Observe the Tilting and sliding operation, look for any looseness or
seizure in the Pivots, Frames, Trappings and Slides. Examine the
Cylinder Rods for pitting or damage and look for oil leaks, observe the
cylinders for excessive sinking which could mean Piston seal internal
bypass leakage or damaged load control cartridges (a small amount of
sinking overnight is normal).
If any pivots or clevises are seized or loose consider the safety aspect,
ie. if severely ‘sloppy’ or totally seized, strip out the joint and re-new
the Pin, and fixings. Leaks in hydraulic cylinders can lead to unsafe
conditions (ie. sinking under load and oil contamination), prevent this by
re-sealing the affected cylinder.
Feed Chains
- Lubricate
Power Chain
- Clean Links
Daily - Thoroughly clean out any drilling debris in the Mast frame and
lubricate the Mast slides. Examine the Feed Chains and Pulleys for
wear and damage, re-tension the chain if necessary (see below) and
re-lubricate.
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Chain specification LH2066 - Pitch = 31.75 mm
During operation observe the Mast Frame for distortion, and also the
slide ways and trappings for looseness or binding. Adjust or re-new
as required. Look for any looseness in the Mast Slide Pivot, and Feed
Chain Pulleys. Examine the Feed Cylinder Rod for pitting or damage
and look for oil leaks, observe the cylinder for excessive sinking which
could mean Piston seal internal bypass leakage or damaged load
control cartridges (a small amount of sinking overnight is normal).
If any pivots or clevises are seized or loose consider the safety aspect,
ie. if severely ‘sloppy’ or totally seized, strip out the joint and re-new the
Pin, Bushes and fixings. Leaks in hydraulic cylinders or damaged load
control cartridges can lead to unsafe conditions (ie. sinking under load
and oil contamination), prevent this by re-sealing the affected cylinder or
replacing cartridges.
97
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.
Breakout
Bracket -
Lubricate
Break-out
Cylinder Clevises
- Lubricate
Break-out Wrench
Cylinder Clevises -
Wrench Jaws Lubricate
Holder Wrench
Check for wear - Cylinder Clevises
Lubricate round - Lubricate
insert pivots
Daily - Thoroughly clean out any drilling debris in the Wrench Jaws.
Examine the Jaws for wear and damage, replace if necessary.
Weekly - Clean and lubricate the Presenter pivots and clevises, the
Breakout cylinder clevises, Wrench cylinder clevises, Breakout bracket
and Jaws.
If the open and close movement of the jaws is unequal, then open
both jaws of the Wrench and /or breaking device completely against
pressure. The flow divider will be then be adjusted for equal and
simultaneous operation. During operation observe the Jaws for wear.
Look for any looseness or seizure in the Breakout bracket pivot, look for
slack causing rocking. Examine the Cylinder Rods for pitting or damage
and look for oil leaks.
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If any pivots or clevises are seized or loose consider the safety aspect,
ie. if severely ‘sloppy’ or totally seized, strip out the joint and re-new the
Pin, Bushes and fixings. Leaks in hydraulic cylinders can lead to unsafe
conditions (ie. sinking under load and oil contamination), prevent this by
resealing the affected cylinder.
99
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Centralising Drill head float shafts and Air Flushing Swivel
Guide Rollers cushion shock absorbers
Daily - Thoroughly clean off any drilling debris, check the motors and
lubrication pump for leaks. Check the Flushing Swivel connecting
thread; if loose, clean and fix in position with Loctite thread lock.
During operation observe the motion of the Drillhead down the mast,
this should be smooth with out wobble, also observe the Mast Frame
and Slide ways for distortion, and trappings for looseness or binding.
Adjust or re-new as required. Look for oil leaks from the front of the
drillhead and also from the drive motors. The Flushing medium should
not leak in the area of the Flushing Swivel. Examine the Cylinder Rods
for pitting or damage and look for oil leaks
100
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could mean a loose connection or worn seals, check it out. Leaks in
hydraulic cylinders can lead to unsafe conditions (ie. sinking under load
and oil contamination), prevent this by re-sealing the affected cylinder
101
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The cradle is centralized on the mast by four Cradle Centralizing Rollers
that guide against the inside of the left and right mast slides. These
Rollers need to be adjusted occasionally to maintain a tight fit of the
cradle to the mast. The clearance between the Rollers and the Mast
Slides is to be checked as part of the weekly maintenance. If the rollers
are adjusted the head may need re-aligning (see next chapter). Also
check the Mast Guides for excessive wear.
Push head sideways until one of the rollers at the top (bottom)
contacts the mast. Check by trying to turn the roller. Insert a 1mm feeler
gauge or, if this is not available, a regular hacksaw blade between the
other roller at the top (bottom) and the mast slide. This should just fit, if
too sloppy or tight the rollers need adjusting (as outlined below).
Start with either top or bottom rollers. Try to have the rollers adjusted
roughly symmetrical. Check by comparing the position of the bolts (B in
picture above) and slots of excenters (C). Push the head over sideways
until one roller contacts the mast guide. The other roller can then be
adjusted: loosen nut (A) while holding allen bolt (B) steady with allen
key. Insert feeler gauge / hacksaw blade between roller and mast slide.
Turn excenter (C) by prying with a screwdriver in slots of excenter until
feeler gauge is tight. Tighten nut (A) while holding allen bolt (B) steady.
Re-check and re-adjust if necessary. Proceed with checking roller
guides at top of head.
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The sideways and depth alignment of the head can be adjusted
separately on the cradle. Check these once a week or when problems
with stabbing rods/casing occur due to misalignment.
Attach core barrel to head and lower head so that bit is approx. at top
clamp. Measure the distance between the side of the core barrel and
the right side of footclamp housing. Lower core barrel into hole and take
same measurement at top of core barrel. If this distance is more than
10mm different then sideways alignment of head should be adjusted.
Note the way the head needs to be tilted to correct.
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The spindle is mounted in the head with axial bearings. These
bearings need to be pre-loaded so that the spindle does not “bounce
up and down” in the bearings. A large nut that is screwed onto the
top of the spindle pushes down the top bearings. By tightening this
nut with a specified torque the correct load is set in the bearings. If
this maintenance is not done regularly the bearings will eventually be
damaged, the water swivel spindle may break and oil leakage across
the top oil seal may result.
Quantity 8 1/4” -
20 x 1 1/4” Socket
Head bolts
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Remove the Top
Quantity 8 1/4” -
20 x 4” Socket
Head bolts
Loosen nut
tension bolts, and
back off by 12mm
(½”)
Nut tension key, Insert the narrow end of the Nut Tension key into the hole.
Part 8400971 Make sure the key is fully engaged into the slot in the nut.
With the rig at a medium idle and low torque, rotate as for casing
(counter clockwise), to 125bar (1800 PSI). Activate the rotation two or
three times to ensure full pre-load is achieved.
105
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Install new seals, if
needed in the Water
Swivel top grooves,
Ensure the Seal Lip is
pointed upward.
Apply grease
¼” Nordlock Washer
Quantity. 8 1/4 -
20 x 1-1/4” Socket Head bolts
¼” Nordlock
Remove key
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Drive Chain Drive Motor Hammer Slide
Shaft
Regular Service -
Daily - Thoroughly clean off any debris from the STP especially
on the slides (jet wash if necessary). Look for any new oil spots
around the motor as an early indication of problems.
Weekly - Check over the Frames and pivots for damage. Clean and
lubricate the slides and pivot pins.
Inspection -
Observe the SPT when in operating mode, look for loose parts,
sloppy pins and rattling joints. Examine slide rods and cylinder
rods for pitting or damage and look for oil leaks around the motor.
Examine the Hammer guide for wear or damage.
107
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Preventive Maintenance -
The Winch is mounted on the top of the mast to facilitate the handling of
rods and casings and for handling of the SPT Auto Hammer.
108
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!
Regular Service -
Lubrication
Points
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!
Regular Service -
Daily - Thoroughly clean off any debris from the Main Frame and
Tracks ( see Track manual for full instructions on Track servicing,
especially Track tensioning, and Track drive gearbox servicing
pages). Prior to start-up walk round the Rig and check for any
damage or anything out of place. Look for any new oil spills as an
early indication of problems.
Weekly - Check over the Main Frame for damage. Clean and
lubricate the cylinder clevises
Preventive Maintenance -
Observe the Rig when in tramming mode, look for loose parts,
sloppy cylinders and rattling joints. Examine cylinder rods for
pitting or damage and look for oil leaks, observe the cylinders for
excessive sinking which could mean Piston seal internal bypass
leakage or damaged Load Control cartridges (a small amount of
sinking overnight is normal)
Repairs -
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Lift engine bay top cover for easy access. Top up with water / antifreeze
mix if required.
Check after operating the rig for some hours. Temp should be below 60
degrees C. at all times.
Replace the filter when the indicator on top of the filter is red. Mark
engine hrs on filter. Notify Supervisor.
Check tank, tank cover, hoses, valves, fittings for damage, leakages
and loose parts.
Check frame, hoses, hoisting cable and hook assembly for damage,
excessive wear and loose parts. Check for oil spots around motor
and gearbox.
Check mast frame, hoses, cylinders, water swivel, pivots for damage,
excessive wear and loose parts and bolts. Check for oil spots around
motors, cylinders and seals. Check if all flange bolts are tight. Centralise
Sonic head and torque the Head spindle nut if required. See section
previous instructions.
Lift tracks of the ground with stabilizers and check for excessive sagging
(more than approx. 30mm) of bottom track half. To adjust: Remove
cover plate from side of track frame. Connect grease gun to nipple and
pump to 250 bar or until grease runs out of release valve. See Operator
manual Tracks section.
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Check frame, hoses, water swivel, pivots for damage, excessive wear
and loose parts. Check for oil spots around cylinders.
With one roller touching mast slide, clearance of other roller should be
1mm. If not adjust.
Adjustment eccentric is located at
the lower pin of the tip-out cylinder. Loosen bolts that secure eccentric
and turn this via the large hexagonal at the back. Re-tighten the
securing bolts.
Adjust by loosening top allen bolts that hold the head float shafts. Turn
the adjustment bolts in/out as required. Ensure both head float shafts
are aligned symmetrically by counting exposed threads on adjustment
bolts before tightening large allen bolts.
Check case, hoses and fittings for damage, excessive wear and loose
parts. Check for oil spots around motor and gearbox. Check FMC Pump
Crankcase Oil Level Level plug. Also check for contamination with
water.
Check cases, hoses and fittings for damage, excessive wear and loose
parts. Check for oil spots around motor and gearbox. Check Bredel
Pump Glycerin Level through Window
Check frame, hoses, pivots for damage,
excessive wear and loose parts. Check for oil spots around motors,
cylinders and seals. Lubricate Feed Chain With mast upright raise head
to top. Apply motor oil with brush on chain at bottom pulley while slowly
lowering head. Put mast in horizontal position and apply oil with brush
on top chain. Lubricate SPT Chain. Lower the mast into the horizontal
position and move weight to the top position. Apply motor oil onto chain
with brush. DO NOT DO THIS WITH MAST UPRIGHT AS WEIGHT
DROPPING ONTO UNSUPPORTED ANVIL WILL CAUSE DAMAGE.
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A pre-shift inspection must be performed at the start of each shift or day. Turn it in with the job file or fax to
office weekly.
Fire Extinguishers (incl. current inspections) Site Clean & Orderly - No Trip Hazards
First Aid, CPR, Bloodborne Pathogens Kits Proper PPE Available / Worn By Crew
Eye Wash Utilities Located - Safe Distance / Clearance
Hospital Route Exclusion Zone Delineated
Safety Meeting Held Proper Fuel Storage
JSA Reviewed (nrs)
113
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Replace Hydraulic Pressure and Return Oil Filter
Mark engine hrs on filter.
Check Undercarriage Bolt Torques
Check all bolts on undercarriage with torque wrench.
Torques shown in rig manual section Tracks
Check Oil Level in Track Gear Units Take out centre plug of gear unit;
oil level should just reach hole. Top up with Statoil 80W90 - (SAE90) if
required.
Check Bredel Pump Gearbox Oil Level Take out level plug at side of
gearbox; oil level should just reach hole. Top up if required.
Check SPT Chain Tension Position chain so that drop weight is not
lifted up. Check chain tension by prying the chain off back in the
centre with screwdriver. If sloppy tighten chain at bottom pulley; do not
overtighten and re-check.
Replace Engine Oil and Oil Filter see Cummins Manual. Oil: Statoil
MaxWay E6 5W-30 15L
Replace FMC Pump Crankcase Oil Also clean magnetic drain plug.
Check for larger steel parts. Oil: Statoil 10W40 - (SAE30)
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Oil: Chevron Ursa Ultra 10W-40, 12-14L. Fill new filter with new clean oil
before mounting it. Mark engine hrs on filter. Cummins Manual.
Fill new filter with clean diesel before mounting it. Mark engine hrs on
filter.
Clean block and fins with pressure washer. Take care not to damage
fan.
Also clean magnetic drain plug; check for larger steel parts.
Contact Supervisor.
With mast in vertical position and head down measure and replace if
required as shown in section 3.
Contact Supervisor.
115
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Clean tank on the inside with lint-free cloths. Be
sure to remove all sludge and debris, report metal particles. Fill with new
oil via filter and pump.
Condensation
116
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Please refer to the following list when
selecting hydraulic fluids from leading manufacturers. Other non-
listed hydraulic fluids may also be used, providing they meet the
quality standard of the oils indicated below. Boart Longyear strongly
recommends using hydraulic oils of class (ISO 4406)-17/15/13.
AGIP OSO 32
ARAL VITAM HF 32, VITAM GF 32, VITAM DE 32
BP ENERGOLHLP 32, ENERGOL HLP-D32,BARTRAN HV 32
CHEVRON EP OIL 32, EP OIL 32HV
ESSO NUTO H32, UNIVIOS N32
MOBIL DTE 13, DTE 24
SHELL TELLUS OIL 32, HYDROL DO32
TEXACO RANDO OIL HD A-32
AGIP OSO 68
ARAL VITAM GF 68, VITAM DE 68
BP ENERGOLHLP 68, ENERGOL HLP-D68,BARTRAN HV 68
CHEVRON EP OIL 68, EP OIL 68HV
ESSO NUTO H68, UNIVIOS N56
MOBIL DTE 16, DTE 26
SHELL TELLUS OIL 68, HYDROL DO 68
STATOIL HYDRAULIC SUPER 68
TEXACO RANDO OIL HD A-68
Rigs are Factory filled with Lubricants marked’*’
Please refer to the following list when selecting Gear oil or Grease.
Other non-listed lubricants may be used, providing they meet the quality
standards indicated below. Boart Longyear strongly recommends using
Gearbox Oils of class SAE 80W-90 conforming to DIN 51517 Part 3
CLP,and Muti-purpose Lithium based Grease for general lubrication
and protection.
Levelling Jacks - -
Cylinder Rods Coat with grease Thin film
Clevises Grease gun Fill
Pivots Grease gun Fill
Slideways Coat with grease Thin film
- -
Cylinder Rods Coat with grease Thin film
Clevises Grease gun Fill
Pivots Grease gun Fill
Mast slides Coat with grease Thin film
Support slides Coat with grease Thin film
Feed chain Coat with oil Thin film
Rope pulleys Coat with grease Thin film
- -
Cylinder Rods Coat with grease Thin film
Clevises Grease gun Fill
Pivots Grease gun Fill
Jaw slides Coat with grease Thin film
Breaker bearing Coat with grease Thin film
- -
Cylinder Rods Coat with grease Thin film
Clevises Grease gun Fill
Pivots Grease gun Fill
Jaw slides Coat with grease Thin film
- -
Slides Coat with grease Thin film
Chains Coat with oil Thin film
Pivots Grease gun Fill
118
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Component Part Number Designation Quantity
Mud Pump FMC E04 9016145 Statoil 10W40 - (SAE30) 0.95 litres
Mud Pump FMC L09 9016145 Statoil 10W40 - (SAE30) 2.1 litres
119
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6.1.1 No Pressure .................................................................................. 123
6.1.2 Flow low or Pressure fluctuating ................................................... 124
6.1.3 Valves not operating correctly ...................................................... 124
6.1.4 Hydraulic oil temperature too high ................................................ 124
6.1.5 Leakage from drillhead ................................................................. 125
6.1.6 Noises from pumps, no oil supply ................................................. 125
6.1.7 Engine stalling .............................................................................. 126
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Do not attempt to repair everything yourself. If you are not fully familiar
with the item or do not have the right tools, you may cause greater
damage. It is no disgrace not to be familiar with every machine. If in
doubt, contact the Boart Longyear Service Section.
123
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Valve sticking Contaminated hydraulic Drain hydraulic oil
oil Clean tank and
components, fill with
new oil
Air enclosure in System not properly Bleed system
system causing jerky
movements
ventilated
Valves knocking Valve seat(s) damaged Replace / Repair
124
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Leakage from spindle Seal rings worn Replace upper and
lower rings
Leakage from space Case drain too small Check limits 0.7 to 1.5 l/
hydraulic motor min
Shaft seal worn Replace hydraulic motor
Leakage from water Damaged packing Replace packing
flushing head
Blocked up flushing Damaged bearings Replace bearings
head
125
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Engine stalls shortly Operating too soon after After engine has started
after start-up start-up raise to 1200 until
the red ignition light
extinguishes
126
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Portal Riesco
Huechuraba, Santiago
info@boartlongyear.com
Switzerland
infoEU@boartlongyear.com
infosa@boartlongyear.com
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